Page 1
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
4195KA, K B, KC, and KS Series Gauge
Pressure Controllers
Contents
1. Introduction
Scope of Manual 1-3. . . . . . . . . . . . . . . . . . . . . . . .
Description 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Educational Services 1-4. . . . . . . . . . . . . . . . . . . .
2. Installation
Controller Mounting Orientation 2-1. . . . . . . . . . .
Pipestand Mounting 2-1. . . . . . . . . . . . . . . . . . . . .
Panel Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . .
Wall Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Mounting 2-1. . . . . . . . . . . . . . . . . . . . . .
Pressure Connections 2-2. . . . . . . . . . . . . . . . . . .
Process Pressure Connection 2-3. . . . . . . . . . .
Supply Pressure Connection 2-4. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Pressure Connection 2-4. . . . . . . . . . . . . . . .
External Feedback Pressure Connection
(4195KB Series Controllers Only) 2-4. . . . . .
Vent 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. 4195KA Series Proportional-Only Controllers
Adjustments for 4195KA Series Controllers 3-1.
Manual Set Point Adjustment 3-1. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Adjustment 3-1. . . . . . . . . . . . . . . . . . . . . . . . .
Proportional Band Adjustment (PB ADJ) 3-1. .
Changing Controller Action 3-2. . . . . . . . . . . . . .
Switching The Auto/Manual Station
(suffix letter E) 3-2. . . . . . . . . . . . . . . . . . . . . .
Prestartup Checks for 4195KA Series
Controllers 3-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Startup for 4195KA Series Controllers 3-3. . . . .
Calibration of 4195KA Series Controllers 3-4. . .
General Calibration Instructions 3-4. . . . . . . . .
Process Indicator Zero and Span
Calibration 3-4. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 3-6. . . . . . . . . . . .
Flapper Alignment 3-6. . . . . . . . . . . . . . . . . . . . .
Principle of Operation for 4195KA Series
Controllers 3-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Operation 3-7. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .
4. 4195KB Series Proportional-Plus-Reset
Controllers and 4195KC Series
Proportional-Plus-Reset-Plus-Rate Controllers
Adjustments for 4195KB and KC Series
Controllers 4-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Set Point Adjustment 4-1. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Adjustment 4-1. . . . . . . . . . . . . . . . . . . . . . . . .
Proportional Band Adjustment (PB ADJ) 4-2. .
Changing Controller Action 4-2. . . . . . . . . . . . . .
Reset Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . .
Rate Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . . . .
Switching the Auto/Manual Station
(suffix letter E) 4-3. . . . . . . . . . . . . . . . . . . . . .
Prestartup Checks for 4195KB and
KC Series Controllers 4-3. . . . . . . . . . . . . . . . .
Startup for 4195KB and KC Series
Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of 4195KB and KC Series
Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .
General Calibration Instructions 4-5. . . . . . . . .
Process Indicator Zero and Span
Calibration 4-5. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 4-5. . . . . . . . . . . .
Flapper Alignment 4-7. . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Differential Relief Valve Calibration 4-9. . . .
Principle of Operation for 4195KB and
KC Series Controllers 4-10. . . . . . . . . . . . . . . .
Overall Operation 4-10. . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
External Feedback Operation 4-13. . . . . . . . . .
www.Fisher.com
D200160X012
Page 2
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Contents (continued)
5. 4195KS Series Differential Gap Controllers
Operating Information 5-1. . . . . . . . . . . . . . . . . . .
Adjustments for 4195KS Series Differential
Gap Controllers 5-1. . . . . . . . . . . . . . . . . . . . . .
Manual Set Point 5-1. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (Option M) 5-1. . . . . . . . . . . .
Proportional Band (Differential Gap) 5-1. . . . . .
Changing Controller Action 5-1. . . . . . . . . . . . . .
Auto/Manual Switching (Option E) 5-1. . . . . . .
Prestartup Checks 5-2. . . . . . . . . . . . . . . . . . . . . .
Startup 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Zero and Span Adjustment 5-3. . . . . .
Remote Set Point Zero and Span
(Option M) 5-4. . . . . . . . . . . . . . . . . . . . . . . . .
Setting Switching Points 5-5. . . . . . . . . . . . . . . .
Direct-Acting Controllers 5-5. . . . . . . . . . . . . . .
Reverse-Acting Controllers 5-5. . . . . . . . . . . . .
Principle of Operation 5-7. . . . . . . . . . . . . . . . . . .
Overall Operation 5-7. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (Option M) 5-8. . . . . . . . . . . .
Auto/Manual Option 5-8. . . . . . . . . . . . . . . . . . . .
6. Maintenance
Inspection and Maintenance 6-1. . . . . . . . . . . . . .
Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . .
Replacing Common Controller Parts 6-1. . . . . . .
Replacing the Process Pressure Scale 6-5. . .
Replacing the Relay 6-6. . . . . . . . . . . . . . . . . . . .
Replacing the Case and Cover 6-6. . . . . . . . . .
Replacing the Gauges 6-6. . . . . . . . . . . . . . . . . .
Replacing the Supply Gauge, Proportional,
Reset, Reset Valve and Positive Tubing
Feedback Assemblies 6-7. . . . . . . . . . . . . . .
Replacing the Proportional Band Adjustment
Knob, Nozzle Assembly, and Set Point
Beam Assembly 6-7. . . . . . . . . . . . . . . . . . . . .
Replacing the Flapper Assembly and
Flapper Flexure Pivot Assembly 6-11. . . . . .
Replacing the Proportional or Reset
Bellows 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Reset Restriction Valve
(4195KB Series) 6-17. . . . . . . . . . . . . . . . . . .
Replacing the Rate/Reset Valve Assembly
(4195KC Series) 6-18. . . . . . . . . . . . . . . . . . .
Replacing the Anti-Reset Windup
(suffix letter F) Differential Relief Valve 6-19
Replacing the Anti-Reset Windup
(suffix letter F) Relief Valve Tubing
Assembly 6-19. . . . . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Maintenance
and Calibration 6-20. . . . . . . . . . . . . . . . . . . . . .
Replacing the Bourdon Tube 6-20. . . . . . . . . . .
Replacing Bourdon Tube Controller Links 6-20
Replacing Link 1 6-20. . . . . . . . . . . . . . . . . . . .
Replacing Link 2 6-21. . . . . . . . . . . . . . . . . . . .
Replacing Link 3 6-22. . . . . . . . . . . . . . . . . . . .
Replacing Link 4 6-22. . . . . . . . . . . . . . . . . . . .
Bourdon Tube Travel Stop Installation
and Adjustment 6-23. . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Calibration:
Zero and Span Adjustment 6-24. . . . . . . . . .
Capsular Element Controller Maintenance
and Calibration 6-27. . . . . . . . . . . . . . . . . . . . . .
Replacing the Capsular Element
Assembly 6-27. . . . . . . . . . . . . . . . . . . . . . .
Replacing Capsular Element Parts 6-27. . . .
Replacing the Long Pivot Assembly 6-27. . .
Replacing the Short Pivot Assembly 6-28. . .
Replacing the Process Drive Flexure 6-28. .
Replacing the Process Tubing 6-29. . . . . . . .
Replacing Capsular Element
Controller Links 6-29. . . . . . . . . . . . . . . . . .
Replacing Link 1 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 2 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 3 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 4 6-31. . . . . . . . . . . . . . . . . . . .
Replacing Link 5 6-31. . . . . . . . . . . . . . . . . . . .
Capsular Element Controller
Maintenance Calibration 6-32. . . . . . . . . . . . .
Precalibration Procedure 6-32. . . . . . . . . . . .
Aligning the Drive Bracket Assembly 6-32. .
Setting the Travel Stops 6-32. . . . . . . . . . . . .
Aligning the Linkage 6-33. . . . . . . . . . . . . . . .
Capsular Element Controller
Zero and Span Adjustment 6-34. . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance 6-36. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Remote Set Point
Assembly 6-36. . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Remote Set Point
Assembly Parts 6-36. . . . . . . . . . . . . . . . . .
Replacing Pivot Assembly A (key 114) 6-36.
Replacing Pivot Assembly B (key 115) 6-37.
Replacing the Drive Flexure 6-37. . . . . . . . . .
Replacing the Remote Set Point Tubing 6-38
Replacing Link A 6-38. . . . . . . . . . . . . . . . . . .
Replacing Link B 6-38. . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance Calibration 6-38. . . . . . . . . . . . . .
Precalibration Procedure 6-38. . . . . . . . . . . . . .
Aligning the Flexures 6-39. . . . . . . . . . . . . . . . . .
Setting the Travel Stops 6-39. . . . . . . . . . . . . . .
Aligning the Linkage 6-39. . . . . . . . . . . . . . . . . .
Remote Set Point Zero and Span
Adjustment 6-40. . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point Linearity Adjustment 6-41. .
Auto/Manual Station (suffix letter E)
Maintenance 6-41. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Auto/Manual Station 6-41. . . . . .
1-2
Page 3
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
W5663-1 / IL
Figure 1-1. 4195K Series Gauge Pressure Controllers
Contents (continued)
Replacing the Switch Body Assembly,
Lever O-Ring, Switch Body O-Ring,
and Tubing Assembly 6-42. . . . . . . . . . . . . . .
Replacing the Loader Range Spring,
Diaphragm Assembly, Ball Seat,
Tubing, and Ball 6-43. . . . . . . . . . . . . . . . . . . .
Replacing the Loader Valve Plug and
Valve Plug Spring 6-44. . . . . . . . . . . . . . . . . .
7. Parts
Parts Ordering 7-1. . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations Used In The Parts List 7-1. . . . .
Controller Common Parts 7-1. . . . . . . . . . . . . . .
Process and Set Point Indicator
Assembly 7-11. . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Assembly 7-14. . . . . . . . . . . . . . . . . . .
Capsular Element Assembly 7-14. . . . . . . . . . .
Remote Set Point Assembly
(suffix letter M) 7-16. . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E) 7-17. . . . .
Controller Mounting Parts 7-19. . . . . . . . . . . . . .
Pipestand Mounting 7-19. . . . . . . . . . . . . . . . .
Pipestand Mounting with Regulator 7-19. . .
Panel Mounting 7-19. . . . . . . . . . . . . . . . . . . .
Wall Mounting 7-19. . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE
W6831 / IL
Controller Mounting Parts for Actuator
with Casing-Mounted Controller 7-19. . . .
Controller Mounting Parts for Actuator
with Yoke-Mounted Controller 7-19. . . . . .
Regulator Mounting Parts 7-19. . . . . . . . . . . . . .
Regulator Mounting Parts for
Casing-Mounted Regulator 7-19. . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator (Mounting
Bracket Not Required) 7-19. . . . . . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator
(With Mounting Bracket) 7-19. . . . . . . . . . .
Fittings 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Introduction
Scope of Manual
This instruction manual provides installation,
operating, calibration, maintenance, and parts
ordering information for 4195KA, KB, KC, and KS
Series gauge pressure indicating controllers.
1-3
Page 4
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Portions of this manual apply only to specific 4195K
Series controller configurations. These
configurations are indicated by letter suffixes in the
type number that correspond to the mode and option
designated in table 1-2.
The specific controller type number (with letter
suffixes) is located on the nameplate shown in figure
1-1. Refer to table 1-2 for the definition of each
4195K Series type number.
Do not install, operate, or maintain this product
without first D being fully trained and qualified in
valve, actuator, and accessory installation,
operation, and maintenance, and D carefully reading
and understanding the contents of this manual. If
you have any questions about these instructions,
contact your Emerson Process Managementt sales
office before proceeding.
Description
The controllers described in this manual provide
gauge pressure control with the options as shown in
table 1-2.
Specifications
Specifications for the 4195KA, KB, KC, and KS
Series controllers are listed in table 1-1.
Educational Services
For information on available courses for the 4195KA,
4195KB, 4195KC, and 4195KS Series gauge
pressure indicating controllers, as well as a variety
of other products, contact:
Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158−2823
Phone: 800−338−8158 or
Phone: 641−754−3771
FAX: 641−754−3431
e-mail: education@emersonprocess.com
D 4195KA Series: Proportional-only control
D 4195KB Series: Proportional-plus-reset control
D 4195KC Series:
Proportional-plus-reset-plus-rate control
D 4195KS Series: Differential gap control
These controllers show process pressure and set
point on an easy-to-read process scale. The
controller output is a pneumatic signal that operates
a final control element.
Note
Neither Emerson, Emerson Process
Management, nor any of their affiliated
entities assumes responsibility for the
selection, use, and maintenance of
any product. Responsibility for the
selection, use, and maintenance of
any product remains with the
purchaser and end-user.
1-4
Page 5
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Table 1-1. Specifications
Available Configurations
See table 1-2
Input Signal (Process Sensor Range
(1)
)
Lower and Upper Range Limits: See tables 1-3
and 1-4
Maximum Allowable Operating Limits: See
tables 1-3 and 1-4
Output Signal
(1)
Proportional-Only, Proportional-Plus-Reset,
or Proportional-Plus-Reset-Plus-Rate Range:
0.2 to 1.0 bar or 0.4 to 2.0 bar (3 to 15 psig or 6
to 30 psig)
Differential Gap Range: 0 and 1.4 bar (0 and 20
psig) or 0 and 2.4 bar (0 and 35 psig)
Action: Field-reversible between direct
(increasing sensed process pressure increases
output pressure) or reverse (increasing sensed
process pressure decreases output pressure).
Process Scale
Standard scale is matched to the range of the
sensing element, with the exception of receiver
controllers. Optional
(2)
scales are available.
Process Connections
Standard: 1/4 NPT, internal, stainless steel (all
input ranges)
Optional: 1/2 NPT, see table 1-5
Supply and Output Connections
1/4 NPT, internal
Supply Pressure Requirements
(3)
See table 1-6
Supply Pressure Medium
Air or natural gas
(4)
Remote Set Point Pressure Ranges
0.2 to 1.0 bar or 0.4 to 2.0 bar (3 to 15 psig or 6
to 30 psig)
continued
Controller Adjustments
Proportional Band
input span
(1)
Reset
: Adjustable from 0.01 to more than 74
(1)
: 5 to 500% of process
minutes per repeat (from 100 to less than 0.0135
repeats per minute)
(1)
Rate
Differential Gap
: Adjustable from 0 to 20 minutes
(1)
Controllers: Adjustable from
5 to 100% of process scale range
Set Point: Adjustable from 0 to 100% of the scale
span
Controller Performance
Repeatability
Dead Band
(1)
: 0.4% of output span
(1)
: Less than 0.4% of process scale
span
Typical Frequency Response: 1.5 hertz and 90
degree phase shift with 3.05 m (10 feet) of 6.4
mm (1/4-inch) tubing and 1639 cm
3 (
100 cubic
inch) volume
Steady-State Air Consumption
(1,5,6)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 0.1 normal
m3/hr (3.5 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 0.14 normal
m3/hr (5.0 scfh)
Delivery Capacity
(5)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 5.9 normal
m3/hr (240 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 10.4 normal
m3/hr (350 scfh)
Operative Ambient Temperature Limits
(1,3,7)
−40 to 71_C (−40 to 160_F)
Exhaust Capacity
(5)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 4.6 normal
m3/hr (186 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 7.0 normal
m3/hr (295 scfh)
Hazardous Area Classification
Complies with the requirements of ATEX Group II
Category 2 Gas and Dust
1-5
Page 6
4195KA, KB, KC, and KS Controllers
Table 1-1. Specifications (continued)
Instruction Manual
Form 5207
April 2007
Housing
Designed to NEMA 3 (Weatherproof) and IEC
529 IP54 Specifications
Declaration of SEP
Fisher Controls International LLC declares this
product to be in compliance with Article 3
paragraph 3 of the Pressure Equipment Directive
Mounting
Controller can be mounted on actuator, panel,
wall, or pipestand.
Approximate Weight
4.5 kg (10 pounds)
1. These terms are defined in ISA Standard S51.1.
2. Consult your Emerson sales office for additional information.
3. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded.
4. This product can be used with natural gas. Natural gas should not contain more than 20 ppm of H2S.
5. Normal m3/hr—Normal cubic meters per hour (0_C and 1.01325 bar, absolute). Scfh—Standard cubic feet per hour (60_F and 14.7 psia).
6. Without auto/manual station. With auto/manual station, air consumption is 0.28 normal m3/hr (10.0 Scfh) for either output range.
7. Also use these temperatures for transportation and storage limits.
Table 1-2. Available Configurations for 4195KA, 4195KB, 4195KC, and 4195KS Series Controllers
MODES OPTIONS
Proportional-
Plus-Reset-
Plus-Rate
(Three-Mode
Controllers)
(1)
Proportional-
Only
(One-Mode
Controllers)
X
X
X
X
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SERIES
4195KA
4195KB
4195KC
4195KS
1. Reverse-acting constructions are designated by the suffix letter R added to the type number.
TYPE
NUMBER
4195KA
4195KAE
4195KAM
4195KAME
4195KB
4195KBE
4195KBF
4195KBFE
4195KBM
4195KBME
4195KBFM
4195KBFME
4195KC
4195KCE
4195KCF
4195KCFE
4195KCM
4195KCME
4195KCFM
4195KCFME
4195KS
4195KSE
4195KSM
4195KSME
Proportional-
Plus-Reset
(Two-Mode
Controllers)
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X
X
X
X
X
X
X
X
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(PED) 97 / 23 / EC. It was designed and
manufactured in accordance with Sound
Engineering Practice (SEP) and cannot bear the
CE marking related to PED compliance.
However, the product may bear the CE marking
to indicate compliance with other applicable EC
Directives.
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X
X
X
X
X
X
X
X
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Differential
Gap
Controller
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X
X
X
X
Auto/Manual
Internal
Station
E
− − −
X
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X
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X
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X
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X
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X
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X
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X
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X
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X
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X
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X
Anti-Reset
Windup
F
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X
X
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X
X
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X
X
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X
X
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Remote
Setpoint
M
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X
X
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− − −
− − −
X
X
X
X
− − −
− − −
− − −
− − −
X
X
X
X
− − −
− − −
X
X
1-6
Page 7
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Table 1-3. Process Sensor (Capsular Element) Pressure Ratings
(1)
CAPSULE
MATERIAL
Metric units
N09902
U.S. units
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 350 mbar (0 to 5 psig) sensing element is used
and the minimum span of 1.75 mbar (2.5 psig) is set, the process indication can be calibrated to a range of −340 mbar to −203 mbar (−10 inch Hg to −6 inch Hg), 0 to 172 mbar
(0 to 2.5 psig), 172 to 345 mbar (2.5 to 5 psig), 305 to 480 mbar (4.5 to 7 psig), or any value between minimum and maximum values of operating range.
2. Capsules with the travel stops set may be pressured to this value without permanent zero shift.
CAPSULAR
STANDARD RANGES
Positive pressure
Vacuum
Compound
Positive pressure
Vacuum
Compound
0 to 150 mbar
0 to 400 mbar
0 to 0.6 bar
0.2 to 1 bar
0 to 1 bar
0 to 1.4 bar
0 to 1.6 bar
0.4 to 2 bar
0 to 2 bar
−150 to 0 mbar
−340 to 0 mbar
−400 to 0 mbar
−0.6 to 0 bar
−1 to 0 bar
−50 to 100 mbar
−175 to 175 mbar
−150 to 250 mbar
−0.2 to 0.4 bar
−0.4 to 0.6 bar
−0.6 to 0.8 bar
−1 to 0.6 bar
−1 to 1 bar
0 to 60 inch wc
0 to 5 psig
0 to 10 psig
3 to 15 psig
0 to 15 psig
0 to 20 psig
6 to 30 psig
0 to 30 psig
−5 to 0 inch Hg
−10 to 0 inch Hg
−20 to 0 inch Hg
−30 to 0 inch Hg
−30 to 30 inch wc
−5 inch Hg to 2.5 psig
−10 inch Hg to 5 psig
−15 inch Hg to 7.5 psig
−20 inch Hg to 10 psig
−30 inch Hg to 15 psig
SPAN
Min Max Min Max
100 mbar
350 mbar
0.35 bar
0.4 bar
0.5 bar
0.7 bar
1 bar
0.8 bar
1 bar
85 mbar
170 mbar
350 mbar
0.35 bar
0.5 bar
100 mbar
175 mbar
350 mbar
0.35 bar
0.5 bar
0.7 bar
1 bar
1 bar
40 inch wc
2.5 psig
5 psig
6 psig
7.5 psig
10 psig
12 psig
15 psig
2.5 inch Hg
5 inch Hg
10 inch Hg
15 inch Hg
40 inch wc
2.5 psig
5 psig
7.5 psig
10 psig
15 psig
160 mbar
700 mbar
0.7 bar
0.8 bar
1 bar
1.4 bar
2 bar
1.6 bar
2 bar
170 mbar
340 mbar
700 mbar
0.7 bar
1 bar
160 mbar
350 mbar
700 mbar
0.7 bar
1 bar
1.4 bar
2 bar
2 bar
60 inch wc
5 psig
10 psig
12 psig
15 psig
20 psig
24 psig
30 psig
5 inch Hg
10 inch Hg
20 inch Hg
30 inch Hg
60 inch wc
5 psig
10 psig
15 psig
20 psig
30 psig
OPERATING RANGE
−350 mbar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−350 mbar
−480 mbar
−1 bar
−1 bar
−1 bar
−350 mbar
−480 mbar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−1 bar
−10 inch Hg
−14 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
−10 inch Hg
−14 inch Hg
−30 inch Hg
−30 inch Hg
−10 inch Hg
−14 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
−30 inch Hg
350 mbar
1 bar
1 bar
1.4 bar
1.4 bar
1.7 bar
2.4 bar
2 bar
2.4 bar
350 mbar
480 mbar
1 bar
1 bar
1.4 bar
350 mbar
480 mbar
1 bar
1 bar
1.4 bar
1.7 bar
2.4 bar
2.4 bar
5 psig
7 psig
15 psig
20 psig
20 psig
25 psig
30 psig
35 psig
5 psig
7 psig
15 psig
20 psig
5 psig
7 psig
15 psig
20 psig
25 psig
35 psig
OPERATING
LIMIT
510 mbar
1.5 bar
1.5 bar
2 bar
2 bar
2.5 bar
3.5 bar
3 bar
3.5 bar
510 mbar
724 mbar
1.5 bar
1.5 bar
2 bar
510 mbar
724 mbar
1.5 bar
1.5 bar
2 bar
2.5 bar
3.5 bar
3.5 bar
7.5 psig
10.5 psig
22.5 psig
30 psig
30 psig
37.5 psig
45 psig
52.5 psig
7.5 psig
10.5 psig
22.5 psig
30 psig
7.5 psig
10.5 psig
22.5 psig
30 psig
37.5 psig
52.5 psig
(2)
1-7
Page 8
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Table 1-4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials
BOURDON TUBES
SPAN
Minimum Maximum Minimum Maximum
OPERATING RANGE
(1)
Bar
Metric units
0 to 1.6
0 to 2.5
0 to 4
0 to 6
0 to 10
0 to 16
0 to 25
0 to 40
0 to 60
0 to 100
0 to 160
0 to 300
10
20
20
55
76
160
250
1
2
2
3.5
7
14
20
40
40
70
100
200
350
2
4
4
7
−1
−1
−1
−1
−1
−1
0
0
0
0
0
0
Psig Psig Psig Inch Hg Psig Psig
0 to 30
0 to 60
0 to 100
0 to 200
U.S. units
0 to 300
0 to 600
0 to 1000
0 to 1500
0 to 3000
0 to 5000
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 2 bar (0 to 30 psig) sensing element is used
and the minimum span of 1 bar (15 psig) is set, the process indication can be calibrated to a range of −1 to 0 bar (−30 inch Hg to 0 psig), 0 to 1 bar (0 to 15 psig), 1 to 2 bar (15 to 30
psig), 2 to 3 bar (27 to 42 psig) or any value between the operating range minimum and maximum values.
2. Travel stops should be used when the maximum or minimum process pressure will be 5% over or under the calibrated range. For example, a 0 to 2 bar (0 to 30 psig) sensing
element is calibrated for 0.7 to 2 bar (10 to 30 psig), the desired range. The minimum expected pressure is 0 psig and the maximum expected pressure is 2.8 bar (40 psig). Travel
stops must be used to prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5% of the 1.4 bar (20 psig) span
which is ±70 mbar (±1 psig).
3. Bourdon tube without travel stops may be pressured to this value without permanent zero shift.
4. Bourdon tube with travel stops set may be pressured to this value without permanent zero shift.
15
30
50
100
150
300
750
1100
2200
3700
30
60
100
200
300
600
1000
1500
3000
5000
−30
−30
−30
−30
−30
0
0
0
0
0
10
20
30
60
60
90
135
270
420
42
84
140
280
420
840
1300
1950
3900
6000
(2)
(3)
3
6
6
OPERATING
LIMITS
(4)
3.3
6.6
6.6
STANDARD
MATERIAL
11
22
33
66
S31600 (316 SST)
66
103
155
310
482
STANDARD
MATERIAL
48
96
160
320
480
960
S31600 (316 SST)
1500
2250
4500
7000
Table 1-5. Optional Process Connections
INPUT RANGE CONNECTION
Bar Psig Size Material
Up to
0 to 400
0 to 400 to
0 to 600
0 to 400 to
0 to 600
Up to
0 to 5000
0 to 5000 to
0 to 10,000
0 to 5000 to
0 to 10,000
J 1/2 NPT external
or J 1/2 NPT
internal
1/2 NPT internal Stainless steel
1/2 NPT external Stainless steel
J Steel or
J stainless
steel
Table 1-6. Supply Pressure Data
OUTPUT SIGNAL
RANGE
Bar
Psig
1. If this pressure is exceeded, control may be impaired.
2. If this pressure is exceeded, damage to the controller may result.
0.2 to 1.0 1.4 2.8
0.4 to 2.0 2.4 2.8
3 to 15 20 40
6 to 30 35 40
NORMAL
OPERATING
SUPPLY
PRESSURE
MAXIMUM
PRESSURE LIMIT
(1)
(2)
1-8
Page 9
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Section 2 Installation
WARNING
To avoid personal injury or property
damage resulting from the sudden
release of pressure:
D Always wear protective clothing,
gloves, and eyewear when performing
any installation operations.
D Personal injury or property
damage may result from fire or
explosion if natural gas is used as the
supply medium and preventative
measures are not taken. Preventative
measures may include: Remote
venting of the unit, re-evaluating the
hazardous area classification,
ensuring adequate ventilation, and the
removal of any ignition sources. For
information on remote venting of this
controller, refer to page 2-5.
D Check with your process or
safety engineer for any additional
measures that must be taken to
protect against process media.
D If installing into an existing
application, also refer to the
WARNING at the beginning of the
Maintenance section of this
instruction manual.
Controller Mounting Orientation
Mount the controller with the housing vertical, as
shown in figure 2-1, so the vent points down.
TYPE 657
ACTUATOR
TYPE 4195K
CONTROLLER
TYPE 67CFR
FILTER
REGULATOR
MOUNTING
W8462−1
Figure 2-1. Typical Actuator Mounting
PLATE
Panel Mounting
Using the dimensions shown in figure 2-3, cut a hole
in the panel surface. Slide the controller into the hole
and attach the bracket (key 68) to the rear of the
controller using three cap screws (key 66) and lock
washers (key 67). Tighten the screws (key 70) to
seat the case snugly and evenly against the panel
surface.
Wall Mounting
Using the dimensions in figure 2-4, drill holes in the
wall to align with the four holes in the bracket (key
68). If the tubing is to run through the wall, drill a
hole in the wall large enough to accept the tubing.
Mount the controller to the bracket using three cap
screws (key 66) and lock washers (key 67). Attach
the bracket to the wall, using suitable screws or
bolts.
Pipestand Mounting
Refer to figure 2-2. Pipestand mounting parts are
provided to mount the controller to a 2-inch
(nominal) pipe. Attach a bracket (key 68) to the
controller with cap screws (key 66) and lock washers
(key 67). Attach two clamps (key 69) to the bracket
and fasten the controller to the pipe.
Actuator Mounting
Refer to figure 2-1. A controller specified for
mounting on a control valve actuator is mounted at
the factory. If the controller is ordered separately for
installation on a control valve actuator, mount the
unit as described in this section. Mounting parts vary
for different actuator types.
2-1
Page 10
4195KA, KB, KC, and KS Controllers
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 362)
Instruction Manual
Form 5207
April 2007
REGULATOR
49A3196-A
A6732 / IL
HEX NUT
(KEY 364)
LOCKWASHER
(KEY 363)
PIPE CLAMP
(KEY 69)
VERTICAL PIPE
LOCKWASHER
(KEY 363)
HEX NUT
(KEY 364)
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
HEX HEAD
CAP SCREW
(KEY 362)
PIPE CLAMP
(KEY 69)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
HORIZONTAL PIPE
Figure 2-2. Pipestand Mounting
Attach the mounting bracket to the actuator yoke
with cap screws, lock washers, and spacer spools.
Attach the controller to the bracket with cap screws,
lock washers, and spacer spools. On some designs,
the mounting bracket is attached to the actuator
casing rather than to the yoke.
Pressure Connections
WARNING
To avoid personal injury or property
damage resulting from the sudden
release of pressure, do not install any
2-2
system component where service
conditions could exceed the limits
given in this manual. Use
pressure-relieving devices as required
by government or accepted industry
codes and good engineering
practices.
Refer to figure 2-5 for pressure connection locations.
Supply, output, remote set point, external feedback,
and vent connections are 1/4 NPT, internal. Process
pressure connections are 1/4 or 1/2 NPT (optional).
Use 1/4-inch or 3/8-inch pipe or tubing for supply,
output, remote set point, and external feedback
connections.
Page 11
Instruction Manual
Form 5207
April 2007
LOCK
WASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 66)
BRACKET
(KEY 68)
ROUND
HEAD
MACHINE
SCREW
(KEY 70)
TOP VIEW
13
(0.50)
84
(3.29)
62
(2.43)
63
(2.49)
14 R
(0.56)
236
(9.31)
4195KA, KB, KC, and KS Controllers
161
(6.35)
306
(12.06)
152
(6.00)
TOP VIEW
260
(10.25)
LOCKWASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 66)
REAR VIEW DIMENSIONS OF
36A9760-A
A6733 / IL
PANEL CUTOUT
mm
(INCH)
Figure 2-3. Panel Mounting
Process Pressure Connection
The connection marked A on the bottom of the case
is the process input for all Bourdon tube controllers
and those capsular element controllers used in
vacuum pressure applications. The connection
marked B is the process input for capsular element
controllers used in positive pressure and compound
pressure applications. See figure 2-5 for the location
of the A and B connections.
When installing process piping, follow accepted
practices to ensure accurate transmission of the
process pressure to the controller. Install a
three-valve bypass, shutoff valves, vents, drains, or
seal systems as needed in the process pressure
lines. If necessary, install a needle valve in a
process pressure sensing line to dampen pulsations.
If the instrument is located such that the adjacent
process pressure lines are approximately horizontal,
62
13
(0.50)
13
(0.50)
(2.43)
BRACKET
(KEY 68)
REAR VIEW
36A9761-B
A6734 / IL
mm
(INCH)
Figure 2-4. Wall Mounting
the lines should slope downward to the instrument
for liquid-filled lines and upward toward the
instrument for gas-filled lines. This reduces the
possibility of air becoming trapped in the sensor with
liquid-filled lines or of condensation becoming
trapped in gas-filled lines. The recommended slope
is 83 millimeters per m (1 inch per foot).
If the controller is being used in conjunction with a
control valve to control pipeline pressure, connect
the process pressure line in a straight section of pipe
approximately 10 pipe diameters away from the
valve and also away from bends, elbows, and areas
of abnormal fluid velocities. For pressure-reducing
service, the process pressure line must be
connected downstream of the control valve. For
pressure-relief service, the process pressure line
must be connected upstream of the control valve.
2-3
Page 12
4195KA, KB, KC, and KS Controllers
Supply Pressure Connection
WARNING
Severe personal injury or property
damage may occur if the instrument
air supply is not clean, dry and
oil-free, or noncorrosive gas. While
use and regular maintenance of a filter
that removes particles larger than 40
microns in diameter will suffice in
most applications, check with an
Emerson Process Management field
office and industry instrument air
quality standards for use with
corrosive gas or if you are unsure
about the proper amount or method of
air filtration or filter maintenance.
Supply pressure must be clean, dry air or
noncorrosive gas that meets the requirements of
ISA Standard S7.3. Use a suitable supply pressure
regulator to reduce the supply pressure source to
the normal operating supply pressure shown in table
1-6. Connect supply pressure to the SUPPLY
connection on the bottom of the case, shown in
figure 2-5.
Remote Set Point (suffix letter M) Pressure Connection
1/4-18 NPT
CONTROLLER OUTPUT
CONNECTION
NOTES:
1
BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR
ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.
2
ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND
PRESSURE APPLICATIONS.
3
ONLY), EITHER THE A OR B CONNECTION IS USED, DEPENDING ON THE
LOCA TION OF THE PROCESS CONNECTION.
46A9765-A
A2892-4 / IL
Instruction Manual
Form 5207
April 2007
102
147
(5.80)
(4.00)
REAR VIEW
51
(2.00)
5/16
UNC-28
3 HOLES
(MOUNTING)
3.44
(87)
10.04
(255)
1/4 NPT
REMOTE SET POINT
CONNECTION
TOP VIEW
mm
(INCH)
260
(10.25)
FRONT VIEW
1/4-18
NPT VENT
CONNECTION
BOTTOM VIEW
1/4-18 NPT PROCESS CONNECTION (MARKED A) FOR ALL
1/4-18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR
FOR THE EXTERNAL FEEDBACK CONNECTIONS (4195KB CONTROLLERS
130
(5.13)
330
(13.00)
1/4-18 NPT
SUPPLY PRESSURE
CONNECTION
66
(2.56)
31
(1.22)
1/4 NPT 4 HOLES
If the controller has remote set point (suffix letter M),
connect the remote set point pressure to the top of
the controller case at the location shown in figure
2-5. Use clean, dry air or noncorrosive gas. Use a
0.2 to 1.0 bar (3 to 15 psig) remote set point
pressure range for a 0.2 to 1.0 bar (3 to 15 psig)
controller output signal range or a 0.4 to 2.0 bar (6
to 30 psig) remote set point pressure range for a 0.4
to 2.0 bar (6 to 30 psig) controller output signal
range. If pressure is supplied to the remote set point
connection with a regulator, a small bleed orifice
should be placed between the regulator and remote
set point connection to prevent pressure variations
due to regulator lock-up.
Figure 2-5. Connection Locations
External Feedback Pressure Connection (4195KB Series Controllers Only)
When a secondary controller in an override
application has this option, reset windup is
minimized in the secondary controller. Connect the
external feedback connection of the secondary
controller to the output of the customer-supplied high
or low select relay (see figures 2-5 and 4-9).
2-4
Page 13
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Vent
WARNING
Personal injury or property damage
could result from fire or explosion of
accumulated gas, or from contact with
hazardous gas, if a flammable or
hazardous gas is used as the supply
pressure medium. Because the
controller case and cover assembly do
not form a gas-tight seal when the
assembly is enclosed, a remote vent
line, adequate ventilation, and
necessary safety measures should be
used to prevent the accumulation of
flammable or hazardous gas.
However, a remote vent pipe alone
cannot be relied upon to remove all
flammable or hazardous gas. Vent line
piping should comply with local and
regional codes and should be as short
as possible with adequate inside
diameter and few bends to reduce
case pressure buildup.
CAUTION
When installing a remote vent pipe,
take care not to over-tighten the pipe
in the vent connection. Excessive
torque will damage the threads in the
connection.
If a remote vent is required, the vent line must be as
short as possible with a minimum number of bends
and elbows. Vent line piping should have a minimum
inside diameter of 19 mm (3/4 inches) for runs up to
6.1 meters (20 feet) and a minimum inside diameter
of 25 mm (1 inch) for runs from 6.1 to 30.5 meters
(20 to 100 feet).
The vent must be protected against the entrance of
any foreign material that could plug it; or if a remote
vent is not required, the vent opening in the case
must be protected against the entrance of any
foreign material that could plug it. Check the vent
periodically to be certain it is not plugged.
2-5
Page 14
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-6
Page 15
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
METAL BALL
SWITCHING ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
W6832 / IL
Figure 3-1. 4195KA Series Controller Adjustment Locations
Section 3 4195KA Series Proportional-Only Controllers
Adjustments for 4195KA Series Controllers
This section includes descriptions of adjustments
and procedures for prestartup, startup, and
calibration. Adjustment locations are shown in
figures 3-1 and 3-3. To better understand the
adjustments and overall controller operation, refer to
the Principle of Operation section and the schematic
diagrams in figures 3-4 and 3-5. Unless otherwise
noted, key numbers given in this section are found in
figure 7-1.
SET POINT
INDICATOR
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE
GAUGE
W3679 / IL
AUTO/MANUAL STATION
(SUFFIX LETTER E)
Remote Set Point (suffix letter M) Adjustment
CAUTION
Do not manually move the set point
indicator on controllers with remote
set point. Manually moving the set
point indicator could damage the
controller.
If the controller is equipped with remote set point
(suffix letter M), vary the remote set point pressure
to change the set point. Increase the pressure to
increase the set point, and decrease the pressure to
decrease the set point.
Manual Set Point Adjustment
Adjust the set point by moving the set point indicator
until the line on the set point indicator is over the
desired value on the process pressure scale. Move
the indicator to the right to increase the set point and
to the left to decrease it. Adjusting the set point does
not affect the proportional band setting.
Proportional Band Adjustment (PB ADJ)
The proportional band determines the controller
output sensitivity. The proportional band adjustment
is marked in percentages of process pressure
required to drive the controller from zero output to
full output.
3-1
Page 16
4195KA, KB, KC, and KS Controllers
D For reverse control action:
An increasing sensed vacuum decreases output
pressure.
After changing the action, tighten the screws on the
proportional band indicator cover.
Switching The Auto/Manual Station (suffix letter E)
W3439 / IL
Figure 3-2. Changing Controller Action on
4195KA Series Controllers
To adjust the proportional band, open the controller
cover and locate the proportional band adjustment
(PB ADJ) knob. Rotate the knob until the desired
value is opposite the line on the proportional band
indicator cover.
Changing Controller Action
To change the controller action from direct to
reverse or vice versa, loosen the screws on the
proportional band indicator cover. Lift the cover out
as shown in figure 3-2 and rotate the proportional
band adjustment to the desired action. Setting the
proportional band to the values in the white portion
of the adjustment provides direct controller action;
setting proportional band in the black portion
provides reverse controller action.
Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure
Refer to figure 3-1 if the controller has the
auto/manual station (suffix letter E). To switch from
automatic to manual mode, or from manual to
automatic, you must first balance the manual output
with the controller output. Two balance methods are
available to equalize the manual output with the
controller output.
To switch from automatic to manual mode, carefully
adjust the loader knob until the metal ball inside the
plastic tube moves into the switching zone. Then
move the automatic/manual switch to MANUAL.
Turn the loader knob clockwise to increase the
controller output or counterclockwise to decrease it.
To switch from manual to automatic mode, adjust
the set point to move the ball into the switching
zone. Turn the switch to AUTO and adjust the set
point to control the output.
Instruction Manual
Form 5207
April 2007
Note
Switching the controller between
automatic and manual, or manual and
automatic mode, without balancing
the outputs, can disturb the process
and cause controller cycling.
D For direct control action:
An increasing sensed pressure increases output
pressure.
D For reverse control action:
An increasing sensed pressure decreases output
pressure.
Capsular Element Controllers for Vacuum Pressure
D For direct control action:
An increasing sensed vacuum increases output
pressure.
3-2
When the auto/manual switch is in AUTO, adjusting
the loader knob has no effect on the controller
output. When the auto/manual switch is in MANUAL,
changing the set point has no effect on the controller
output.
Prestartup Checks for 4195KA Series Controllers
Refer to figure 3-1 for adjustment locations and refer
to figure 7-1 for key number locations.
When performing the checks, open loop conditions
must exist. An open loop exists when the controller
output does not affect the input pressure or other
control signal to the controller.
Page 17
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Note
If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing the prestartup
checks.
1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge. Connect supply pressure to the
supply pressure regulator and be sure it is delivering
the proper supply pressure to the controller. Do not
exceed the normal operating pressure in table 1-6.
2. For a controller with remote set point (suffix letter
M), connect regulated pressure of 0.2 to 1.0 bar (3
to 15 psig) or 0.4 to 2.1 bar (6 to 30 psig) to the
remote set point connection at the top of the
controller case.
3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
4. Adjust the set point a minimum of 20 percent of
input span above the process pointer.
5. Adjust the proportional band for 5 percent
DIRECT.
6. If necessary, connect a pressure source to the
process connection and adjust the process pointer
to the last mark on the left side of the scale. If the
last scale mark is 0 psig, a pressure source is not
required.
7. The controller output pressure should be 0 bar (0
psig).
8. Rotate the proportional band to 5 percent
REVERSE.
9. The controller output should be within 0.14 bar (2
psig) of the supply pressure.
Note
When performing the startup
procedures, keep in mind that the
initial settings are guidelines. They
will vary depending on the actual
process being controlled.
1. Be sure the supply pressure regulator is
delivering the proper supply pressure to the
controller.
2. For controllers with:
Manual set point:
Move the set point adjustment to the desired set
point.
Remote set point:
a. See figure 2-5 for the location of the remote
set point connection. Connect an adjustable
pressure source to the remote set point
connection.
b. Adjust the pressure source until the set point
indicator reaches the desired set point.
Remember: Increasing the remote set point
pressure increases the set point.
3. Set the proportional band adjustment to 100
percent for fast processes. For slow processes,
calculate the proportional band percentage from the
equation below:
P.B. +
For example:
200 Allowable Overshoot
Pressure Span
10. If the controller output is within tolerance, adjust
the proportional band to 400 percent in the desired
action, secure the proportional band indicator cover
(key 36) with the machine screws (key 6), and go to
the startup procedure. If the controller output
pressure is not within tolerance, go to the 4195KA
Series calibration procedure for recalibration.
Startup for 4195KA Series Controllers
Perform the prestartup checks and, if necessary,
calibrate the controller prior to this procedure.
200 0.14 bar
2.1 bar
4. Create a load upset by momentarily changing the
set point. Check for system cycling. If the system
does not cycle, lower the proportional band setting
(thus raising the gain) and disturb the system again
by changing the set point. Continue this procedure
until the system cycles. At this point, double the
proportional band setting (proportional band setting
×2).
5. Check the stability of the recommended
proportional band setting by introducing a
disturbance and monitoring the process.
^ 13%
3-3
Page 18
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Calibration of 4195KA Series Controllers
WARNING
To avoid personal injury or property
damage resulting from the sudden
release of pressure, do not exceed the
operating limits given in this manual.
General Calibration Instructions
Note
If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing calibration.
If the prestartup checks, or startup, reveal faulty
controller operation, perform the calibration
described in this section. These instructions are
valid for either shop or field calibration, provided that
open process loop conditions exist. Unless
otherwise noted, key numbers are found in
figure 7-1.
Do not use the gauges supplied with the controller
during calibration. Monitor process pressure, supply
pressure, controller output pressure, and if
applicable, remote set point pressure with external
gauges.
Process Indicator Zero and Span Calibration
Before starting this procedure:
D Provide a regulated process pressure to the
controller and a means of measurement external to
the controller.
D Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open loop conditions must
exist). Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.
readjustment of the process pointer
zero adjustment.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply process pressure equal to the process
scale span lower limit.
4. The process pointer should indicate the process
scale lower limit. If not, adjust the process pointer to
the process scale lower limit by loosening the zero
adjustment locking screw and turning the zero
adjustment screw. Tighten the zero adjustment
locking screw.
5. Apply process pressure equal to the process
scale span upper limit.
6. The process pointer should indicate the process
scale upper limit. If not, adjust the span screw to
correct one-half of the error as follows: clockwise to
increase span for a low indication (below the upper
limit); counterclockwise to decrease span for a high
indication (above the upper limit).
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate the mid-scale mark, ±2
percent of span. If the error is greater than ±2
percent, refer to the Maintenance section and
perform the appropriate zero and span adjustment
procedure for a Bourdon tube or capsular element
controller.
9. Adjust the process pointer to within ±1 percent of
the mid-scale mark by loosening the locking screw
and turning the zero adjustment screw. This
distributes the error over the entire scale span and
brings all points within ±1 percent of the process
input span.
10. Apply process pressure equal to the process
scale span lower limit.
11. The process pointer should indicate the process
scale lower limit ±1 percent of the scale span.
Refer to figures 3-1 and 3-3 for adjustment
locations.
Note
Any change to the process pointer
span adjustment will require
3-4
12. Apply process pressure equal to the process
scale span upper limit.
13. The process pointer should indicate the process
scale upper limit ±1 percent of the scale span.
14. If the error is greater than ±1 percent, repeat
steps 3 through 13.
Page 19
Instruction Manual
Form 5207
April 2007
REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)
4195KA, KB, KC, and KS Controllers
POINTER ZERO
ADJUSTMENT
POINTER ZERO
ADJUSTMENT
LOCKING SCREW
W6832 / IL
PROCESS
POINTER SPAN
ADJUSTMENT
A6730 / IL
REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)
39A1126-B
REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)
SIDE VIEW OF SET POINT/
PROCESS INDICATOR ASSEMBLY
FRONT VIEW
PROCESS POINTER
SPAN ADJUSTMENT
SCREW 1
SCREW 2
SCREW 3
56A9752-S SHT 1
SIDE VIEW OF CONTROLLER
SHOWING FLAPPER LEVELING SCREWS
Figure 3-3. 4195KA Series Controller Calibration Adjustment Locations
3-5
Page 20
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Remote Set Point (suffix letter M) Zero
and Span Calibration
Refer to figures 3-1 and 3-3 for adjustment
locations. Refer to figure 7-1 for key number
locations.
Note
Any adjustment of the remote set
point span adjustment screw requires
readjustment of the remote set point
zero adjustment screw.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply remote set point pressure equal to the
lower range limit.
4. The set point indicator should indicate the
process scale lower limit. If not, loosen the remote
set point zero adjustment locking screw and adjust
the remote set point zero adjustment screw until the
set point indicator aligns with the process scale
lower limit. Tighten the zero adjustment locking
screw.
5. Apply remote set point pressure equal to the
upper range limit.
6. The set point indicator should indicate the
process scale upper limit. If not, adjust the remote
set point span adjustment screw to correct one-half
the error as follows: clockwise to increase span for a
low indication; counterclockwise to decrease span
for a high indication.
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Apply remote set point pressure equal to the
mid-range value.
9. Make sure the set point indicator is within ±1
percent of the mid-scale mark and if so, proceed to
step 12. If the set point indicator is not within 1
percent, but is within ±2 percent of the mid-scale
mark, then proceed with step 10. If the set point
indicator is not within ±2 percent, proceed to the
remote set point calibration procedure in the
Maintenance section.
10. Loosen the remote set point zero adjustment
locking screw and adjust the remote set point zero
adjustment screw to correct for half the error at
mid-scale. Tighten the zero adjustment locking
screw.
11. Apply remote set point pressure equal to the
lower and upper range limits and make sure the set
point indicator is within ±1 percent.
12. If necessary, perform the process indicator zero
and span calibration procedure in this section.
Otherwise, perform the flapper alignment procedure
in this section.
Flapper Alignment
Note
Perform the process indicator zero
and span calibration procedure and,
for controllers with remote set point
(suffix letter M), the remote set point
zero and span calibration procedure
before the flapper alignment.
Flapper leveling screw numbers and adjustments
are shown in figure 3-3. Key number locations are
shown in figure 7-1.
Provide a means of measuring the controller output
pressure by connecting the controller output to a
pressure gauge (open-loop conditions must exist).
Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6. After performing the flapper
alignment procedure, go to the startup procedure.
1. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point
(suffix letter M), adjust the remote set point pressure
until the set point indicator is at the mid-scale mark
on the process scale.
2. Apply process pressure equal to the mid-scale
value of the process scale span. If pressure is not
available to pressure the input element to the
mid-scale value, an alternate method is to
disconnect link number 1 at the input element and
tape the process pointer at the mid-scale mark on
the process scale. If the controller has a capsular
input element, note the hole from which link number
1 was removed for proper replacement. This method
should only be used if pressure is not available to
pressure the input element to the mid-scale value.
3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
4. Adjust the proportional band between DIRECT
and REVERSE.
5. The controller output should be 0.62 ±0.007 bar
(9 ±0.10 psig) for a 0.2 to 1.0 bar (3 to 15 psig)
output or 1.2 ±0.01 bar (18 ±0.2 psig) for a 0.4 to 2.0
bar (6 to 30 psig) output. If not, adjust flapper
leveling screw 2 (the screw nearest the nozzle) until
the output is within tolerance.
6. Set the proportional band to 30 percent DIRECT.
3-6
Page 21
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
SET POINT INDICATOR
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
BEAM
SUPPLY PRESSURE
OUTPUT PRESSURE
PROPORTIONAL PRESSURE
NOZZLE PRESSURE
46A9764-A
B1489-2 / IL
PROPORTIONAL
BELLOWS
FLAPPER
RESET BELLOWS (VENTED)
NOZZLE
Figure 3-4. 4195KA Series Controller Schematic
7. The controller output should be 0.62 ±0.02 bar (9
±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not,
adjust flapper leveling screw 3 (the screw nearest
the nozzle).
8. Set the proportional band to 30 percent
REVERSE.
9. The controller output should be 0.62 ±0.02 bar (9
±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle).
10. Repeat steps 4 through 9 until the controller
output remains in tolerance without further leveling
screw adjustments.
REVERSE ACTION
QUADRANT
PROPORTIONAL
BAND ADJUSTMENT
FEEDBACK
LINK
FEEDBACK
MOTION
DIRECT ACTION
QUADRANT
SUPPLY
PRESSURE
INPUT
MOTION
FLAPPER DETAIL
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY
FLAPPER PIVOT
Principle of Operation for 4195KA Series Controllers
Overall Operation
Refer to the schematic diagram in figure 3-4.
The input element is connected to the process
pointer and to the flapper by connecting links. As the
process pressure increases (in a direct-acting
controller), the flapper moves toward the nozzle,
restricting flow through the nozzle and increasing
nozzle pressure. When this occurs, relay action
increases the output pressure (delivery) of the
controller. Output pressure is fed back to the
proportional bellows. The action of the proportional
bellows counteracts the flapper movement that
resulted from the process pressure change and
backs the flapper away from the nozzle until
equilibrium is reached.
11. If link 1 was disconnected, remove the tape and
reconnect link 1 to the input element.
12. Set the proportional band to 400 percent in the
desired controller action and replace the proportional
band indicator cover.
Moving the set point indicator changes the distance
between the nozzle and flapper as does a change in
process pressure, except that when the set point is
changed, the nozzle moves with respect to the
flapper.
The proportional band adjustment positions the
nozzle on the flapper. Increasing (widening) the
proportional band moves the nozzle to a position on
3-7
Page 22
4195KA, KB, KC, and KS Controllers
AUTOMATIC
POSITION
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
AUTO/MANUAL
SWITCH
PLASTIC
TUBE
METAL BALL
Instruction Manual
MANUAL LOADER
MANUAL
LOADER
KNOB
Form 5207
April 2007
RELAY
SUPPLY
PRESSURE
RELAY OUTPUT PRESSURE
SUPPLY PRESSURE
MANUAL LOADER OUTPUT PRESSURE
48A5230-A
A2999-1 / IL
Figure 3-5. 4195KA Series Auto/Manual Station Schematic
the flapper where less input and more feedback
motion occurs, which decreases the gain of the
controller. Decreasing (narrowing) the proportional
band moves the nozzle toward a position where
more input and less feedback motion occurs, which
increases the gain. The controller action is changed
from direct to reverse by turning the proportional
band adjustment to position the nozzle on the
flapper quadrant to a point where the direction of the
flapper motion versus input motion is reversed as
shown in the flapper detail of figure 3-4. With the
controller in the reverse-acting mode, an increase in
process pressure causes a decrease in output
pressure.
Remote Set Point (suffix letter M) Operation
The capability to adjust the controller set point from
a remote location is available with all 4195KA Series
controllers. This option is designated by the letter M
in the type number.
A control pressure is applied to the capsular element
within the remote set point assembly. The expansion
and contraction of the capsule moves the set point
adjustment via a connecting linkage. Increasing the
control pressure to the capsule increases the set
point setting and decreasing the control pressure
reduces the set point setting.
MANUAL
POSITION
AUTO/MANUAL
SWITCH
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
Auto/Manual Station (suffix letter E) Operation
A controller with the auto/manual station (designated
by the suffix letter E in the type number) has piping
on the output side of the relay as shown in figure
3-5. Supply pressure to the relay is also applied to
the manual loader. The manual loader, functioning
as a regulator, applies pressure to one side of the
plastic tube and to the auto/manual switch. Output
pressure from the relay registers on the other side of
the plastic tube as well as in the auto/manual switch.
When the auto/manual switch is in the MANUAL
position, the manual loader output is channeled
through the auto/manual switch and becomes the
controller output. When the auto/manual switch is in
the AUTO position, the relay output is channeled
through the switch to become the controller output.
Before the auto/manual switch is operated, the relay
output must equal the manual loader output to avoid
bumping the process. Adjusting the set point varies
the pressure on the left-hand side of the plastic tube.
Adjusting the manual loader knob varies the
pressure on the right-hand side. When the pressures
are equal, the metal ball is centered in the tube and
it is held in place by a small magnet. A pressure
imbalance forces the ball to one end of the tube
where it forms a seal, blocking air flow through the
tube.
3-8
Page 23
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
METAL BALL
SWITCHING ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
SET POINT
INDICATOR
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
ANTI-RESET WINDUP
DIFFERENTIAL RELIEF
VALVE (SUFFIX LETTER F)
W3679 / IL
AUTO/MANUAL STATION
(SUFFIX LETTER E)
SUPPLY
PRESSURE GAUGE
W6833 / IL
RESET
ADJUSTMENT
TYPICAL ADJUSTMENTS
4195KB SHOWN
Figure 4-1. 4195KB and KC Series Controller Adjustment Locations
OUTPUT PRESSURE
GAUGE
Section 4
4195KB Series ProportionalPlus-Reset Controllers and 4195KC
Series ProportionalPlus-Reset-Plus-Rate Controllers
Adjustments for 4195KB and KC Series Controllers
This section includes descriptions of adjustments
and procedures for prestartup, startup, and
calibration. Adjustment locations are shown in
figures 4-1 and 4-3. To better understand the
adjustments and overall controller operation, refer to
the Principle of Operation section and to the
schematic diagrams in figures 4-5 through 4-9.
Unless otherwise noted, key numbers given in this
section are found in figure 7-1.
Manual Set Point Adjustment
Adjust the set point by opening the controller cover
and moving the set point indicator until the line on
RATE
ADJUSTMENT
W3599−1 / IL
4195KC RESET AND RATE ADJUSTMENTS
RESET
ADJUSTMENT
the set point indicator is over the desired value on
the process pressure scale. Move the indicator to
the right to increase the set point and to the left to
decrease it. Adjusting the set point does not affect
the proportional band setting.
Remote Set Point (suffix letter M) Adjustment
CAUTION
Do not manually move the set point
indicator on a controller with remote
set point. Manually moving the set
point indicator could damage the
controller.
If the controller is equipped with remote set point
(suffix letter M), vary the remote set point pressure
to change the set point. Increase the pressure to
increase the set point and decrease the pressure to
decrease the set point.
4-1
Page 24
4195KA, KB, KC, and KS Controllers
Capsular Element Controllers for Vacuum
Pressure
D For direct control action:
An increasing sensed vacuum increases output
pressure.
D For reverse control action:
An increasing sensed vacuum decreases output
pressure.
After changing the action, tighten the screws on the
W3439 / IL
Figure 4-2. Changing Controller Action on
4195KB and KC Series Controllers
Proportional Band Adjustment (PB ADJ)
The proportional band determines the controller
output sensitivity. The proportional band adjustment
is marked in percentages of process pressure
required to drive the controller from zero output to
full output.
To adjust the proportional band, open the controller
cover and locate the proportional band adjustment
(PB ADJ) knob. Rotate the knob until the desired
value is opposite the line on the proportional band
indicator cover.
Changing Controller Action
To change the controller action from direct to reverse
or vice versa, loosen the screws on the proportional
band indicator cover. Lift the cover out as shown in
figure 4-2 and rotate the proportional band
adjustment to the desired action. Setting the
proportional band to the values in the white portion
of the adjustment provides direct controller action;
setting proportional band in the black portion
provides reverse controller action.
Bourdon Tube or Capsular Element Controllers
for Positive or Compound Pressure
D For direct control action:
An increasing sensed pressure increases output
pressure.
D For reverse control action:
An increasing sensed pressure decreases output
pressure.
proportional band indicator cover.
Reset Adjustment
To adjust reset, open the controller cover and locate
the RESET adjustment. Rotate the adjustment
clockwise to decrease the minutes per repeat or
counterclockwise to increase the minutes per repeat.
Increasing the minutes per repeat provides a slower
reset action.
Rate Adjustment
To adjust rate, open the controller cover and locate
the RATE adjustment. Rotate the adjustment
clockwise to decrease the minutes (less rate action)
or counterclockwise to increase the minutes (more
rate action).
Anti-Reset Windup (suffix letter F) Adjustment
If the arrow on the relief valve points toward the
bottom of the controller case, as shown in figure 4-1,
the valve opens with increasing controller output
pressure. If the arrow points in the opposite
direction, the relief valve opens with decreasing
controller output pressure. Differential relief pressure
is factory set at 0.3 bar (5 psig). Maximum relief
pressure is 0.5 bar (7 psig). The minimum is 0.1 bar
(2 psig).
Turn the adjusting screw counterclockwise to
increase differential relief pressure, clockwise to
decrease it.
Instruction Manual
Form 5207
April 2007
4-2
Page 25
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Switching the Auto/Manual Station (suffix letter E)
Note
Switching the controller between
automatic and manual, or manual and
automatic mode, without balancing
the outputs, can disturb the process
and cause controller cycling.
Refer to figure 4-1 if the controller has the
auto/manual station (suffix letter E). To switch from
automatic to manual mode, or from manual to
automatic, you must first balance the manual output
with the controller output. Two balance methods are
available to equalize the manual output with the
controller output.
To switch from automatic to manual mode, carefully
adjust the loader knob until the metal ball inside the
plastic tube moves into the switching zone. Then
move the automatic/manual switch to MANUAL.
Turn the loader knob clockwise to increase the
controller output or counterclockwise to decrease it.
To switch from manual to automatic mode, adjust
the set point to move the ball into the switching
zone. Turn the switch to AUTO and adjust the set
point to control the output.
When the automatic/manual switch is in AUTO,
adjusting the loader knob has no effect on the
controller output. When the automatic/manual switch
is in MANUAL, changing the set point has no effect
on the controller output.
Prestartup Checks for 4195KB and KC Series Controllers
Refer to figure 4-1 for adjustment locations, and
refer to figure 7-1 for key number locations.
When performing the checks, open loop conditions
must exist. An open loop exists when the controller
output does not affect the input pressure or other
control signal to the controller.
controller output connection to the
external feedback connection (see
figure 2-5). Adjust the controller for
full output pressure and with the
RESET knob adjusted to 0.01
minutes/repeat, verify the tubing
connections do not leak. Disconnect
after completing the prestartup
checks.
1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge. Connect supply pressure to the
supply pressure regulator and be sure it is delivering
the proper supply pressure to the controller. Do not
exceed the normal operating pressure in table 1-6.
2. For a controller with remote set point (suffix letter
M), connect regulated pressure of 0.2 to 1.0 bar (3
to 15 psig) or 0.4 to 2.1 bar (6 to 30 psig) to the
remote set point connection at the top of the
controller case.
3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
4. Adjust the set point a minimum of 20 percent of
input span above the process pointer.
5. Turn the reset adjustment to 0.01 minutes per
repeat.
6. Turn the rate adjustment to OFF (4195KC
Series).
7. Adjust the proportional band for 5 percent
DIRECT.
8. If necessary, connect a pressure source to the
process connection and adjust the process pointer
to the last mark on the left side of the scale. If the
last scale mark is 0 bar (0 psig), a pressure source
is not required.
9. The controller output pressure should be 0 bar (0
psig).
10. Rotate the proportional band to 5 percent
REVERSE.
11. The controller output should be within 0.14 bar
(2 psig) of the supply pressure.
Note
If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing prestartup checks.
If the controller has the external
feedback option, connect the
12. If the controller output is within tolerance, adjust
the proportional band to 400 percent in the desired
action. Secure the proportional band indicator cover
(key 36) with the machine screws (key 6), and go to
the startup procedure. If the controller output
pressure is not within tolerance, go to the 4195KB
and KC Series calibration procedure for
recalibration.
4-3
Page 26
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Startup for 4195KB and KC Series Controllers
Perform the prestartup checks and, if necessary,
calibrate the controller prior to this procedure.
Note
When performing the startup
procedures, keep in mind that the
initial settings are guidelines. They
will vary depending on the actual
process being controlled.
1. Be sure the supply pressure regulator is
delivering the proper supply pressure to the
controller.
2. For controllers with:
Manual set point:
Move the set point indicator to the desired set point.
Remote set point:
a. See figure 2-5 for the location of the remote
set point connection. Connect an adjustable
pressure source to the remote set point
connection.
b. Adjust the pressure source until the set point
indicator reaches the desired set point.
Remember: Increasing the remote set point
pressure increases the set point.
3. Set the reset adjustment to 0.05 minutes per
repeat for fast processes. Set it to 0.5 minutes per
repeat for slow processes. For controllers with rate,
set the rate adjustment to OFF.
4. Set the proportional band to 100 percent for fast
processes. For slow processes, calculate the
proportional band percentage from the equation
below:
P.B. +
For example:
5. If the controller is used in conjunction with a
control valve, return the control valve to service by
slowly opening the upstream and downstream
manual control valves in the pipeline. Close the
manual bypass valve, if one is used.
6. Tune the various controller actions.
200 Allowable Overshoot
Pressure Span
200 0.14 bar
2.1 bar
^ 13%
Tuning proportional action: Create a load upset
by momentarily changing the set point. Check for
system cycling. If the system does not cycle, lower
the proportional band setting (thus raising the gain)
and disturb the system again by changing the set
point. Continue this procedure until the system
cycles. At this point, double the proportional band
setting (proportional band setting ×2).
Tuning reset action: Disturb the system. If the
system does not cycle, speed up the reset by
changing the setting to a lower value (faster reset).
Disturb the system again. Continue this procedure
until the system cycles. When the system cycles,
multiply the reset time setting by a factor of three
(reset setting ×3) and slow down the reset by
changing the reset setting to the higher value. The
reset is now tuned.
Tuning rate action: For a controller with rate
(4195KC Series), adjust the rate toward the higher
setting until cycling occurs. When the system cycles,
divide the rate value by a factor of three (rate setting
÷3) and decrease the rate by changing the setting to
the lower value. The rate is now tuned.
7. Check the stability of the recommended
proportional band setting by introducing a
disturbance and monitoring the process.
8. Once stable control is attained, the process
pointer and set point indicator should be in line. If
they are aligned, return the set point to the desired
value. If they are not, readjust the set point to the
desired control point and proceed with step 9.
9. If the process pointer is within 5 percent of the
set point indicator, turn the link 3 adjustment (see
figure 6-13 or 6-21 for location) until the process
pointer aligns with the set point indicator. Turn the
link 3 adjustment screw clockwise to increase the
process indication or counterclockwise to decrease
it. If the process pointer is misaligned with the set
point indicator by more than 5 percent of the scale
span, perform the calibration procedures for 4195KB
and KC Series controllers.
Calibration of 4195KB and KC Series Controllers
WARNING
To avoid personal injury or property
damage resulting from the sudden
release of pressure, do not exceed the
operating limits given in this manual.
4-4
Page 27
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
General Calibration Instructions
Note
If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing calibration.
If the prestartup checks, or startup, reveal faulty
controller operation, perform the calibration
described in this section. These instructions are
valid for either shop or field calibration, provided that
open loop conditions exist. Unless otherwise noted,
key numbers are found in figure 7-1.
Do not use the gauges supplied with the controller
during calibration. Monitor process pressure, supply
pressure, controller output pressure, and if
applicable, remote set point pressure with external
gauges.
Process Indicator Zero and Span Calibration
Before starting this procedure:
D Provide a regulated process pressure to the
controller and a means of measurement external to
the controller.
D Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open-loop conditions must
exist). Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.
Refer to figures 4-1 and 4-3 for adjustment
locations.
Note
Any change to the process pointer
span adjustment will require
readjustment of the process pointer
zero adjustment.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply process pressure equal to the process
scale span lower limit.
4. The process pointer should indicate the process
scale lower limit. If not, adjust the process pointer to
the process scale lower limit by loosening the zero
adjustment locking screw and turning the zero
adjustment screw. Tighten the zero adjustment
locking screw.
5. Apply process pressure equal to the process
scale span upper limit.
6. The process pointer should indicate the process
scale upper limit. If not, adjust the process pointer
span screw to correct one-half the error as follows:
clockwise to increase span for a low indication
(below the upper limit); counterclockwise to
decrease span for a high indication (above the upper
limit).
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Apply process pressure equal to the mid-scale
value on the process scale span. The process
pointer should indicate the mid-scale mark, ±2
percent of span. If the error is greater than ±2
percent, refer to the Maintenance section and
perform the appropriate zero and span adjustment
procedure for Bourdon tube or capsular element
controllers.
9. Adjust the process pointer to within ±1 percent of
the mid-scale mark by loosening the zero
adjustment locking screw and turning the zero
adjustment screw. This distributes the error over the
entire scale range and brings all points within ±1
percent of the process scale span.
10. Apply process pressure equal to the process
scale lower limit.
11. The process pointer should indicate the process
scale lower limit ±1 percent of the scale span.
12. Apply process pressure equal to the process
scale upper limit.
13. The process pointer should indicate the process
scale upper limit ±1 percent of the process scale
span.
14. If the error is greater than ±1 percent, repeat
steps 3 through 13.
Remote Set Point (suffix letter M) Zero and Span Calibration
Refer to figures 4-1 and 4-3 for adjustment
locations. Refer to figure 7-1 for key number
locations.
Note
Any adjustment of the remote set
point span adjustment screw requires
readjustment of the remote set point
zero adjustment screw.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
4-5
Page 28
4195KA, KB, KC, and KS Controllers
POINTER ZERO
ADJUSTMENT
POINTER ZERO
ADJUSTMENT
LOCKING SCREW
PROCESS POINTER
SPAN ADJUSTMENT
ANTI-RESET WINDUP
RELIEF VALVE
(SUFFIX LETTER F)
ANTI-RESET WINDUP
VALVE ADJUSTING SCREW
(SUFFIX LETTER F)
Instruction Manual
Form 5207
April 2007
W6833 / IL
REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)
REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)
FRONT VIEW, 4195KB SERIES
PROCESS
POINTER SPAN
ADJUSTMENT
SIDE VIEW OF
SET POINT/PROCESS
INDICATOR ASSEMBLY
39A1126-B
A6731 / IL
RESET
ADJUSTMENT
REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)
RATE
ADJUSTMENT
W3599−1 / IL
59A9752-S SHT 1
SIDE VIEW OF
CONTROLLER SHOWING
FLAPPER LEVELING SCREWS
4195KC SERIES
SCREW 1
SCREW 2
SCREW 3
RESET
ADJUSTMENT
4-6
Figure 4-3. 4195KB and KC Series Controller Calibration Adjustment Locations
Page 29
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply remote set point pressure equal to the
lower range limit.
4. The set point indicator should indicate the
process scale lower limit. If not, loosen the remote
set point zero adjustment locking screw and adjust
the remote set point zero adjustment screw until the
set point indicator aligns with the process scale
lower limit. Tighten the zero adjustment locking
screw.
5. Apply remote set point pressure equal to the
upper range limit.
6. The set point indicator should indicate the
process scale upper limit. If not, adjust the remote
set point span adjustment screw to correct one-half
the error as follows: clockwise to increase span for a
low indication; counterclockwise to decease span for
a high indication.
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Adjust the remote set point pressure to the
mid-range value.
9. Make sure the set point indicator is within ±1
percent of the mid-scale mark, and if so, proceed to
step 12. If the set point indicator is not within 1
percent, but is within ±2 percent of the mid-scale
mark, proceed with step 10. If the set point indicator
is not within ±2 percent, proceed to the remote set
point zero and span adjustment procedure in the
Maintenance section.
10. Loosen the remote set point zero adjustment
locking screw and adjust the remote set point zero
adjustment screw to correct for half the error at mid
scale. Tighten the zero adjustment locking screw.
11. Apply remote set point pressure equal to the
lower and upper range limits and make sure the set
point indicator is within ±1 percent.
12. If necessary, perform the process indicator zero
and span calibration procedure in this section.
Otherwise, perform the flapper alignment procedure
in this section.
Flapper Alignment
Note
Perform the process indicator zero
and span calibration procedure and,
for controllers with remote set point
(suffix letter M), the remote set point
zero and span calibration procedure
before the flapper alignment.
Flapper leveling screw numbers and adjustments
are shown in figure 4-3. Key number locations are
shown in figure 7-1.
Provide a means of measuring the controller output
pressure by connecting the controller output to a
pressure gauge (open-loop conditions must exist).
Do not apply supply pressure at this time.
Note
4195KB and KC Series controllers with
anti-reset windup (suffix letter F) are
supplied with two O-rings (key 52),
valve cover (key 51), and two machine
screws (key 53). Use these parts in the
next step.
1. For controllers with anti-reset windup (suffix letter
F), record the direction of the arrow on the anti-reset
windup relief valve (key 55). Remove the relief valve
and install the two O-rings (key 52) and valve cover
(key 51) supplied with the controller. Secure the
valve cover with the two machine screws (key 53)
provided.
2. If necessary, remove the two machine screws
(key 6) and lift off the proportional band indicator
cover (key 36).
3. If the controller has the external feedback option
(available with the 4195KB Series only), connect the
controller output to the external feedback
connection. See figure 2-5 for the location of the
output and external feedback connections.
4. Provide regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.
5. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point
(suffix letter M), adjust the remote set point pressure
until the set point indicator is at the mid-scale mark
on the process scale.
6. Set the reset adjustment to 0.01 minutes per
repeat.
7. If the controller has rate (4195KC Series), turn
the rate adjustment to OFF.
8. Apply process pressure equal to the mid-scale
value of the process scale span. If pressure is not
available to pressure the input element to mid-scale
value, an alternate method is to disconnect link
number 1 at the input element and tape the process
pointer at mid-scale mark on the process scale. If
4-7
Page 30
4195KA, KB, KC, and KS Controllers
the controller has a capsular input element, note the
hole where link number 1 is connected to the input
element, then disconnect link 1. This method should
only be used if pressure is not available to pressure
the input element to the mid-scale value.
Instruction Manual
Form 5207
April 2007
Note
Because of the high controller gain,
the controller output will not remain
stable in steps 9 through 13. The
controller output gauge is adequate to
check the output pressure during this
procedure.
9. Set the proportional band between DIRECT and
REVERSE.
10. The controller output should be relatively stable
at any value within the output range. If not, adjust
flapper leveling screw 2 (the screw nearest the
nozzle) until the output is relatively stable.
11. Set the proportional band to 30 percent
DIRECT. The controller output should be relatively
stable at any value within the output range. If not,
adjust flapper leveling screw 3 (the screw nearest
the nozzle) until the output is relatively stable.
12. Set the proportional band to 30 percent
REVERSE. The controller output should be relatively
stable at any value within the output range. If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle) until the output is relatively stable.
13. Repeat steps 9 through 12 until the controller
output remains relatively stable without further
flapper leveling screw adjustment.
Note
Steps 14 through 20 check the flapper
alignment.
14. Set the proportional band to 30 percent
DIRECT.
W4039 / IL
W4038 / IL
Figure 4-4. Alignment of the Process Pointer with the
RIGHT-HAND EDGE
LEFT-HAND EDGE
Set Point Indicator
15. Apply process pressure to the input element or,
if link 1 was disconnected, remove the tape from the
process pointer and move the pointer until it aligns
with the right-hand edge of the set point indicator as
shown in figure 4-4.
The controller output should be within 0.14 bar (2
psig) of the supply pressure.
16. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the left-hand edge of the set point
indicator as shown in figure 4-4.
The controller output pressure should go to 0 bar (0
psig).
17. Set the proportional band to 30 percent
REVERSE.
18. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the right-hand edge of the set point
indicator as shown in figure 4-4. The controller
output should be 0 bar (0 psig).
19. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the left-hand edge of the set point
indicator as shown in figure 4-4. The controller
output should be within 0.14 bar (2 psig) of the
supply pressure.
20. If the controller does not perform as indicated in
steps 14 through 19, the flapper is not correctly
4-8
Page 31
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
aligned. This may occur because the output was not
sufficiently stabilized in steps 9 through 13. Repeat
steps 8 through 19.
21. When the flapper is correctly aligned, set the
proportional band to 400 percent in the desired
controller action and replace the proportional band
indicator cover. If link 1 was disconnected,
reconnect link 1 to the input element using the same
hole noted in step 8.
22. Remove supply pressure.
23. If the controller has the external feedback
option, disconnect the outside tubing which connects
the external feedback connection to the output
connection.
24. For controllers with anti-reset windup (suffix
letter F), remove the two machine screws, valve
cover and two O-rings installed in step 1 of this
procedure. Install the anti-reset windup relief valve
(key 55) with the arrow pointing in the direction
recorded in step 1.
Anti-Reset Windup (suffix letter F) Differential Relief Valve Calibration
Calibration for the differential relief valve to relieve on rising controller output pressure
1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open-loop conditions must
exist). Do not apply supply pressure at this time.
2. Set the reset adjustment to 0.01 minutes per
repeat (wide open) and the rate adjustment (4195KC
Series only) to the OFF position.
3. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point,
adjust the remote set point pressure until the set
point indicator is at the mid-scale mark on the
process scale.
6. Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.
Note
Because of the high controller gain
with the reset adjustment at 0.01
minutes per repeat, the controller
output will not balance perfectly in the
following step. If the controller output
is stable for approximately 5 seconds,
it is adequately balanced.
7. Increase the process pressure (or vacuum for a
vacuum controller) to the controller until the
controller output pressure balances at 0.4 bar (6
psig) for a 0.2 to 1.0 bar (3 to 15 psig) output range
or 0.8 bar (12 psig) for a 0.4 to 2.0 bar (6 to 30 psig)
output range.
8. Turn the reset adjustment to the CLOSED
(4195KB Series) or OFF (4195KC Series) position.
9. Increase the controller output pressure in small
steps [approximately 0.04 bar (0.5 psig)] by
changing the process pressure to the controller or by
changing the controller set point. After each change
in process pressure or set point, the controller
output pressure should quickly change and then
stabilize at the new value.
10. Continue to change the controller output
pressure in 0.04 bar (0.5 psi) steps and check the
output pressure after each step to make sure it
stabilizes. At some point, the controller output will
start to ramp upward to supply pressure with no
further change to the controller input or set point.
Record the controller output pressure where this
ramping action begins because this is the point at
which the differential relief valve has relieved.
11. To obtain the differential relief valve differential
setting, calculate the difference between the original
controller output pressure in step 7 and the
controller output pressure recorded in step 10.
4. Set the proportional band to 100 percent in either
the DIRECT or REVERSE action depending on the
application requirements.
5. Refer to figure 4-3 for the location of the
anti-reset windup differential relief valve. For the
differential relief valve to relieve on rising controller
output pressure, install the valve so the arrow on the
valve points down. To change the direction of the
arrow, loosen the two mounting screws, pull the
valve out, and reinstall the valve with the arrow
pointing down. Tighten the two mounting screws.
12. If the differential pressure calculated in step 11
is incorrect for the application, adjust the differential
pressure by turning the differential relief valve
adjustment screw shown in figure 4-3. Turn the
screw clockwise to decrease the differential
pressure or counterclockwise to increase the
differential pressure. The differential relief valve is
set at the factory to relieve at approximately 0.4 bar
(5 psi) differential pressure.
13. Repeat steps 7 through 12 until the required
differential pressure is obtained.
4-9
Page 32
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Calibration for the differential relief valve to relieve on falling controller output pressure
1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open-loop conditions must
exist). Do not apply supply pressure at this time.
2. Set the reset adjustment to 0.01 minutes per
repeat (wide open) and the rate adjustment (4195KC
Series only) to the OFF position.
3. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point,
adjust the remote set point pressure until the set
point indicator is at the mid-scale mark on the
process scale.
4. Set the proportional band to 100 percent in either
the DIRECT or REVERSE action depending on the
application requirements.
5. Refer to figure 4-3 for the location of the
anti-reset windup differential relief valve. For the
differential relief valve to relieve on falling controller
output pressure, install the valve so the arrow on the
valve points up. To change the direction of the
arrow, loosen the two mounting screws, pull the
valve out, and reinstall the valve with the arrow
pointing up. Tighten the two mounting screws.
6. Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.
changing the controller set point. After each change
in controller process pressure or set point, the
controller output pressure should quickly change and
then stabilize at the new value.
10. Continue to change the controller output
pressure in 0.04 bar (0.5 psi) steps and check the
output pressure after each step to make sure it
stabilizes. At some point, the controller output will
start to ramp downward to 0 bar (0 psig) with no
further change to the controller input or set point.
Record the controller output pressure where this
ramping action begins because this is the point at
which the differential relief valve has relieved.
11. To obtain the differential relief valve differential
setting, calculate the difference between the original
controller output pressure in step 7 and the
controller output pressure recorded in step 10.
12. If the differential pressure calculated in step 11
is incorrect for the application, adjust the differential
pressure by turning the differential relief valve
adjustment screw, shown in figure 4-3. Turn the
screw clockwise to decrease the differential
pressure or counterclockwise to increase the
differential pressure. The differential relief valve is
set at the factory to relieve at approximately 0.4 bar
(5 psi) differential pressure.
13. Repeat steps 7 through 12 until the required
differential pressure is obtained.
Note
Because of the high controller gain
with the reset adjustment at 0.01
minutes per repeat, the controller
output will not balance perfectly in the
following step. If the controller output
is stable for approximately 5 seconds,
it is adequately balanced.
7. Increase the process pressure (or vacuum for a
vacuum controller) to the controller until the
controller output pressure balances at 0.8 bar (12
psig) for a 0.2 to 1.0 bar (3 to 15 psig) output range
or 1.6 bar (24 psig) for a 0.4 to 2.0 bar (6 to 30 psig)
output range.
8. Turn the reset adjustment to the CLOSED
(4195KB Series) or OFF (4195KC Series) position.
9. Decrease the controller output pressure in small
steps [approximately 0.04 bar ( 0.5 psig)] by
changing the process pressure to the controller or by
4-10
Principle of Operation for 4195KB and KC Series Controllers
Overall Operation
Refer to the schematic diagram in figure 4-5 for the
4195KB Series controllers, or to the schematic
diagram in figure 4-6 for the 4195KC Series
controllers.
The input element is connected to the process
pointer and to the flapper by connecting links. As the
process pressure increases (in a direct-acting
controller), the flapper moves toward the nozzle,
restricting flow through the nozzle and increasing
nozzle pressure. When this occurs, relay action
increases the output pressure (delivery) of the
controller. Output pressure is fed back to the
proportional bellows and to the reset bellows. The
action of the proportional bellows quickly
counteracts the flapper movement that resulted from
the process pressure change and backs the flapper
away from the nozzle.
Page 33
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
SET POINT
INDICATOR
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
SUPPLY PRESSURE
OUTPUT PRESSURE
BEAM
RESET BELLOWS
PROPORTIONAL
BELLOWS
FLAPPER
NOZZLE
PROPORTIONAL-PLUS-RESET CONTROL
RESET
VALVE
PROPORTIONAL
BAND ADJUSTMENT
SUPPLY
PRESSURE
TO
PROPORTIONAL
BELLOWS
FEEDBACK
LINK
FEEDBACK
MOTION
DIRECT ACTION
QUADRANT
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY
TO
RESET
BELLOWS
REVERSE ACTION
QUADRANT
INPUT MOTION
FLAPPER DETAIL
TO
NOZZLE
FLAPPER
PIVOT
OUTPUT
NOZZLE PRESSURE
RESET PRESSURE
46A9764−C
B1908−4 / IL
Figure 4-5. 4195KB Series Controller Schematic
Pressure in the reset bellows opposes the action of
the proportional bellows and slowly moves the
flapper closer to the nozzle. The result of this
interaction is that, when the process pressure
changes, proportional action temporarily reduces the
gain of the controller for improved stability. The
process pressure then slowly returns to set point, as
pressure in both bellows equalizes via the reset
action.
Moving the set point indicator changes the distance
between the nozzle and flapper as does a change in
process pressure, except that when the set point is
changed, the nozzle moves with respect to the
flapper.
RELAY
SUPPLY
PRESSURE
DIFFERENTIAL
RELIEF VALVE
RESET
VALVE
PROPORTIONAL-PLUS-RESET CONTROL WITH ANTI-RESET WINDUP
The proportional band adjustment positions the
nozzle on the flapper. Increasing (widening) the
proportional band moves the nozzle to a position on
the flapper where less input and more feedback
motion occurs, which decreases the gain of the
controller. Decreasing (narrowing) the proportional
band moves the nozzle toward a position where
more input and less feedback motion occurs, which
increases the gain. The controller action is changed
from direct to reverse by turning the proportional
band adjustment to position the nozzle on the
flapper quadrant to a point where the direction of the
flapper motion versus input motion is reversed as
shown in the flapper detail of figure 4-5 or 4-6. With
the controller in the reverse-acting mode, an
increase in process pressure causes a decrease in
output pressure.
4-11
Page 34
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
SET POINT
INDICATOR
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
SUPPLY PRESSURE
OUTPUT PRESSURE
NOZZLE PRESSURE
BEAM
PROPORTIONAL
BELLOWS
FLAPPER
NOZZLE
PROPORTIONAL-PLUS-RESET-PLUS-RATE CONTROL
DIFFERENTIAL
RELIEF VALVE
RESET BELLOWS
RATE VALVE
RESET VALVE
TO
PROPORTIONAL
BELLOWS
PROPORTIONAL
BAND ADJUSTMENT
TO
RESET
BELLOWS
TO
NOZZLE
DIRECT ACTION
QUADRANT
SUPPLY
PRESSURE
FEEDBACK
LINK
FEEDBACK
MOTION
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
REVERSE ACTION
QUADRANT
INPUT MOTION
FLAPPER DETAIL
RELAY
OUTPUT
RELAY
FLAPPER
PIVOT
RESET PRESSURE
PROPORTIONAL PRESSURE
46A9764-B
C0593-3 / IL
Figure 4-6. 4195KC Series Controller Schematic
A 4195KC Series controller also has a rate valve as
shown in figures 4-6 and 4-7. This valve is an
adjustable restriction that momentarily increases the
controller gain to accelerate the corrective action for
slow pressure systems. A
proportional-plus-reset-plus-rate controller responds
to a change in process pressure as follows:
4-12
SUPPLY
PRESSURE
RATE VALVE
RESET VALVE
PROPORTIONAL-PLUS-RESET-PLUS-RATE CONTROL
WITH ANTI-RESET WINDUP
D First, the rate action delays the proportional
action just long enough to allow the controller to
respond to the change quickly with high gain, but not
long enough for the high gain to cause instability.
D Then, the low gain provided by the proportional
action keeps the system stable. Finally, reset action
slowly increases the gain and returns the process
pressure toward the set point.
Page 35
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
RESET
BELLOWS
19A5000−A
A3237-2 / IL
RESET
VALVE
RATE
VALVE
PROPORTIONAL
BELLOWS
GAIN
LIMITER
RELAY OUTPUT
PRESSURE
and contraction of the capsule moves the set point
indicator via connecting linkage. Increasing the
control pressure to the capsule increases the set
point setting and decreasing the control pressure
reduces the set point setting.
Auto/Manual Station (suffix letter E) Operation
A controller with the auto/manual station (designated
by the suffix letter E in the type number) has piping
on the output side of the relay as shown in figure
4-8. Supply pressure to the relay is also applied to
the manual loader. The manual loader, functioning
as a regulator, applies pressure to one side of the
plastic tube and to the auto/manual switch. Output
pressure from the relay registers on the other side of
the plastic tube as well as in the auto/manual switch.
When the auto/manual switch is in the MANUAL
position, the manual loader output is channeled
through the auto/manual switch and becomes the
controller output. When the auto/manual switch is in
the AUTO position, the relay output is channeled
through the switch to become the controller output.
Figure 4-7. Reset-Rate Schematic
Anti-Reset Windup (suffix letter F) Operation
Anti-reset windup is available on all 4195KB and KC
Series controllers and is designated by the letter F in
the type number. The differential relief valve
operates when the difference between the
proportional bellows pressure and the reset bellows
pressure reaches a predetermined value. Anti-reset
windup reduces overshoot of the process pressure
that can result from a large or prolonged deviation
from set point.
Remote Set Point (suffix letter M) Operation
The capability to adjust the controller set point from
a remote location is available with all 4195KB and
KC Series controllers. This option is designated by
the letter M in the type number.
A control pressure is applied to the capsular element
within the remote set point assembly. The expansion
Before the auto/manual switch is operated, the relay
output must equal the manual loader output to avoid
bumping the process. Adjusting the set point varies
the pressure on the left-hand side of the plastic tube.
Adjusting the manual loader knob varies the
pressure on the right-hand side. When the pressures
are equal, the metal ball is centered in the tube and
it is held in place by a small magnet. A pressure
imbalance forces the ball to one end of the tube
where it forms a seal, blocking air flow through the
tube.
External Feedback Operation
External feedback is available for all 4195KB Series
controllers. Controllers with this option have an
external connection on the bottom of the controller
case as shown in figure 2-5. This connection breaks
the positive feedback (reset) loop inside the
controller and brings it outside as shown in figure
4-9. The connection allows the positive feedback
loops of two controllers (primary and secondary) to
be tied together when the controllers are used in an
override application. When connected, the
secondary controller tracks the primary controller,
minimizing reset windup.
4-13
Page 36
4195KA, KB, KC, and KS Controllers
AUTOMATIC
POSITION
AUTO/MANUAL
SWITCH
Instruction Manual
Form 5207
April 2007
MANUAL LOADER
MANUAL
LOADER
KNOB
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY OUTPUT PRESSURE
SUPPLY PRESSURE
MANUAL LOADER OUTPUT PRESSURE
48A5230-A
A2999-1 / IL
Figure 4-8. 4195KB and KC Series Auto/Manual Station Schematic
SUPPLY
PRESSURE
TO
RESET
BELLOWS
RELAY
TO
NOZZLE
PLASTIC TUBE
METAL BALL
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
MANUAL
POSITION
AUTO/MANUAL
SWITCH
4-14
OUTPUT
RESET
VALVE
RELAY
TO
PROPORTIONAL
BELLOWS
EXTERNAL FEEDBACK TO
OUTPUT OF HIGH OR LOW
SELECT RELAY
SUPPLY PRESSURE
OUTPUT PRESSURE
47A0975−A
A3342-1 / IL
SUPPLY
PRESSURE
NOZZLE PRESSURE
RESET PRESSURE
SELECT RELAY
OUTPUT
Figure 4-9. Schematic of External Feedback Option
Page 37
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Section 5 4195KS Series Differential Gap Controllers
Operating Information
This section includes descriptions of adjustments
and procedures for prestartup and startup. Location
of adjustments is shown in figures 5-1 and 5-2. To
better understand the adjustments and overall
operation of the controller, refer to the Principle of
Operation section and the schematic diagrams,
figures 5-4 and 5-5.
Note
Some of the following procedures
require that the proportional band
knob be adjusted to between DIRECT
and REVERSE. If this is done, it will
be necessary to set the proportional
band knob to 400 (direct or reverse
action) before replacing the
proportional band indicator cover.
Adjustments for 4195KS Series Controllers
Manual Set Point
The set point adjustment adjusts the upper or lower
switching point, depending on controller action. To
adjust the set point, open the controller cover, and
move the set point adjustment until the pointer
indicates the desired value of pressure on the
process pressure scale. Move the adjustment to the
right to increase the set point, and to the left to
decrease it. Adjusting the set point does not affect
the differential gap setting.
Remote Set Point (Option M)
the set point. Increase the pressure to increase the
set point, and decrease the pressure to decrease
the set point.
Proportional Band (Differential Gap)
The proportional band knob adjusts width of the gap
between switching points. Rotate the knob until the
desired value is opposite the line on the proportional
band indicator cover.
Changing Controller Action
Controller action can be switched from direct to
reverse or vice versa by loosening the screws on the
proportional band indicator cover and moving the
cover out so the proportional band knob can be
rotated to the desired action. The white portion of
the adjustment enables direct controller action; the
black portion enables reverse controller action.
Auto/Manual Switching (Option E)
Refer to figure 5-5 if the controller has the
auto/manual option. Two balance methods are
available to equalize the manual output with the
controller pressure. To switch from automatic to
manual mode, carefully adjust the loader knob until
the metal ball inside the plastic tube moves into the
switching zone. The move the automatic/manual
switch to MANUAL. Turn the loader knob clockwise
to increase the controller output or counter clockwise
to decrease it. To switch from manual to automatic
mode, adjust the set point manually or with remote
set point pressure to move the ball into the switching
zone. Turn the switch to AUTOMATIC, and adjust
the set point manually or with the remote set point
pressure to control the output.
When the automatic/manual switch is in
AUTOMATIC, adjusting the loader knob has no
effect on the controller output. When the
automatic/manual switch is in MANUAL, changing
the set point adjustment has no effect on the
controller output.
CAUTION
Do not move the set point manually
on controllers with remote set point.
Doing so could damage the controller.
If the controller is equipped with remote set point
option, vary the remote set point pressure to change
Note
Switching the controller between
automatic and manual, or manual and
automatic mode, without balancing
the outputs, can disturb the process
and cause controller cycling.
5-1
Page 38
4195KA, KB, KC, and KS Controllers
TIE BAR
LINK 5
LONG PIVOT
ASSEMBLY
SHORT
PIVOT
ASSEMBLY
LINEARITY
ADJUSTMENT
PROCESS
SPAN
ADJUSTMENT
LINK 1
INDICATOR
ZERO
ADJUSTMENT
ZERO
ADJUSTMENT
LOCKING SCREW
Instruction Manual
Form 5207
April 2007
SET POINT
ADJUSTMENT
PROCESS
PROCESS
INDICATOR
INDICATOR
PROPORTIONAL
BAND INDICATOR
COVER
PROPORTIONAL
BAND ADJUSTMENT
BOURDON
TUBE
CONNECTING
LINK
INDICATOR
ZERO ADJUSTMENT
ZERO ADJUSTMENT
LOCKING SCREW
PROCESS
SPAN ADJUSTMENT
CAPSULAR ELEMENT
PROCESS SENSOR
NOTE:
SENSING ELEMENT CAN ALSO BE A CAPSULAR ELEMENT
C0528-1/IL
Figure 5-1. 4195KS Series Controller Parts and Adjustments Locations
Prestartup Checks for 4195KS Series Controllers
When performing the checks, open loop conditions
must exist. Refer to figure 5-1 for location of
adjustments.
Note
If the controller has the auto/manual
option (option E), be sure the
controller is in the automatic mode
prior to performing prestartup checks.
1. Connect supply pressure to the supply pressure
regulator, and be sure it is delivering the proper
supply pressure to the controller. Provide a means
of measuring the controller output pressure.
2. For controllers with remote set point (option M),
connect regulated pressure of 0.2 to 1.0 bar (3 to 15
psig) or 0.4 to 2.1 bar (6 to 30 psig) to the remote
set point connection at the top of the controller case.
3. Loosen two screws (key 6), lift off the
proportional band cover (key 36), and set the
OUTPUT PRESSURE
SUPPLY PRESSURE
GAUGE
FRONT VIEW OF CONTROLLER WITH
BOURDON TUBE PROCESS SENSOR
BI METAL STRIP FOR
TEMPERATURE COMPENSATION
GAUGE
proportional band knob between DIRECT and
REVERSE.
4. The process indicator should indicate the process
pressure. For example, with the process pressure at
50 percent of the input span, the process pointer
should be 50 percent (+/-1 percent) of its span.
Slight adjustment of the indicator zero screw may be
necessary. See figure 5-1 for zero adjustment and
locking screw location.
5. If desired, the accuracy can be verified at other
points on the scale. If the indicator appears to be out
of calibration, refer to the process zero and span
adjustment portion of the calibration procedure.
6. Install the proportional band cover and install two
screws (key 6).
Startup for 4195KS Series Controllers
It is recommended that the controller switching
points be set as described in the calibration
procedures.
5-2
Page 39
Instruction Manual
Form 5207
April 2007
PROCESS
SPAN
ADJUSTMENT
C0528-1/IL
REMOTE SET POINT
SPAN ADJUSTMENT
SIDE VIEW OF
SET POINT/PROCESS
INDICATOR ASSEMBLY
4195KA, KB, KC, and KS Controllers
SCREW 1
SCREW 2
SCREW 3
SIDE VIEW OF
CONTROLLER SHOWING
FLAPPER LEVELING SCREWS
Figure 5-1. 4195KS Series Controller Parts and Adjustments Locations (continued)
If they are used, slowly open the upstream and
downstream manual control valves in the pipeline
and close the manual bypass valve.
Calibration of 4195KS Series Controllers
Note
Some of the following procedures
require that the proportional band
knob be adjusted to between DIRECT
and REVERSE. If this is done, it will
be necessary to set the proportional
band knob to 400 (direct or reverse
action) before replacing the
proportional band indicator cover.
If the prestartup checks revealed faulty adjustment
of the process indicator, perform the calibration
procedures. These procedures are valid for either
shop or field calibration, provided that open process
loop conditions exist.
Note
If the controller has the auto/manual
option, be sure the controller is in the
automatic mode prior to performing
the calibration procedures.
Process Zero and Span Adjustment
Note
Any adjustment of the pointer span
adjustment screw will require
readjustment of the pointer zero
adjustment screw.
1. Refer to figure 5-1 for location of adjustments.
2. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
3. Set the proportional band between DIRECT and
REVERSE.
4. Adjust the process pressure to the low limit of the
input range.
5. Adjust the process pointer to the lowest limit of
the input scale by loosening the zero adjustment
locking screw and turning the zero adjustment
screw.
6. Adjust the process pressure to the upper limit of
the input span. Note whether the pointer indication is
above or below the upper limit of the process scale.
5-3
Page 40
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
PIVOT
ASSEMBLY A
36A9751-C
B1668-4 / IL
GUIDE
FLEXURE
TIE BAR
REMOTE SET POINT ZERO ADJUSTMENT SCREW
ZERO ADJUSTMENT LOCKING SCREW
MOUNTING
SCREW
Figure 5-2. 4195KS Series Controller Parts and Adjustments Locations (Remote Set Point Option)
7. Adjust the span screw as follows: Clockwise to
increase span for a low indication; counterclockwise
to decrease span for a high indication. Adjust the
span screw to correct one-half the error.
8. Repeat steps 4 through 7 until the error is
eliminated.
9. Install the proportional band indicator cover
(key 36), and tighten the two screws (key 6).
Remote Set Point Zero and Span Adjustment (Option M)
Note
Any adjustment of the pointer span
adjustment screw will require
readjustment of the pointer zero
adjustment screw.
1. Refer to figures 5-1 and 5-2 for location of
adjustments.
2. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
LINK A
MOUNTING
SCREW
ADJUSTMENT
SCREW
LINK B
LINEARITY
ADJUSTMENT
PIVOT
ASSEMBLY B
CAPSULES
DRIVE FLEXURE
LOWER TRAVEL
STOP
UPPER TRAVEL
STOP
SIDE VIEWFRONT VIEW
3. Set the proportional band between DIRECT and
REVERSE.
4. Adjust the process pressure to the low limit of the
input range.
5. Adjust the process pointer to the lowest limit of
the input scale by loosening the zero adjustment
locking screw and turning the zero adjustment
screw.
6. Adjust the process pressure to the upper limit of
the input span. Note whether the pointer indication is
above or below the upper limit of the process scale.
7. Adjust the span screw as follows: Clockwise to
increase span for a low indication; counterclockwise
to decrease span for a high indication. Adjust the
span screw to correct one-half the error.
8. Repeat steps 4 through 7 until the error is
eliminated.
9. Install the proportional band indicator cover (key
36), and tighten the two screws (key 6).
5-4
Page 41
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Setting Switching Points
Direct-Acting Controllers
The controller output signal will switch from zero
pressure to full supply pressure when increasing
process pressure passes the upper switching point.
The controller output signal will not return to zero
pressure until decreasing process pressure passes
the lower switching point. When making adjustments
as described in the following steps, keep in mind
that:
D Changing the set point adjustment will move
both switching points equally in the direction of
adjustment.
D Changing the proportional band adjustment will
widen or narrow the differential gap between the two
switching points by moving the position of the lower
switching point.
Figure 5-3 shows the relationship between the
percent of sensor range between switching points
and the proportional band setting on the controller.
The following example illustrates how to use figure
5-3.
Example: The sensing element has a range of 30
psi. The lower switching point is to be set at 10 psi
and the upper switching point is to be set at 25 psi.
Proceed as follows:
D Divide the differential gap (the difference
between the upper and lower switching points) by
the sensing element range. Multiply the result by
100 as shown in the following equation.
Differential Gap
x 100 =
Sensing Element Range
D Locate the 50 percent line on figure 5-3. Move
along this line until you intersect the curve. Read the
proportional band setting on the left hand axis. For
this example, the setting is approximately 35
percent.
1. Using the curve in figure 5-3, determine the
correct proportional band setting for the desired gap
(expressed as a percent of the input span) between
the switching points.
2. Set the proportional band knob to the desired
setting determined in step 1.
15 psi
30 psi
x 100 = 50
PROPORTIONAL BAND SETTING
SIDE
A2853−1 / IL
Figure 5-3. Curve for Determining Proportional Band Setting
% SENSOR RANGE BETWEEN SWITCHING POINTS
3. Adjust the set point to the desired upper
switching point.
4. Increase the process pressure until the controller
output signal switches from zero pressure to full
supply pressure.
5. Decrease the process pressure to the desired
switching point at which the controller output signal
switches from full supply pressure to zero pressure.
6. Narrow or widen the proportional band slowly
until the output signal switches from full supply
pressure to zero pressure.
7. Repeat steps 4 through 6 until the controller
output switches at the desired points.
8. Observe the process pointer when the output
switches at the upper switching point. The process
pointer indication should be within "2 percent of the
set point indication.
Reverse-Acting Controllers
The controller output signal will switch from zero
pressure to full supply pressure when decreasing
process pressure passes the lower switching point.
The controller output signal will not return to zero
pressure until increasing process pressure passes
the upper switching point. When making
adjustments as described in the following steps,
keep in mind that:
D Changing the set point adjustment will move
both switching points equally in the direction of
adjustment.
D Changing the proportional band adjustment will
widen or narrow the differential gap between the two
switching points by moving the position of the lower
switching point.
5-5
Page 42
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
SUPPLY PRESSURE
OUTPUT PRESSURE
POSITIVE FEEDBACK PRESSURE
NOZZLE PRESSURE
B1546−2 / IL
SET POINT
INDICATOR
POSITIVE FEEDBACK
PROPORTIONAL
BELLOWS
(VENTED)
FLAPPER
NOZZLE
BELLOWS
PROPORTIONAL
BAND ADJUSTMENT
Figure 5-4. 4195KS Series Controller Schematic
FEEDBACK
LINK
FEEDBACK
MOTION
DIRECT ACTION
QUADRANT
SUPPLY
PRESSURE
REVERSE ACTION
QUADRANT
INPUT MOTION
FLAPPER DETAIL
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY
FLAPPER
PIVOT
Figure 5-3 shows the relationship between the
percent of sensor range between switching points
and the proportional band setting on the controller.
The following example illustrates how to use figure
5-3.
Example: The sensing element has a range of 30
psi. The lower switching point is to be set at 10 psi
and the upper switching point is to be set at 25 psi.
Proceed as follows:
D Divide the differential gap (the difference
between the upper and lower switching points) by
the sensing element range. Multiply the result by
100 as shown in the following equation.
D Locate the 50 percent line on figure 5-3. Move
along this line until you intersect the curve. Read the
proportional band setting on the left hand axis. For
this example, the setting is approximately 35
percent.
Differential Gap
x 100 =
Sensing Element Range
15 psi
30 psi
x 100 = 50
1. Using the curve in figure 5-3, determine the
correct proportional band setting for the desired gap
(expressed as a percent of the maximum input
element span) between the switching points.
2. Set the proportional band knob to the desired
setting determined in step 1.
3. Adjust the set point to the desired lower switching
point.
4. Decrease the process pressure until the
controller output signal switches from zero pressure
to full supply pressure.
5. Increase the process pressure to the desired
switching point at which the controller output signal
switches from full supply pressure to zero pressure.
6. Narrow or widen the proportional band slowly
until the output signal switches from full supply
pressure to zero pressure.
7. Repeat steps 4 through 6 until the controller
output switches at the desired points.
8. Observe the process pointer when the output
switches at the upper switching point. The process
pointer indication should be within +/-2 percent of
the set point indication.
5-6
Page 43
Instruction Manual
Form 5207
April 2007
AUTOMATIC
POSITION
4195KA, KB, KC, and KS Controllers
MANUAL LOADER
AUTO/MANUAL
SWITCH
MANUAL
LOADER
KNOB
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY
SUPPLY
PRESSURE
RELAY OUTPUT PRESSURE
SUPPLY PRESSURE
MANUAL LOADER OUTPUT PRESSURE
48A5230-A
A2999-1 / IL
Figure 5-5. 4195KS Series Auto/Manual Schematic
Principle of Operation
Overall Operation
Refer to the schematic diagram in figure 5-4.
The input element is connected to the process
pointer and to the flapper by connecting links. As the
process pressure increases (in a direct-acting
controller). This movement restricts the flow through
the nozzle and increases nozzle pressure. When
this occurs, relay action increases the output
pressure (delivery) of the controller. Output pressure
is fed back to the positive feedback bellows. The
action of this bellows is a positive feedback action
that moves the flapper closer to the nozzle,
increasing nozzle pressure, which in turn, increases
the relay output. Output pressure to the final control
element switches to full supply pressure.
As the process pressure decreases, approaching
the lower switching point, the flapper moves away
from the nozzle (in a direct-acting controller)
reducing nozzle pressure. Through relay action,
pressure to the positive feedback bellows is
PLASTIC TUBE
METAL BALL
MANUAL
POSITION
AUTO/MANUAL
SWITCH
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
reduced, moving the flapper further away from the
nozzle, and further reducing nozzle pressure. Output
pressure to the final control element switches to
zero.
The set point adjustment changes the proximity of
the nozzle and flapper as does a change in process
pressure except that, when the set point is changed,
the nozzle moves with respect to the flapper. The
set point adjustment moves both the upper and
lower switching points.
The proportional band knob positions the nozzle on
the flapper. Increasing (widening) the proportional
band moves the nozzle away from the input
connection. When the proportional band adjustment
moves the nozzle across the feedback connection,
the controller action changes between direct and
reverse. On a direct-acting controller, changing the
proportional band adjustment will widen or narrow
the differential gap between the two switching
points. This is accomplished by moving the position
of the lower switching point. On a reverse-acting
controller, changing the proportional band
adjustment will widen or narrow the differential gap
5-7
Page 44
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
between the two switching points by moving the
position of the upper switching point.
Remote Set Point (Option M)
The capability to adjust the controller set point from
a remote location is available with all 4195KS Series
controllers. This option is designated by the letter M
in the type number.
Auto/Manual Option
Controllers with the auto/manual option (designated
by the letter E in the type number) have piping on
the output side of the relay as shown in figure 5-5.
Supply pressure to the relay is also applied to the
manual loader. The manual loader, functioning as a
regulator, applies pressure to one side of the plastic
tube and to the auto/manual switch. Output pressure
from the relay registers on the other side of the
plastic tube as well as in the auto/manual switch.
When the auto/manual switch is in the MANUAL
position, the manual loader output is channeled
through the auto/manual switch and becomes the
output of the controller. When the auto/manual
switch is in the AUTO position, the relay output is
channeled through the switch to become the output
of the controller.
Before the auto/manual switch is operated, the relay
output must equal the manual loader output to avoid
bumping the process. Adjusting the set point varies
the pressure on the left-hand side of the plastic tube.
Adjusting the manual loader knob varies the
pressure on the right-hand side. When the pressures
are equal, the metal ball is centered in the tube.
Pressure imbalance forces the ball to one end of the
tube where it forms a seal, blocking air flow through
the tube.
5-8
Page 45
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Section 6 Maintenance
Controller parts are subject to normal wear and must
be inspected and replaced as necessary. The
frequency of inspection and parts replacement
depends upon the severity of the service conditions.
When inspection or repairs are required,
disassemble only those parts necessary to
accomplish the job.
Inspection and Maintenance
WARNING
The following maintenance
procedures require taking the
controller out of service. To avoid
personal injury and property damage
caused by uncontrolled process
pressure, observe the following before
performing any maintenance
procedures:
Before performing any maintenance
operations:
D Always wear protective clothing,
gloves, and eyewear.
D Provide some temporary means
of control for the process before
taking the controller out of service.
D Shut off the supply pressure to
the controller.
D Personal injury or property
damage may result from fire or
explosion if natural gas is used as the
supply pressure medium and
preventative measures are not taken.
Preventative measures may include:
Remote venting of the unit,
Re-evaluation the hazardous area
classification, ensuring adequate
ventilation, and the removal of any
ignition sources. For information on
remote venting of this controller, refer
to page 2-5.
D Disconnect any operating lines
providing supply air pressure, a
process input signal, or other
pressure source to the controller.
D Check with your process or
safety engineer for any additional
measures that must be taken to
protect against process media.
Note
Unless otherwise noted, key numbers
refer to figures 7-1 through 7-7.
Figures 3-1 and 3-3 show adjustment
locations for 4195KA Series
controllers, figures 4-1 and 4-3 show
adjustment locations for 4195KB and
KC Series controllers, and figures 5-1
and 5-2 show adjustment locations for
4195KS Series controllers. For
maintenance on the indicator
assembly, refer to figures 7-2, 7-3 and
7-4.
Select the appropriate maintenance procedure and
perform the numbered steps. Each procedure
requires that the supply pressure be shut off before
beginning maintenance.
The maintenance procedures section describes part
replacement common to 4195KA, KB, KC, and KS
Series controllers. After completing the maintenance
procedures, perform the appropriate calibration
procedures. Unless otherwise noted, calibration
procedures for the 4195KA Series controller are in
Section 3, calibration procedures for the 4195KB
and KC Series controller are in Section 4, and
calibration procedures for the 4195KS Series
controller are in Section 5. If difficulty is encountered
performing the calibration procedures in Section 3,
4, or 5 refer to the calibration procedures in this
section.
Troubleshooting
As an aid to troubleshooting, table 6-1 lists some
common operating faults, their probable cause, and
suggests procedures for correcting the faults.
Replacing Common Controller Parts
WARNING
To avoid personal injury or property
damage caused by the uncontrolled
release of pressure, be sure any
trapped process pressure is properly
vented from the controller. Vent any
supply pressure from the controller
before disassembly.
6-1
Page 46
4195KA, KB, KC, and KS Controllers
Table 6-1. Troubleshooting Chart
Fault Possible Cause Check Correction
1. Process wanders or cycles
about set point
2. Controlling off set point as
reflected by process and set point
indicators.
Note: Some offset is inherent with
proportional-only controllers
(4195KA Series). The amount of
offset is a function of the
proportional band setting
1.1 Proportional band and reset
settings
1.2 Supply pressure varying
1.3 Process pointer rubbing on
cover or scale
1.4 Input element failure
1.5 Linkage failure
1.6 Relay malfunction
1.7 Anti-reset windup differential
relief valve set too low (suffix letter
F only)
2.1 Supply pressure not set
correctly
2.2 Flapper not aligned
2.3 Leak in input element/tubing
assembly
2.4 Indicators out of calibration
2.5 Linkage not connected
correctly
2.6 Leak in feedback system
1.1 Refer to the startup procedures
for controller settings
1.2 Monitor the supply pressure
with an external gauge. Ensure that
it is set correctly and does not
fluctuate. Note the number of
instruments being supplied by the
regulator
1.3 Note if the pointer is bent
1.4 Inspect the element for loose
screws and damaged flexures,
links or pivots. Using a soap
solution, check the sensing
element for leaks
1.5 Check for links that are bent or
not connected properly, flexures
bent or broken, pivots broken
1.6 By changing the process set
point and observing the output
verify that the output will change at
about the same rate in both
directions.
1.7 The minimum relief valve
setting is dependent on the loop
dynamics and the controller
settings. If under normal load
changes, the relief valve opens,
instability can occur. Check by
observing the controller reaction to
a set point or load change under
closed loop conditions
2.1 Check with an external source 2.1 Reset the supply pressure if
2.2 Refer to the flapper alignment
procedure
2.3 Using soap solution, check the
input element and tubing for leaks
2.4 Refer to the process indicator
(and remote set if applicable) zero
and span calibration procedures in
this manual
2.5 Inspect for loose screws and
damaged flexures, links or pivots
2.6 Open the reset valve to 0.1
minute/repeat. Adjust output
pressure to 1.4 bar (20 psig). Using
soap solution, check for leaks in
the proportional and reset bellows
in the tubing that connects these
bellows
(continued)
Instruction Manual
Form 5207
April 2007
1.1 If stable control cannot be
attained, and all other elements of
the loop are functionally correct,
examine other possible causes
related to the controller
1.2 Correct as necessary. One
regulator per instrument is
recommended
1.3 Bend pointer to provide
clearance
1.4 Repair or replace parts as
necessary
1.5 Replace or repair as necessary
1.6 If the output changes quickly in
one direction and sluggishly in the
other, replace the relay
1.7 If the differential relief valve
appears to be set too low, refer to
the section of this instruction
manual that covers the anti-reset
windup option
necessary. If the condition occurs
again, the regulator should be
rebuilt or replaced
2.2 Align the flapper as necessary
2.3 Repair or replace parts as
necessary
2.4 Adjust as necessary
2.5 Repair or replace parts as
necessary
2.6 Repair as necessary
6-2
Page 47
Instruction Manual
Form 5207
April 2007
Fault CorrectionCheckPossible Cause
2. Controlling off set point as
reflected by process and set point
indicators.
Note: Some offset is inherent with
proportional-only controllers
(4195KA Series). The amount of
offset is a function of the
proportional band setting
3. Controlling off set point but not
reflected by process and set point
indicators
4. No reset action (4195KB and
4195KC Series)
5. Abnormal control point shift
when proportional band is changed
Note: Control point shift is inherent
when changing proportional band in
proportional-only controllers
(4195KA Series).
6. Controller will not attain full
output range
4195KA, KB, KC, and KS Controllers
Table 6-1. Troubleshooting Chart (continued)
2.7 Reset valve leaks
2.8 Leak in remote set point
system
2.9 Input element overpressured 2.9 Check for zero shift
3.1 Controller is out of calibration 3.1 Refer to the process indicator,
4.1 Reset valve is plugged 4.1 Turn the reset valve through its
4.2 Reset pressure leak
4.3 Tubing leak
5.1 Flapper is out of alignment 5.1 Refer to flapper alignment
5.2 Flapper is dirty or pitted 5.2 Inspect the flapper
6.1 Output pressure gauge not
functioning
6.2 Supply pressure not correct 6.2 Check with an external source
6.3 Proportional band setting too
wide (4195KA Series only)
6.4 Input element or linkage failure
2.7 Hold the input constant and
adjust the output to 1.0 bar (15
psig) for a 0.2 to 1.0 bar (3 to 15
psig) output or 2.0 bar (30 psig) for
a 0.4 to 2.0 bar (6 to 30 psig)
output. Close the reset valve. If the
controller output varies as the reset
valve is closed and no leaks were
found in the rest of the feedback
system (Step 2.6), the reset valve
is leaking
2.8 Adjust remote set point
pressure to 1.0 bar (15 psig). Using
soap solution, check for leaks in
the remote set point and tubing
assembly
remote set point (if applicable), and
flapper alignment procedures
range several times to remove any
restrictions
4.2 Adjust the output to 1.0 bar (15
psig) for a 0.2 to 1.0 bar (3 to 15
psig) output or 2.0 bar (30 psig) for
a 0.4 to 2.0 bar (6 to 30 psig)
output. Close the reset valve. If the
output varies and no leaks were
found in the rest of the feedback
system (see Step 2.6), the reset
valve is leaking
4.3 With reset valve positioned at
.01 minute/repeat put 1.0 bar (15
psig) to the output port. Using soap
solution, check for leaks in the
reset bellows and attached tubing
assembly
procedure
6.1 Measure the output with an
external pressure gauge
6.3 Adjust proportional band
setting to 10. Manually cap the
nozzle. Output should increase
6.4 Inspect the element for
alignment and loose screws
(continued)
2.7 Replace the reset valve
(4195KB Series) or the rate/reset
valve (4195KC Series)
2.8 Repair or replace parts as
necessary
2.9 Replace input element and
adjust travel stops of applicable
3.1 Adjust as necessary
4.1 If reset action returns, no
further action is necessary. If not,
replace the reset valve (4195KB
Series) or rate/reset valve (4195KC
Series)
4.2 Replace the reset valve
(4195KB Series) or the rate/reset
valve (4195KC Series)
4.3 Repair or replace parts as
necessary
5.1 Align flapper as necessary
5.2 Clean, or replace flapper as
necessary
6.1 Replace the gauge if it is
defective
6.2 Repair or replace the supply
pressure regulator, if necessary.
Replace the supply pressure gauge
if necessary
6.3 Use a narrower proportional
band setting
6.4 Repair or replace parts as
necessary
6-3
Page 48
4195KA, KB, KC, and KS Controllers
Table 6-1. Troubleshooting Chart (continued)
Fault CorrectionCheckPossible Cause
6. Controller will not attain full
output range (continued)
7. Controller remains at full output
8. Controller remains at zero
output
6.5 Nozzle pressure leak
6.6 Leak in nozzle pressure tubing 6.6 Using soap solution, check for
6.7 Relay malfunction
7.1 Supply pressure too high
7.2 Output gauge not functioning
7.3 Sensor or linkage failure
7.4 Flapper mis-alignment
7.5 Relay failure or restriction in
nozzle passage
8.1 Gauge not functioning
8.2 Sensor or linkage failure
8.3 Flapper misalignment
8.4 Relay malfunction
8.5 Nozzle pressure leak
6.5 Check for nozzle tubing leaks
with a water bottle and soap
solution with the nozzle capped by
the flapper. Press the nozzle cap
(key 23) gently to ensure the
nozzle assembly is sealing. Ensure
the relay nozzle tubing nut (key 18)
is tight and the manifold screws
(keys 34 and 131) are tight
leaks in the nozzle tubing assembly
6.7 Manually push the flapper
away from the nozzle. The output
pressure should be zero. Cap the
nozzle. The output should increase
rapidly to within 35 mbar (0.5 psig)
of the supply pressure
7.1 Check with an external
pressure gauge
7.2 Reduce supply pressure to 0
bar (0 psig) to see if output gauge
responds
7.3 Vary the process pressure and
observe the flapper for movement.
Inspect the sensor and linkage for
damage
7.4 Vary the process pressure and
verify that the nozzle can be
uncapped by the flapper
7.5 Loosen the relay nozzle tubing
nut (key 18) with full supply
pressure
8.1 Verify that the supply pressure
is at its correct value and that the
controller output is zero
8.2 Vary the process pressure and
observe the flapper for movement.
Inspect the sensor and linkage for
damage
8.3 Vary the process pressure and
verify that the nozzle can be
capped by the flapper
8.4 Check for air at the nozzle.
Cap the nozzle and see if the
controller output increases to within
0.03 bar (0.5 psig) of supply
pressure
8.5 Check for nozzle tubing leaks
with a water bottle and soap
solution with the nozzle capped by
the flapper. Press the nozzle cap
(key 23) gently to ensure the
nozzle assembly is sealing. Ensure
the relay nozzle tubing nut (key 18)
is tight and the manifold screws
(keys 34 and 131) are tight
Instruction Manual
Form 5207
April 2007
6.5 Tighten the relay nozzle tubing
nut (key 18). Tighten the manifold
screws (keys 34 and 131). Replace
the nozzle assembly (key 21),
O-ring (key 24), or set point beam
assembly (key 23) as necessary if
leaking
6.6 Replace faulty parts as
necessary. Clean out the relay
primary orifice with the cleanout
wire attached to the relay to ensure
the orifice is not clogged
6.7 If the output does not change
as described, remove the relay.
Replace the O-rings if necessary.
Replace relay if necessary
7.1 Supply pressure regulator or
gauge may have to be replaced
7.2 If output gauge does not
respond, replace it
7.3 Repair or replace parts as
necessary
7.4 Perform flapper alignment
procedures
7.5 If the output pressure remains
at the supply pressure, replace the
relay. If the output pressure moves
to 0 bar (0 psig), clean or replace
nozzle or nozzle tubing.
8.1 Replace gauges as necessary
8.2 Repair or replace parts as
necessary
8.3 Perform flapper alignment
procedures
8.4 Clean out the relay primary
orifice with the cleanout wire
attached to the relay to ensure the
orifice is not clogged. If the problem
persists, replace the relay
8.5 Tighten the relay nozzle tubing
nut (key 18). Tighten the manifold
screws (keys 34 and 131). Replace
the nozzle assembly (key 21),
O-ring (key 24), or set point beam
assembly (key 23) as necessary if
leaking
6-4
Page 49
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
CLEAN-OUT
WIRE
EXHAUST PORT
(NO O-RING
USED)
O-RINGS
(KEY 15)
O-RING
(KEY 13)
W3440 / IL
W3492 / IL
DEFLECT LOWER PORTION OF THE SLOT
AND LIFT THE SCALE UP AND OFF
Figure 6-1. Changing the Scale
Replacing the Process Pressure Scale
WARNING
W5744 / IL
RELAY
TAB
Figure 6-2. Relay Construction
RELAY
MOUNTING
SCREWS
(KEY 10)
1. Adjust the set point indicator (either manually or
with the remote set point pressure) to the mid-scale
mark on the process scale.
2. Remove the four self-tapping screws (key 37).
3. Slide the process scale (key 61) downward so
that the top of the slot touches the set point
indicator. Deflect the lower portion of the slot
outward and carefully slide the scale up and off,
clearing the set point indicator as shown in
figure 6-1.
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
To prevent the pointer or set point
indicator from rubbing on the cover or
scale and producing an inaccurate
indication, take care not to bend the
process pointer or the set point
indicator while performing the
following procedure.
Refer to figure 6-1.
4. To install the replacement scale, deflect the lower
part of the slot slightly so that the scale slides
downward over the set point indicator and under the
process pointer.
5. Secure the scale with the four self-tapping
screws (key 37).
6. If the controller has remote set point (suffix letter
M), perform the appropriate remote set point zero
and span calibration procedure in Section 3, 4, or 5.
7. Perform the appropriate process indicator zero
and span calibration and the flapper alignment
procedures in Section 3, 4, or 5.
6-5
Page 50
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Replacing the Relay
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Loosen the two captive screws that hold the relay
(key 50) in place.
2. Tip the relay slightly toward the side of the case
to clear the output pressure gauge (key 46) and lift
out the relay.
3. Make sure the replacement relay has three
O-rings (keys 13 and 15) installed as shown in figure
6-2. The fourth port is for exhaust and does not
require an O-ring.
4. Install the replacement relay, making sure the tab
on the relay, shown in figure 6-2, aligns with the tab
on the frame.
5. Tighten the two screws that hold the relay in
place.
6. Perform the appropriate flapper alignment
procedure in Section 3, 4, or 5.
4. Position the controller assembly in the
replacement case and cover.
5. Start the nine mounting screws, but do not
tighten.
6. Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
7. Remove the blow-out plug (key 72) from the
original case, and install it in the replacement case.
8. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
9. Mount the controller as described in the
Installation section.
10. Connect the external piping to the controller.
Replacing the Gauges
Replacing the Case and Cover
WARNING
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
The case and cover are an integral
unit; attempting to separate them will
damage the hinge. If the cover needs
to be replaced, replace the case also.
1. Remove the external piping and fittings from the
controller.
2. Remove the controller from its mounting to a
maintenance area.
3. Remove the nine screws (key 38) from the case
and cover assembly (key 1) and lift out the controller
assembly. If the controller has remote set point
(suffix letter M), use a screwdriver or appropriate
tool to deflect the case slightly at the remote set
point connection to remove the controller assembly.
Inspect the O-rings around the external piping
connections and replace as necessary.
WARNING
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
Before performing this procedure, be
sure the replacement gauges are the
correct range so that they are not
damaged by overpressure.
1. Unscrew the output pressure gauge or the supply
pressure gauge (key 46) from the frame (key 3).
2. Before installing the replacement gauge, coat the
threads on the gauge with a sealant such as key 311
or equivalent.
3. Screw the replacement gauge into the frame.
4. Apply the correct supply pressure and check for
leaks with the nozzle capped for full output pressure.
6-6
Page 51
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Replacing the Supply Gauge, Proportional, Reset, Reset Valve, and Positive Feedback Tubing Assemblies
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Unscrew the nuts at each end of the tubing
assembly. Remove the tubing assembly.
3. Install the replacement tubing assembly.
4. Set the reset adjustment to 0.01 (4195KB and
KC Series) and set the rate adjustment to OFF
(4195KC Series).
5. Apply the correct supply pressure and check for
leaks with the nozzle capped for full output pressure.
Then, remove the supply pressure.
6. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
7. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Disassembly
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
See figure 7-1 for parts location.
3. Disconnect link 3 from the set point beam shoe,
part of the set point beam assembly (key 23).
4. Remove the set point beam bias spring (key 28).
5. Remove the screw and washer (keys 19 and 20)
that hold the adjustable set point pivot assembly
(key 17) to the frame and remove the pivot
assembly.
6. Unscrew the nut that secures the relay nozzle
tubing assembly (key 18) to the frame manifold
(key 135).
7. While holding the proportional band adjustment
knob, remove the screw and washer (keys 19
and 20) that hold the relay nozzle tubing assembly
(key 18) to the frame.
8. Remove the proportional band adjustment knob,
relay nozzle tubing assembly, and set point beam
assembly from the controller.
9. Remove the relay nozzle tubing assembly
(key 18) from the set point beam assembly (key 23).
8. Mount the controller as described in the
Installation section.
9. Connect the external piping to the controller.
Replacing the Proportional Band Adjustment Knob, Nozzle Assembly, and Set Point Beam Assembly
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Figure 6-3 shows the parts locations for the
proportional band adjustment and set point beam.
Unless otherwise noted, refer to this figure while
performing the following procedures.
10. Remove the E-ring (key 27) from the nozzle
assembly (key 21).
11. Remove the nozzle assembly (key 21) and
plastic washer (key 22) from the bottom of the set
point beam assembly (key 23).
12. Remove the retaining clip (key 26).
13. Remove the proportional band adjustment knob
(key 25) and plastic washer from the set point beam
assembly (key 23).
14. Inspect the nozzle assembly (key 21) and, if
necessary, replace it. Inspect the nozzle orifice and,
if necessary, clean it. Also, inspect the plastic
washers and, if necessary, replace them.
15. Inspect the nozzle assembly O-ring (key 24)
and, if necessary, replace it.
6-7
Page 52
4195KA, KB, KC, and KS Controllers
E-RING
(KEY 27)
RETAINING CLIP
(KEY 26)
PROPORTIONAL
BAND ADJUSTMENT
(KEY 25)
W4193 / IL
ADJUSTABLE
SET POINT
PIVOT ASSEMBLY
(KEY 17)
RETAINING
CLIP
E-RING
FLAPPER
PLASTIC
WASHER
SET POINT
BEAM ASSEMBLY
(KEY 23)
EXPLODED VIEW
CAP
RELAY
NOZZLE TUBING
ASSEMBLY
(KEY 18)
PLASTIC
WASHER
(KEY 22)
SET POINT
BEAM SHOE
(KEY 29)
Instruction Manual
Form 5207
April 2007
WASHER
(KEY 20)
SCREW
(KEY 19)
O-RING
NOZZLE
ASSEMBLY
(KEY 21)
CAP
PROPORTIONAL
BAND
ADJUSTMENT
KNOB
SET POINT BEAM
BIAS SPRING
SHOE
ADJUSTMENT
SCREWS
SET POINT
BEAM ASSEMBLY
W4194 / IL
SET POINT
BEAM SHOE
LINK 3
RELAY NOZZLE
TUBING ASSEMBLY
ASSEMBLED VIEW (CONTROLLER REMOVED FROM CASE)
Figure 6-3. Proportional Band Adjustment and Set Point Beam Details
6-8
Page 53
Instruction Manual
Form 5207
April 2007
Assembly
4195KA, KB, KC, and KS Controllers
1. Apply a suitable lubricant, such as key 318 or
equivalent, to the set point beam assembly; then
position a plastic washer (key 22) and the
proportional band adjustment knob (key 25) on the
set point beam assembly (key 23) as shown in
figure 6-3.
2. Position the retaining clip (key 26) on the three
posts on the proportional band adjustment knob.
3. Place the second plastic washer on the nozzle
assembly. Apply a suitable lubricant, such as key
317 or equivalent, to the nozzle assembly O-ring.
4. Insert the nozzle assembly (key 21) through the
set point beam assembly (key 23), the plastic
washer (key 22), the proportional band adjustment
knob (key 25), and the retaining clip (key 26) into the
cap. Align the nozzle with the tab on the proportional
band adjustment knob shown in figure 6-4; make
sure the proportional band adjustment knob engages
the flats on the nozzle assembly.
5. While holding the nozzle assembly (key 21)
against the set point beam assembly (key 23),
depress the retaining clip (key 26), and install the
E-ring (key 27) into the E-ring groove on the nozzle
assembly (key 21). Ensure that all three tabs of the
E-ring are engaged.
6. Inspect the O-ring on the relay nozzle tubing
assembly (key 18) and, if necessary, replace it.
Apply a suitable lubricant to the O-ring.
7. Install the relay nozzle tubing assembly (key 18)
into the set point beam assembly.
8. Set the proportional band adjustment between
DIRECT and REVERSE. Do this by aligning the tab
on the proportional band adjustment knob with the
hole in the set point beam assembly as shown in
figure 6-4.
9. Position the proportional band adjustment knob,
relay nozzle tubing assembly, and the set point
beam assembly on the frame. Screw the relay
nozzle tubing nut loosely into the frame manifold.
10. Insert the machine screw, with plain washer
(keys 19 and 20), through the frame and start it into
the relay nozzle tubing assembly (key 18), but do
not tighten.
TAB
HOLE
W3761 / IL
Figure 6-4. Proportional Band Adjustment Knob Setting
11. Center the nozzle on the flapper as shown in
figure 6-5 while squeezing the set point beam
assembly firmly against the relay nozzle tubing
assembly. With the nozzle centered on the flapper,
tighten the machine screw (key 19). Ensure that the
nozzle is still centered on the flapper.
12. Insert the pivot of the adjustable set point pivot
assembly (key 17) into the hole in the set point
beam assembly (key 23).
13. Insert the screw, with washer (keys 19 and 20),
through the frame (key 3) and start it into the
adjustable set point pivot assembly (key 17), but do
not tighten.
14. Squeeze the adjustable set point pivot assembly
against the set point beam assembly. Check to be
sure the nozzle is still centered on the flapper and
tighten the machine screw (key 19). If necessary,
loosen both machine screws (key 19) to allow
slightly moving the adjustable set point pivot
assembly, set point beam assembly and the relay
nozzle tubing assembly as a unit to center the
nozzle on the flapper. After centering the nozzle,
tighten the two machine screws.
6-9
Page 54
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
FLAPPER NOZZLE
W3449 / IL
Figure 6-5. Nozzle-Flapper Positioning
15. Turn the proportional band adjustment knob to 5
percent DIRECT. Refer to figure 6-6 to locate the
locking nut on the adjustable set point pivot
assembly. Loosen the locking nut and back out the
set screw slightly so that the set point beam
assembly falls under its own weight when pivoted
upward. Also, maintain a minimum side play
between the adjustable set point pivot assembly and
the nozzle tubing assembly. Tighten the locking nut.
16. At the frame manifold (key 135), tighten the nut
that secures the tubing from the relay nozzle tubing
assembly (key 18). Apply full supply pressure with
the nozzle capped and check for leaks. Remove
supply pressure.
17. Install the set point beam bias spring (key 28)
into the frame bore and onto the spring seat on the
set point beam assembly.
18. Attach link 3 to the set point beam shoe as
shown in figure 6-3.
19. For controllers with reset or rate adjustment
(4195KB or 4195KC Series), turn the reset
adjustment to the CLOSED (4195KB) or OFF
(4195KC) position. Set the rate adjustment to the
OFF position.
LOCKING
NUT
SCREW AND WASHER
(KEYS 19 AND 20)
NOTES:
1
SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY.
2
SCREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY.
W4195 / IL
Figure 6-6. Adjustable Set Point Pivot Assembly
Locking Nut Location
2
ADJUSTABLE SET POINT
PIVOT ASSEMBLY
SCREW AND WASHER
(KEYS 19 AND 20)
1
The controller output must be 0 bar (0 psig). To be
sure the controller output is 0 bar (0 psig ), remove
supply pressure, set the reset adjustment to 0.01
minutes per repeat and wait 30 seconds; then, turn
the reset adjustment to the CLOSED position
(4195KB) or to the OFF position (4195KC).
20. Apply the correct supply pressure (refer to table
1-6) to the controller and provide an accurate means
of measuring the controller output pressure.
21. Perform the appropriate process indicator zero
and span calibration procedure and, if necessary,
the remote set point zero and span calibration
procedure in Section 3, 4, or 5. When calibration is
complete, continue with step 22 below.
Note
The following procedure (steps 22
through 28) matches the process
pointer motion to the set point
indicator motion so the controller will
control at set point at all positions on
the process scale.
22. Set the proportional band to 40 percent in
REVERSE or DIRECT depending on the desired
controller action.
23. Adjust the set point to the lower limit on the
process scale.
6-10
Page 55
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
24. Disconnect link 1 from the input element, noting
the hole from which it is removed, for capsular input
elements, and tape the process pointer to the lower
limit on the process scale. The output pressure may
be anywhere between 0.2 to 1.0 bar (3 to 15 psig)
for a 0.2 to 1.0 bar (3 to 15 psig) output signal range
or between 0.4 to 2.0 bar (6 to 30 psig) for a 0.4 to
2.0 bar (6 to 30 psig) output signal range. If the
output is not within the specified range, adjust the
flapper leveling screw nearest the nozzle until the
output is within the range specified. Record the
controller output pressure.
25. Adjust the set point to the upper limit on the
process scale.
26. Remove the tape and move the process pointer
until the controller output equals the pressure
recorded in step 24. Note the process pressure
indication.
27. The process pressure indication should be
within ±2 percent of the upper limit on the process
scale.
If the process pressure indication in step 26 is
greater than the upper limit of the process scale by 2
percent, loosen the shoe adjustment screws (key
30), shown in figure 6-3, and move the set point
beam shoe (key 29) slightly away from the center of
the flapper assembly.
If the process pressure indication in step 26 is less
than the upper limit of the process scale by 2
percent, loosen the shoe adjustment screws (key
30), shown in figure 6-3, and move the set point
beam shoe (key 29) slightly toward the center of the
flapper assembly.
28. Repeat steps 23 through 27 until the error is
less than 2 percent of process scale span at the
upper limit of the process scale.
29. Remove the tape from the process pointer and
reconnect link 1 to the input element. If the controller
has a capsular input element, be sure to reconnect
link 1 in the same hole noted in step 24.
30. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
32. Mount the controller as described in the
Installation section.
33. Connect the external piping to the controller.
Replacing the Flapper Assembly and Flapper Flexure Pivot Assembly
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
3. Disconnect link 3 from the set point beam shoe,
part of the set point beam assembly (key 23). Refer
to figure 6-3 for the link location.
4. Remove the set point beam bias spring (key 28).
Refer to figure 6-3 for the spring location.
5. Remove the screw and washer (keys 19 and 20)
that hold the adjustable set point pivot assembly
(key 17) to the frame.
6. Remove the adjustable set point pivot assembly
(key 17).
7. Unscrew the nut that secures the relay nozzle
tubing assembly (key 18) to the frame manifold (key
135). Refer to figure 6-3.
8. While holding the proportional band adjustment
knob, remove the screw and washer (keys 19
and 20) that hold the relay nozzle tubing assembly
(key 18) to the frame.
9. Remove the proportional band adjustment knob,
relay nozzle tubing assembly, and the set point
beam assembly from the controller.
10. Disconnect link 2 from the flapper assembly
(key 11). Refer to figure 6-7 for the link location.
11. Disconnect link 4 from the bellows bracket
(key 31). Refer to figure 6-7 for the link location.
31. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
12. Remove the two cap screws (key 12) from the
flexure pivot assembly (key 9). See figure 6-8 for
screw location.
6-11
Page 56
4195KA, KB, KC, and KS Controllers
PROPORTIONAL
BELLOWS
BELLOWS
BRACKET
(KEY 31)
ADJUSTABLE
SET POINT PIVOT
ASSEMBLY (KEY 17)
SCREW AND
WASHER
(KEYS 19 AND 20)
Instruction Manual
Form 5207
April 2007
W4199 / IL
Figure 6-7. Bellows Assembly and Proportional Band Adjustment
(Process Scale and Proportional Band Indicator Cover Removed)
13. Remove the flapper assembly and link 4 as
shown in figure 6-9.
14. Remove the four machine screws (key 10),
shown in figure 6-9, that hold the flexure pivot
assembly to the frame.
15. Remove the flexure pivot assembly (key 9).
16. Install the replacement flexure pivot assembly
with the four screws (key 10). Do not tighten the
screws.
17. With the controller in the upright position, move
the flexure pivot assembly down as far as possible
and tighten the four screws (key 10).
18. Place the flapper assembly (key 11) on the
flexure pivot assembly (key 9) with link 4 through the
hole in the frame.
FLAPPER LEVELING
SCREW NUMBER 2
OBLONG HOLE
IN FRAME
W4770 / IL
Figure 6-8. Leveling Screw Alignment
LINK 4
LINK 2
FLAPPER
ASSEMBLY
FLEXURE PIVOT
ASSEMBLY SCREWS (KEY 12)
6-12
Page 57
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
LINK 4 ADJUSTMENTLINK 4
FLEXURE PIVOT
FOUR SCREWS
(KEY 10)
W4198 / IL
Figure 6-9. Exploded View of Flexure Pivot Assembly
ASSEMBLY
(KEY 9)
FLAPPER
ASSEMBLY
AND LINK 4
19. Position the flapper assembly (key 11) on the
flexure pivot assembly (key 9) and start the cap
screws (key 12) that hold the flapper assembly to
the flexure pivot assembly. Do not tighten the
screws.
20. Align flapper leveling screw number 2 with the
centerline of the oblong hole in the frame as shown
in figure 6-8. Tighten the cap screws (key 12).
Note
The following procedure (steps 21
through 23) adjusts link 2 to ensure
that it will always be in tension to
eliminate possible instability due to
lost motion.
21. Disconnect link 1 from the input element, noting
the hole location if the controller has a capsular input
element, and manually position the process pointer
to the process scale upper limit. Tape the pointer in
this position.
22. Adjust the length of link 2 by turning the
adjustment screw, shown in figure 6-10, clockwise to
increase the length or counterclockwise to
LINK 2
LINK 2 ADJUSTMENT
W3442-1 / IL
Figure 6-10. Link 2 and 4 Adjustment Locations
LINK 3
decrease the length, so that the pin on the end of
the link is approximately one-half of its diameter
short of aligning with the hole in the flapper
assembly, as shown in figure 6-11.
23. Connect link 2 to the flapper assembly.
24. Set the proportional band between DIRECT and
REVERSE. Do this by aligning the tab on the
proportional band adjustment knob with the hole in
the set point beam assembly as shown in figure 6-4.
25. Position the proportional band adjustment knob,
nozzle assembly, and set point beam assembly, and
nozzle tubing assembly on the frame, and screw the
relay nozzle tubing assembly nut loosely into the
frame manifold (key 135).
26. Insert the machine screw, with washer (keys 19
and 20), through the frame and start it into the relay
nozzle tubing assembly (key 18), but do not tighten.
27. Center the nozzle on the flapper as shown in
figure 6-5 while squeezing the set point beam
assembly firmly against the relay nozzle tubing
assembly. With the nozzle centered on the flapper,
tighten the machine screw (key 19). Ensure that the
nozzle is still centered on the flapper.
6-13
Page 58
4195KA, KB, KC, and KS Controllers
LEVELING
SCREW
NUMBER 1
Instruction Manual
Form 5207
April 2007
CONNECTING TAB ON
FLAPPER ASSEMBLY
W3451 / IL
W4191 / IL
Figure 6-11. Link 2 Adjustment
28. Insert the pivot of the adjustable set point pivot
assembly (key 17) into the hole in the set point
beam assembly (key 23).
29. Insert the screw, with washer (keys 19 and 20),
through the frame (key 3) and start it into the
adjustable set point pivot assembly (key 17), but do
not tighten.
30. Squeeze the adjustable set point pivot assembly
against the set point beam assembly. Check to be
sure the nozzle is still centered on the flapper and
tighten the machine screw (key 19). If necessary,
loosen both machine screws (key 19) to allow
slightly moving the adjustable set point pivot
assembly, set point beam assembly and the relay
nozzle tubing assembly as a unit to center the
nozzle on the flapper. After centering the nozzle,
tighten the two machine screws.
31. Turn the proportional band adjustment knob to 5
percent DIRECT. Refer to figure 6-6 to locate the
locking nut on the adjustable set point pivot
assembly. Loosen the locking nut and back out the
set screw slightly so that the set point beam
assembly falls under its own weight when pivoted
upward. Also, maintain a minimum side play
between the adjustable set point pivot assembly and
the nozzle tubing assembly. Tighten the locking nut.
32. At the frame manifold (key 135), tighten the nut
that secures the tubing from the relay nozzle tubing
assembly (key 18). Apply full supply pressure with
the nozzle capped (to obtain maximum output
pressure) and check for leaks. Remove supply
pressure.
1/2 OF PIN
DIAMETER
33. Install the set point beam bias spring (key 28)
into the frame bore and onto the spring seat on the
set point beam assembly, as shown in figure 6-3.
34. Attach link 3 to the set point beam shoe as
shown in figure 6-3.
Note
The following procedure (steps 35
through 41) adjusts link 4 so it will
always be in compression to eliminate
possible instability due to lost motion.
35. For controllers with reset and rate adjustments
(4195KB or 4195KC Series), remove the supply
pressure; then turn the reset adjustment to the
CLOSED (4195KB) or OFF (4195KC) position.
The controller output must be 0 bar (0 psig). To be
sure the controller output is 0 bar (0 psig), remove
supply pressure, set the reset adjustment to 0.01
minutes per repeat and wait 30 seconds; then, turn
the reset adjustment to the CLOSED (4195KB) or
OFF (4195KC) position.
36. Apply the correct supply pressure (refer to table
1-6) to the controller and provide an accurate means
of measuring the controller output pressure.
37. Adjust the proportional band to 5 percent
REVERSE and adjust the set point to the process
scale upper limit.
38. With link 1 disconnected, tape the process
pointer at the process scale lower limit. The output
pressure should be within 0.14 bar (2 psig) of the
6-14
Page 59
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
supply pressure. If not, adjust flapper leveling screw
1 (the screw nearest the nozzle) until the output is
within 0.14 bar (2 psig) of supply pressure.
39. Loosen the two adjustment screws on link 4,
shown in figure 6-10, and connect the link to the
bellows bracket (key 31), allowing the link to find its
free length.
40. Tighten the two adjusting screws on link 4.
41. Lift link 4 out of the hole in the bellows bracket
(key 31) and ensure it drops back into the hole
under its own weight. If not, repeat steps 39 and 40.
42. Adjust the proportional band to 40 percent
REVERSE or DIRECT depending on the desired
controller action.
43. Adjust the set point to the process scale lower
limit.
44. Tape the process pointer at the process scale
lower limit. The output pressure may be anywhere
between 0.2 to 1.0 bar (3 and 15 psig) for a 0.2 to
1.0 bar (3 to 15 psig) output signal range or between
0.4 to 2.0 bar (6 and 30 psig) for a 0.4 to 2.0 bar (6
to 30 psig) output signal range. If the output is not
within the specified range, adjust the flapper leveling
screw nearest the nozzle until the output is within
the range specified. Record the controller output
pressure.
45. Adjust the set point to the process scale upper
limit.
46. Remove the tape and move the process pointer
until the controller output equals the pressure
recorded in step 44. Note the process pressure
indication.
47. The process pressure indication should be
within ±2 percent of the process scale upper limit.
If the process pressure indication in step 46 is
greater than the process scale upper limit by 2
percent, loosen the shoe adjustment screws (key
30), shown in figure 6-3, and move the set point
beam shoe (key 29) slightly away from the center of
the flapper assembly.
If the process pressure indication in step 46 is less
than the process scale upper limit by 2 percent,
loosen the shoe adjustment screws (key 30), shown
in figure 6-3, and move the set point beam shoe
(key 29) slightly toward the center of the flapper
assembly.
48. Repeat steps 43 through 47 until the error is
less than 2 percent of the process scale span at the
process scale upper limit.
49. Remove the tape from the process pointer and
reconnect link 1 to the input element. If the controller
has a capsular input element, be sure to reconnect
link 1 in the same hole noted in step 21.
50. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
51. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
52. Mount the controller as described in the
Installation section.
53. Connect the external piping to the controller.
Replacing the Proportional, Reset or Positive Feedback Bellows
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 6-12, unless otherwise noted.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
3. Disconnect link 4 (key 65) from the bellows
bracket (key 31).
4. Remove the two machine screws (key 35) and
washer (key 362) from the bellows assemblies.
6-15
Page 60
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
FOUR SCREWS (KEY 6)
RESET
BELLOWS
WASHER
(KEY 362)
TWO SCREWS
(KEY 35)
RESET
GAIN
BELLOWS
BRACKET
(KEY 31)
W4199 / IL
Figure 6-12. Bellows Assembly, Bellows Bracket,
and Bellows Beam Location
PROPORTIONAL
BELLOWS
LINK 4
(KEY 65)
5. Remove the four machine screws (key 6) from
the bellows beam (key 49) and remove the bellows
bracket (key 31).
6. Remove the proportional tubing assembly (key
40) from the proportional bellows, the reset tubing
assembly (key 43) from the reset bellows or the
positive feedback tubing assembly (key 45) from the
positive feedback bellows, depending on which
bellows is to be replaced.
7. Remove the four machine screws (key 71) from
the bellows beam and remove the bellows beam
from the frame.
8. Unscrew the bellows assembly (key 48). If the
bellows assembly cannot be removed by hand,
thread a machine screw (key 35) into the bellows
until tight; then loosen the bellows assembly by
applying clockwise torque to the machine screw.
9. Before installing the replacement bellows, coat
the threads with a suitable lubricant, such as key
310. Screw in the replacement bellows until it is
finger tight against the frame (key 3).
10. Reinstall the bellows beam (key 49) and tighten
the machine screws (key 71).
11. Position the bellows bracket (key 31) over the
bellows. Insert a machine screw (key 35) through
the bellows bracket (key 31) and into the
proportional bellows. Do not tighten.
12. Place the washer (key 362) on the second
machine screw (key 35) and start the screw through
the bellows bracket (key 31) into the reset bellows.
Do not tighten.
13. Compress the bellows and start the four
machine screws (key 6) through the bellows bracket
(key 31) into the bellows beam (key 49), but do not
tighten.
14. Be sure that the bellows bracket is aligned such
that it does not rub on the frame at any point and
tighten the screws (keys 6 and 35).
15. Install the proportional, reset, or positive
feedback tubing assembly on the bellows base.
16. For a 4195KB or KC Series controller, set the
reset adjustment for 0.01 minutes per repeat. For a
4195KC Series controller, set the rate adjustment to
OFF.
17. Apply the correct supply pressure with the
nozzle capped and check for leaks. Remove the
supply pressure.
CAUTION
When removing and replacing the
proportional, reset, or positive
feedback bellows, keep in mind that
the bellows has left-hand threads.
Overtightening could damage the
threads.
Note
Both bellows need not be removed if
only one requires replacement.
6-16
18. Reconnect link 4 (key 65) to the bellows
bracket. Be sure that the link does not contact the
frame. If it does, loosen the four screws (key 6) that
attach the bellows bracket to the bellows beam and
reposition the bellows bracket to provide clearance.
Be sure the bellows bracket does not rub on the
frame; then, tighten the screws.
19. Lift link 4 out of the hole in the bellows bracket
(key 31) and ensure it drops back into the hole
under its own weight. If not, perform steps 35
through 41 of the flapper assembly and flapper
flexure pivot assembly replacement procedures.
20. If the controller is a proportional-only (4195KA
or KS Series), go to step 33. If the controller has
reset (4195KB or KC Series), continue with step 21.
Page 61
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Note
The following procedure (steps 21
through 32) adjusts the reset gain of
the controller to minimize steady-state
offset.
21. Apply the correct supply pressure (refer to table
1-6) to the controller and provide an accurate means
of measuring the controller output pressure. Also
provide a means of applying regulated process
pressure.
22. Adjust the proportional band to 100 percent
DIRECT.
23. Adjust the set point to the mid-scale mark on
the process scale.
24. Adjust the reset adjustment to 0.01 minutes per
repeat. For a 4195KC Series controller, set the rate
adjustment to OFF.
25. Increase the process pressure until the output
pressure stabilizes at 0.2 bar (3 psig) for a 0.2 to 1.0
bar (3 to 15 psig) output or 0.4 bar (6 psig) for a 0.4
to 2.0 bar (6 to 30 psig) output. Record the process
pressure reading.
Note
32. If ±1 percent of process scale span cannot be
achieved by adjusting the gain screw (key 34),
loosen the machine screw (key 35) attaching the
reset bellows and slide it to the left if the reading in
step 26 is greater than in step 25, or to the right if
the reading in step 26 is less than in step 25.
Tighten the screw and repeat steps 25 through 31.
33. Remove the supply pressure, the output
measurement device, and the regulated process
pressure source.
34. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
35. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
36. Mount the controller as described in the
Installation section.
37. Connect the external piping to the controller.
Replacing the Reset Restriction Valve (4195KB Series)
When the reset valve is at 0.01, the
controller is very sensitive to any
process pressure change. Only small
process pressure changes may be
necessary.
26. Very slowly increase the process pressure until
the output pressure stabilizes at 1.0 bar (15 psig) for
a 0.2 to 1.0 bar (3 to 15 psig) output or 2.0 bar (30
psig) for a 0.4 to 2.0 bar (6 to 30 psig) output.
Record the process pressure reading.
27. If the difference between the recorded process
pressure in step 25 and the process pressure in step
26 is larger than ±1 percent of the process scale
span, proceed with step 28. If the difference is less
than ±1 percent, go to step 33.
28. Loosen the proportional bellows screw (key 35).
29. If the reading recorded in step 26 is greater than
in step 25, adjust the reset gain screw (key 34)
one-half turn in (clockwise). If the reading recorded
in step 26 is less than in step 25, adjust the gain
screw (key 34) one-half turn out (counterclockwise).
30. Tighten the proportional bellows screw (key 35).
31. Repeat steps 25 through 30 until the difference
is less than ±1 percent of the process scale span.
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to the 4195KB Series portion of figure 7-1 for
key number locations.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Remove the reset valve tubing assembly (key 42)
from the reset restriction valve (key 54).
3. Remove the reset tubing assembly (key 43) from
the reset restriction valve.
4. For controllers with anti-reset windup (suffix letter
F), remove the relief valve tubing assembly (key 44)
from the reset restriction valve.
5. Remove the screw (key 162) that fastens the
reset restriction valve to the frame.
6. Install the replacement reset restriction valve and
secure it with the screw removed in step 5.
7. Install the reset valve tubing assembly (key 42),
the reset tubing assembly (key 43), and for
controllers with anti-reset windup, the relief tubing
assembly (key 44). Tighten all connections.
6-17
Page 62
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
8. Set the reset adjustment to 0.01 minutes per
repeat.
9. Apply the proper supply pressure to the
controller, cap the nozzle and check for leaks.
Remove the supply pressure.
10. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
11. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 4.
12. Mount the controller as described in the
Installation section.
13. Connect the external piping to the controller.
Replacing the Rate/Reset Valve Assembly (4195KC Series)
WARNING
7. While holding the rate/reset valve assembly,
remove the machine screw (key 162) from the
frame.
8. Remove the rate/reset valve assembly from the
frame.
9. Inspect and, if necessary, replace the gasket
(key 5).
10. To install the replacement rate/reset valve
assembly, position the assembly on the frame (key
3) and secure it with the mounting screw (key 162).
11. Position the gasket (key 5) on the rate/reset
valve assembly. Hold the gasket in place while
installing the rate tubing assembly (key 137) on the
valve assembly using the two machine screws (key
71).
12. Insert the reset tubing assembly (key 43) into
the rate/reset valve assembly and tighten the nut.
13. Insert the proportional tubing assembly (key 40)
into the rate/reset valve assembly and tighten the
nut.
Refer to the Maintenance WARNING
on page 6-1.
Note
Read this entire procedure before
removing any parts. Refer to the
4195KC Series portion of figure 7-1 for
key number locations.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Remove the two machine screws (key 71) on the
side of the rate/reset valve assembly (key 262).
3. Gently pull the rate tubing assembly away from
the rate/reset assembly and, remove the gasket (key
5) from the side of the rate/reset assembly.
4. Unscrew the nut holding the reset tubing
assembly (key 43) into the rate/reset valve
assembly.
5. Unscrew the nut holding the proportional tubing
assembly (key 40) into the rate/reset assembly.
6. For controllers with anti-reset windup (suffix letter
F), unscrew the nut holding the relief tubing
assembly (key 44) into the rate/reset assembly.
14. For controllers with anti-reset windup (suffix
letter F), insert the relief tubing assembly (key 44)
into the rate/reset valve assembly and tighten the
nut.
15. Set the reset to 0.01 minutes per repeat and the
rate to OFF.
16. Apply the proper supply pressure to the
controller and check for leaks. Remove the supply
pressure.
17. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
18. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 4.
19. Mount the controller as described in the
Installation section.
20. Connect the external piping to the controller.
6-18
Page 63
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Replacing the Anti-Reset Windup (suffix letter F) Differential Relief Valve
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to the 4195KB or 4195KC Series suffix letter F
portion of figure 7-1 for key number locations.
1. Loosen the two mounting screws in the
differential relief valve (key 55) and remove the relief
valve.
2. Inspect the O-rings on the replacement relief
valve. Apply a suitable lubricant to the O-rings.
3. Install the replacement relief valve into the
controller frame, keeping in mind that:
D When the arrow points up, the valve relieves
with decreasing output pressure.
D When the arrow points down, the valve relieves
with increasing output pressure.
4. Tighten the two screws that hold the relief valve
to the frame.
5. The relief valve differential pressure is factory-set
at 0.3 bar (5 psig). Maximum differential pressure is
0.5 bar (7 psig); minimum differential pressure is
0.14 bar (2 psig). If a different differential pressure
setting is desired, refer to the anti-reset windup
valve calibration procedure in Section 4.
COURSE ZERO ADJUSTMENT
LINK 1
LINK 2
LINK 2 ADJUSTMENT
W5745 / IL
Figure 6-13. Bourdon Tube Controller Link
Locations and Adjustments
LINK 4 ADJUSTMENT
LINK 4
LINK 3 ADJUSTMENT
LINK 3
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Loosen the nuts at both ends of the relief valve
tubing (key 44) and remove the tubing.
3. Install the replacement relief valve tubing, and
tighten the tubing nuts at both ends.
4. Apply the proper supply pressure to the
controller, cap the nozzle and check for leaks.
Remove the supply pressure.
Replacing the Anti-Reset Windup (suffix letter F) Relief Valve Tubing Assembly
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to the 4195KB or 4195KC Series suffix letter F
portion of figure 7-1 for key number locations.
5. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
6. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 4.
7. Mount the controller as described in the
Installation section.
8. Connect the external piping to the controller.
6-19
Page 64
4195KA, KB, KC, and KS Controllers
7. Connect link 1 to the Bourdon tube.
8. With the process pressure at 0 percent, the
process pointer should indicate 0 percent on the
process scale. If not, loosen the two screws on link 1
and adjust the length of link 1 to position the process
pointer at 0 percent. Tighten the screws.
9. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Bourdon Tube Controller Links
Instruction Manual
Form 5207
April 2007
W5747 IL
Figure 6-14. Disconnecting Link 1 from the Bourdon Tube
Bourdon Tube Controller Maintenance and Calibration
Replacing the Bourdon Tube
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 7-2 for key number locations. Refer
to figure 6-13 for a detailed photograph of the
Bourdon tube controller link locations and
adjustments.
1. Disconnect link 1 (key 382) from the Bourdon
tube (key 383) as shown in figure 6-14.
2. Unscrew the tubing nut from the Bourdon tube to
allow for Bourdon tube removal.
3. Remove the self-tapping screws (key 384) that
fasten the Bourdon tube (key 383) to the indicator
assembly (key 101).
4. With care, separate the Bourdon tube (key 383)
from the process tubing assembly (key 381) and lift
out the Bourdon tube.
5. Carefully place the replacement Bourdon tube in
position and start the two self-tapping screws.
Connect the process tubing assembly then tighten
the self-tapping screws to secure the Bourdon tube.
6. Apply process pressure equal to the process
scale upper limit and check for leaks. Remove
process pressure.
WARNING
Refer to the Maintenance WARNING
on page 6-1.
This section describes the separate replacement of
four links in the controller. Figure 6-13 shows the
location of each link. To clarify the location of each
link, the links are numbered as follows:
D Link 1 connects the Bourdon tube and the
process pointer
D Link 2 connects the process pointer and the
flapper assembly (key 11)
D Link 3 connects the set point indicator and the
set point beam assembly (key 23)
D Link 4 (key 65) connects the flapper assembly
and the bellows bracket (key 31).
Replacing Bourdon Tube Controller Link 1
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Note the hole position of link 1 in the process
pointer. As shown in figure 6-14, disconnect the link
from the Bourdon tube and from the process pointer.
Adjust the length of the replacement link to the same
length as the link being replaced.
3. Attach the replacement link to the original holes
in the process pointer and the Bourdon tube. If you
do not know in which hole in the process pointer the
link was connected, place it in the middle hole. If
during the process indicator zero and span
calibration, the pointer will not travel the full scale
6-20
Page 65
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
ALIGNED
W3443-1 / IL
Figure 6-15. Process Pointer Alignment
even after full span adjustment, move the link to the
bottom hole (the hole nearest the pointer pivot). If
the process pointer has too much travel, move the
link to the top hole (the hole furthest from the pointer
pivot).
4. Move the set point Indicator, either manually or
with remote set point pressure, to the mid-scale
mark on the process scale and set the proportional
band between DIRECT and REVERSE.
5. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the process pointer zero adjustment to align the
process pointer and pointer subassembly. Tighten
the zero adjustment locking screw.
6. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate mid-scale ±3 percent of the
process scale span. If not, loosen the two screws in
link 1 and move the process pointer to the mid-scale
mark on the process scale. Tighten the screws.
ZERO ADJUSTMENT
LOCKING SCREW
W3475-1 / IL
MISALIGNED
FINE ZERO
ADJUSTMENT
7. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Bourdon Tube Controller Link 2
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 2 from the process pointer and
from the flapper assembly (key 11). Remove the
link.
3. Install the replacement link with the screw head
nearest the process pointer as shown in figure 6-13.
Connect the link to the process pointer only.
4. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the process pointer zero adjustment to align the
process pointer and pointer subassembly. Tighten
the zero adjustment locking screw.
5. Move the set point indicator, either manually or
with the remote set point pressure, to the process
scale lower limit and set the proportional band to 5
percent REVERSE. The nozzle should not be
touching the flapper. If it is, adjust flapper leveling
6-21
Page 66
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
screw 1 (the screw nearest the nozzle) until
clearance is obtained.
6. Disconnect link 1 from the Bourdon tube and
manually position the process pointer to the process
scale upper limit. Tape the pointer in this position.
7. Adjust the length of link 2 (by turning the
adjusting screw clockwise to increase the length or
counterclockwise to decrease the length) so that the
pin on the end of the link is approximately one-half
of its diameter short of aligning with the hole in the
flapper assembly as shown in figure 6-11. This
adjustment provides the proper tension on the link to
eliminate lost motion.
8. Connect link 2 to the flapper assembly.
9. Remove the tape from the process pointer and
reconnect link 1 to the Bourdon tube.
10. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Bourdon Tube Controller Link 3
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 3 from the set point indicator and
the set point beam assembly (key 23).
3. Adjust the replacement link to the same length as
the link removed.
4. Install the replacement link with the screw head
toward the set point beam assembly as shown in
figure 6-13.
5. Check that the set point beam bias spring (key
28) is correctly located in the frame bore and the
spring seat on the set point beam assembly as
shown in figure 6-3.
6. Move the set point indicator to the mid-scale
mark on the process scale.
7. Apply process pressure to position the process
pointer at the mid-scale mark on the process scale.
8. Adjust the proportional band to 5 percent
DIRECT. Turn flapper leveling screw 3 (the screw
nearest the nozzle) until the nozzle just touches the
flapper.
9. Adjust the proportional band to 5 percent
REVERSE. Turn flapper leveling screw 1 (the screw
nearest the nozzle) until the nozzle just touches the
flapper.
10. Flapper leveling screws 1 and 3 should protrude
the same distance from the clinch nuts. A clinch nut
is shown in figure 6-16.
CLINCH
NUT
W4191-1 / IL
Figure 6-16. Flapper leveling Screw and Clinch Nut
FLAPPER LEVELING
SCREW
11. If leveling screw 1 protrudes further than
leveling screw 3, turn the link 3 adjusting screw
counterclockwise. If leveling screw 3 protrudes
further than leveling screw 1, turn the link 3 adjusting
screw clockwise.
12. Repeat steps 8 through 11 until leveling screws
1 and 3 protrude an equal distance from the clinch
nuts.
13. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Bourdon Tube Controller Link 4
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 4 from the bellows bracket (key
31) and the flapper assembly (key 11).
3. Connect the replacement link to the flapper
assembly so that the two adjusting screws on the
link are nearest to the bellows bracket (key 31) and
so that the screw heads are facing the bottom of the
controller as shown in figure 6-17.
4. For controllers with reset (4195KB Series) or
reset and rate adjustments (4195KC Series), turn
the reset adjustment to the CLOSED (4195KB) or
OFF (4195KC) position. Turn the rate adjustment
(4195KC Series) to the OFF position.
The controller output must be 0 bar (0 psig). To be
sure the controller output is at 0 bar (0 psig), remove
supply pressure, set the reset adjustment to 0.01
minutes per repeat and wait 30 seconds; then, turn
the reset adjustment to the CLOSED (4195KB) or
OFF (4195KC) position.
6-22
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Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
BELLOWS BRACKET
(KEY 31)
W4195 / IL
Figure 6-17. Position of Link 4 Adjustment Screws
LINK 4 ADJUSTMENT
SCREW HEADS
5. Adjust the proportional band to 5 percent
REVERSE and move the set point indicator to the
process scale upper limit.
6. Disconnect link 1 from the Bourdon tube and
move the process pointer to the process scale lower
limit. Tape the process pointer in this position.
7. Apply the correct supply pressure to the
controller. The output of the controller should be
within 0.14 bar (2 psig) of the supply pressure. If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle) until the output is within 0.14 bar (2 psig)
of supply pressure.
8. Loosen the two adjusting screws on link 4.
Connect the free end of the link to the bellows
bracket and allow the link to find its free length.
9. Tighten the two adjusting screws on the link.
10. Raise link 4 out of the hole in the bellows
bracket (key 31) and ensure that it drops back into
the hole under its own weight. If not, repeat steps 8
and 9.
11. For a controller with reset, adjust the reset
adjustment to 0.01 minutes per repeat. The rate
adjustment (4195KC) should remain in the OFF
position.
12. The controller output should be within 0.14 bar
(2 psig) of the supply pressure. If not, adjust flapper
leveling screw 1 (the screw nearest the nozzle) until
the output is within 0.14 bar (2 psig) of supply
pressure.
13. Remove the tape from the process pointer and
connect link 1 to the Bourdon tube.
14. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Bourdon Tube Travel Stop Installation and Adjustment
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Note
The process indicator should be
calibrated before installing or
adjusting travel stops. Refer to the
appropriate process indicator zero
and span calibration procedure in
Section 3, 4, or 5.
Refer to figure 6-18 for adjustment locations and
figure 7-1 for key number locations.
The lower travel stop is necessary only if the
operating range lower limit is greater than 0 bar or 0
psig (elevated zero) For example: The process scale
limits may be 0 to 300 psig, but the range of
operation is 150 to 300 psig. In this example the
elevated zero is 150 psig and the lower travel stop
would be adjusted for 5 percent of the process scale
span less than 150 psig
(150 − (0.05 X 300) = 135 psig).
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Install the upper travel stop (key 73) or upper and
lower travel stops (keys 73 and 74) with the machine
screws (keys 75 and 76). Do not tighten the
machine screws (key 75) that secure the upper
travel stop. If only the upper travel stop is installed,
go to step 10. Otherwise proceed with step 4.
4. If the operating range lower limit is 0 bar (0 psig),
and a lower travel stop is installed, adjust the lower
travel stop adjustment so it does not interfere with
the Bourdon tube. Tighten the lower travel stop
adjustment lock nut and proceed to step 10. If the
operating range lower limit is other than 0 psig
(elevated zero), perform steps 5 through 15.
5. If the process scale lower limit is other than 0
psig, adjust the process pressure to 5 percent of the
process scale span less than the operating range
lower limit (see example at the beginning of this
procedure).
6-23
Page 68
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
6. Adjust the lower travel stop adjustment (shown in
figure 6-18) until it touches the Bourdon tube.
7. Tighten the lower travel stop adjustment lock nut.
8. Increase the process pressure to the operating
range lower limit.
9. The Bourdon tube should not touch the lower
travel stop. If it does, repeat steps 5 through 8.
10. Apply process pressure to the controller equal
to 105 percent of the process scale span.
11. Slide the upper travel stop (key 73) until it
touches the Bourdon tube.
12. Tighten the machine screws (key 75).
13. Decrease the process pressure to 100 percent
of the process scale span.
14. The Bourdon tube should not touch the upper
travel stop. If it does, repeat steps 10 through 13.
15. Adjust the proportional band to 400 percent in
the desired action and install the proportional band
indicator cover (key 36). Tighten the two screws
(key 6).
LOWER TRAVEL STOP
ADJUSTMENT LOCK NUT
LOWER TRAVEL STOP
56A9752-U SHT 4
A6945 / IL
Figure 6-18. Bourdon Tube Controller Travel Stop Adjustment
(KEY 74)
LOWER TRAVEL
STOP ADJUSTMENT
MOUNTING
SCREW
(KEY 76)
MOUNTING
SCREWS
(KEY 75)
LOOSEN
THESE
SCREWS TO
ADJUST
UPPER
TRAVEL
STOP
MOUNTING
SCREW
(KEY 76)
UPPER
TRAVEL
STOP
(KEY 73)
Bourdon Tube Controller Calibration: Zero and Span Adjustment
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Note
For routine zero and span calibration,
refer to the appropriate procedures in
Section 3, 4, or 5. Use the following
maintenance zero and span
adjustment procedure only if difficulty
is encountered with the routine
procedure or if nonlinearity occurs.
Refer to figure 6-19 for location of adjustments and
figure 7-1 for key number locations.
Provide a means of applying process pressure to the
Bourdon tube and a regulated supply pressure
adjusted to the normal operating pressure (see table
1-6). For 4195KA and KS Series controllers, connect
the controller output to an accurate gauge. For
4195KB and KC Series controllers, a gauge is not
necessary and the controller output connection may
be plugged.
Note
Any adjustment of the process pointer
span adjustment screw requires
readjustment of the process pointer
zero adjustment screw. When
checking the zero and span
adjustments, ensure that the Bourdon
tube does not contact the optional
travel stops if used (key 73 and 74).
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band adjustment between
DIRECT and REVERSE.
3. Set the reset valve (4195KB and KC Series only)
to 0.01 minutes per repeat.
4. Set the rate (4195KC Series only) to OFF.
6-24
Page 69
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
POINTER ZERO
ADJUSTMENT
POINTER ZERO
ADJUSTMENT
LOCKING SCREW
PROCESS POINTER
SPAN ADJUSTMENT
ANTI-RESET WINDUP
RELIEF VALVE
2
REMOTE SET POINT
ZERO ADJUSTMENT
W6833 / IL
REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
FRONT VIEW, 4195KB SERIES
PROCESS
POINTER SPAN
ADJUSTMENT
RESET
ADJUSTMENT
REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)
ANTI-RESET WINDUP
VALVE ADJUSTING SCREW
1
2
RATE
ADJUSTMENT
W3599-1 / IL
4195KC SERIES
SCREW 1
SCREW 2
SCREW 3
RESET
ADJUSTMENT
SET POINT/PROCESS
INDICATOR ASSEMBLY
NOTES:
1
AVAILABLE ON 4195KB SERIES ONLY.
2
AVAILABLE ON 4195KB AND KC SERIES SUFFIX
LETTER F ONLY.
39A1126-B
A6731 / IL
Figure 6-19. 4195K Controller Calibration Adjustment Locations
SIDE VIEW OF
59A9752-S SHT 1
SIDE VIEW OF
CONTROLLER SHOWING
FLAPPER LEVELING SCREWS
6-25
Page 70
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
5. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point,
adjust the remote set point pressure until the set
point indicator is at the mid-scale mark on the
process scale.
6. Apply process pressure equal to the mid-scale
value of the process scale span.
7. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the zero adjustment screw to align the process
pointer with the pointer subassembly. Tighten the
zero adjustment locking screw.
8. The process pointer should indicate mid-scale ±3
percent of the process scale span. If not, loosen the
screws in link 1 and adjust the length so that the
process pointer points to the mid-scale mark on the
process scale. Tighten the screws.
9. Apply process pressure equal to the process
scale lower limit.
10. The process pointer should indicate the process
scale lower limit. If not, loosen the zero adjustment
locking screw and adjust the zero adjustment screw
until the process pointer indicates the lower limit.
Tighten the zero adjustment locking screw.
11. Apply process pressure equal to the process
scale upper limit.
12. The pointer should indicate the process scale
upper limit. If not, proceed as follows:
a. If the pointer indicates less than the process
scale upper limit, rotate the pointer span
adjustment clockwise to increase the span.
Adjust the span adjustment screw to correct for
half of the error.
b. If the pointer indicates greater than the
process scale upper limit, rotate the pointer span
adjustment counterclockwise to decrease the
span. Adjust the span adjustment screw to
correct for half of the error.
13. Repeat steps 9 through 12 until the zero and
span indications are within ±1 percent of the scale
limits with no further adjustment. If proper span is
achieved, proceed to step 15. If the span adjustment
screw is adjusted to its limit and the span is still too
short or too long, proceed with step 14.
14. Within the process pointer subassembly, there
are three holes for the connection of link 1. Use
procedure (a.) or (b.) below to make the coarse
span adjustment with link 1.
a. If the span is short (process pointer indication
is less than the process scale upper limit),
disconnect link 1 from the process pointer
subassembly and move the link to the lowest
hole (the hole nearest the pointer pivot). Return
to step 9.
b. If the span is long, (process pointer indication
is greater than the process scale upper limit),
disconnect link 1 from the process pointer
subassembly and move the link to the highest
hole (hole furthermost from the pointer pivot),
and return to step 9.
15. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate mid-scale ±2 percent of the
process scale span. If the process pointer error is ±2
percent or less, proceed to step 17. If the process
pointer error is greater than ±2 percent, loosen the
two Bourdon tube mounting screws (key 384, figure
7-2). Also, loosen the two screws (keys 379 and
380, figure 7-2) holding the process tubing retainer.
16. Slide the Bourdon tube up or down and tighten
the four screws loosened in step 15. Several tries
may be required to determine the direction in which
to move the Bourdon tube to obtain the required
accuracy. Return to step 5.
17. Adjust the process pointer to within ±1 percent
of the mid-scale mark by loosening the zero
adjustment locking screw and adjusting the zero
adjustment screw. Tighten the zero adjustment
locking screw. This distributes the error over the
entire process scale and keeps all points within ±1
percent of the process scale span.
18. Adjust the process pressure to the lower and
upper limits of the process scale span to make sure
the process pointer is still within ±1 percent of the
lower and upper scale limits.
19. Perform the flapper alignment procedure and, if
necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
6-26
Page 71
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Capsular Element Controller Maintenance and Calibration
Replacing the Capsular Element Assembly
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 7-5 for key number locations, unless
noted otherwise.
1. Remove process pressure from the controller.
2. Note the hole location and disconnect link 1 (key
90) from the process pointer.
3. Disconnect the process pressure connection
union (key 93) from the pedestal assembly (key 81).
Use two 5/16-inch hex wrenches.
4. Remove the four machine screws (key 127 in
figure 7-3) that attach the capsular element
assembly to the indicator assembly (key 101 in
figure 7-3).
CAUTION
In the following step, do not lift out
the capsular element assembly by
holding the capsular element or
linkages. These parts may be
damaged.
5. Lift out the capsular element assembly by holding
the tie bar (key 97), mounting plate (key 77), travel
stop (key 83), or pedestal assembly (key 81).
6. Position the replacement capsular element
assembly over the mounting screw holes. Install and
tighten the mounting screws (key 127 in figure 7-3).
7. Reconnect link 1 (key 90) to the process pointer
in the same hole noted in step 2.
8. Reconnect the process pressure connection
union (key 93).
9. Apply process pressure to the controller and
check for leaks.
10. Perform the capsular element maintenance
calibration procedure in this section. Perform the
controller calibration procedures and, if necessary,
the appropriate remote set point calibration
procedure in Section 3, 4, or 5.
Replacing Capsular Element Parts
WARNING
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
Avoid bending or kinking the drive
flexure during the following
procedures. Bending or kinking the
drive flexure can result in product
damage, as well as impaired
performance.
Refer to figure 7-5 for capsular element key number
locations. Refer to figure 6-19 for adjustment
locations and refer to figure 7-4 for indicator
assembly (without process sensing element) part
locations.
Replacing the Long Pivot Assembly
1. Remove process pressure from the controller.
2. Remove the tie bar (key 97) from the capsular
element assembly by removing the mounting screws
(key 103).
3. Note the hole position of link 5 (key 88) and
disconnect the link from the pivot adjustment arm on
the long pivot clevis assembly (key 78).
4. Using an Allen wrench, remove the cap screw
and washer (keys 12 and 13) that attach the drive
flexure (key 79) to the pivot adjustment arm of the
long pivot clevis assembly. Take care not to bend or
kink the drive flexure.
5. Remove the two screws (key 102) attaching the
long pivot clevis assembly to the mounting plate
(key 77).
6-27
Page 72
4195KA, KB, KC, and KS Controllers
10. Connect the left-hand end of link 5 (key 88) to
the pivot adjustment arm in the hole position noted
1
ADJUSTMENT ARM
END BUSHING
BEARING
in step 3.
11. Replace the tie bar (key 97).
12. Perform the capsular element maintenance
calibration procedure in this section. Perform the
controller calibration procedures and, if necessary,
perform the appropriate remote set point calibration
procedure in Section 3, 4, or 5.
Replacing the Short Pivot Assembly
Instruction Manual
Form 5207
April 2007
SHAFT
1
END BUSHING
BEARING
NOTE:
BEFORE TIGHTENING THE DRIVE FLEXURE MOUNTING SCREWS,
1
POSITION THE SHAFT SO THE END BUSHINGS “FLOAT” IN THE BEARINGS.
26A9784-E
A5682 / IL
Figure 6-20. Cutaway of Long Pivot Clevis Assembly
6. Loosen the screw on the pivot adjustment arm of
the replacement pivot clevis assembly, and adjust
the arm to the same length as the arm on the pivot
assembly being replaced.
7. Attach the replacement pivot clevis assembly to
the mounting plate with the two mounting screws
(key 102).
8. Loosely connect the drive flexure to the pivot
adjustment arm on the new pivot clevis assembly.
See figure 6-20. The adjustment arm of the long
pivot clevis assembly is connected to a shaft that
turns on bushings at each end of the shaft. In the
next step, position the shaft so that both bushings
‘‘float’’ inside the bearings and do not rest against
the end of either bearing.
9. Apply 75 percent of the capsular element range
to the capsule. The drive flexure should be straight
and horizontal. Before tightening the drive flexure
cap screws (key 12), hold the pivot shaft in the
middle of the bushing end play. Be sure neither
bushing is resting against the inside end of either
bearing. Tighten the drive flexure cap screws to hold
the pivot shaft in position. Adjust the length of the
pivot adjustment arm as needed until the drive
flexure is horizontal. Take care not to kink or twist
the flexure when tightening the screws.
1. Remove process pressure from the controller.
2. Note the hole positions of links 1 and 5 (keys 88
and 90) and disconnect the links from the short pivot
clevis assembly (key 89). Also, note the screw
position of the linearity adjustment for later
reference.
3. Remove the two machine screws (key 102)
attaching the short pivot clevis assembly (key 89) to
the mounting plate (key 77) and remove the pivot
clevis assembly.
4. Set the linearity adjustment screw in the
replacement pivot assembly to approximately the
same location as noted in step 2.
5. Position the replacement short pivot clevis
assembly on the mounting plate, and attach it with
the two machine screws.
6. Attach links 1 and 5 (keys 88 and 90) in the same
hole position as noted in step 2.
7. Perform the capsular element maintenance
calibration procedures in this section. Perform the
controller calibration procedures and, if necessary,
the appropriate remote set point calibration
procedure in Section 3, 4, or 5.
Replacing the Process Drive Flexure
1. Set the process pressure to 75 percent of the
capsular element range.
2. Remove the tie bar (key 97) from the capsular
element assembly by removing the mounting screws
(key 103).
3. Using an Allen wrench, remove the cap screws
and washers (keys 12 and 13) to disconnect the
drive flexure (key 79) from the drive bracket
assembly (key 84) and from the pivot adjustment
arm of the long pivot clevis assembly (key 78).
Remove the drive flexure.
4. Loosely connect the replacement drive flexure,
making sure it is straight and horizontal.
6-28
Page 73
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
LINK 5
W4769 / IL
Figure 6-21. Capsular Element Controller Link Locations and Adjustments
LINK 1
LINEARITY
ADJUSTMENT
SCREW
LINK 2
LINK 2 ADJUSTMENT
Note
See figure 6-20. The adjustment arm of
the long pivot clevis assembly is
connected to a shaft that turns on
bushings at each end of the shaft. In
the next step, position the shaft so
that both bushings ‘‘float’’ inside the
bearings and do not rest against the
end of either bearing.
5. Before tightening the drive flexure cap screws
(key 12), hold the pivot shaft in the middle of the
bushing end play. Be sure neither bushing is resting
against the inside end of either bearing. Tighten the
drive flexure cap screws to hold the pivot shaft in
position. Take care not to kink or twist the flexure
when tightening the screws.
6. Perform the capsular element maintenance
calibration procedure in this section. Perform the
controller calibration procedures and, if necessary,
the appropriate remote set point calibration
procedure in Section 3, 4, or 5.
Replacing the Process Tubing
LINK 4
LINK 4 ADJUSTMENT
LINK 3
LINK 3 ADJUSTMENT
Replacing Capsular Element Controller Links
WARNING
Refer to the Maintenance WARNING
on page 6-1.
This section describes the separate replacement of
five links in the controller. Figure 6-21 shows the
location of each link. To clarify the location of each
link, the links are numbered as follows:
D Link 1 connects the short pivot clevis assembly
and the process pointer
D Link 2 connects the process pointer and the
flapper assembly (key 11)
1. Remove process pressure from the controller.
2. Using two open-end 5/16-inch wrenches,
disconnect the process tubing (keys 91 or 92) at the
pedestal assembly (key 81) and at the bottom of the
controller case. Remove the tubing.
3. Install the replacement tubing, and tighten all
connections. Check for leaks.
4. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
D Link 3 connects the set point indicator and the
set point beam assembly (key 23)
D Link 4 (key 65) connects the flapper assembly
and the bellows bracket (key 31)
D Link 5 (key 88 in figure 7-5) connects the short
pivot clevis assembly (key 89) and the long pivot
clevis assembly (key 78).
6-29
Page 74
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Replacing Capsular Element Controller Link 1
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Note the hole position of link 1 and disconnect
the link from the short pivot clevis assembly and
from the process pointer. Remove the link.
3. Attach the replacement link in the same holes
noted in step 2 to the process pointer and the short
pivot clevis assembly. If you do not know in which
hole in the process pointer the link was connected,
place it in the middle hole. If during the process
indicator zero and span calibration, the pointer will
not travel the full scale, even after full span
adjustment, move the link to the bottom hole (the
hole nearest the pointer pivot). If the process pointer
has too much travel, move the link to the top hole
(the hole furthermost from the pointer pivot).
4. Move the set point indicator, either manually or
with remote set point pressure, to the mid-scale
mark on the process scale and set the proportional
band between DIRECT and REVERSE.
5. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the process pointer zero adjustment to align the
process pointer and pointer subassembly. Tighten
the zero adjustment locking screw.
6. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate mid-scale ±3 percent of the
process scale span. If not, loosen the screw in link 1
or link 5, and move the pointer to the mid-scale mark
on the process scale. Tighten the screw.
7. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Capsular Element Controller Link 2
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 2 from the process pointer and
from the flapper assembly (key 11). Remove the
link.
3. Install the replacement link with the screw head
nearest the process pointer as shown in figure 6-21.
Connect the link to the process pointer only.
4. The process pointer should be lined up with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the process pointer zero adjustment to align the
pointer with the process pointer subassembly.
Tighten the zero adjustment locking screw.
5. Move the set point indicator, manually or with
remote set point pressure, to the process scale
lower limit and set the proportional band at 5 percent
REVERSE. The nozzle should not be touching the
flapper. If it is, adjust flapper leveling screw 1 (the
screw nearest the nozzle) until clearance is
obtained.
6. Note the hole position and disconnect link 1 from
the short pivot clevis assembly. Manually position
the process pointer to the process scale upper limit
and tape the process pointer in this position.
7. Adjust the length of link 2 (by turning the
adjusting screw clockwise to increase the length or
counterclockwise to decrease the length) so that the
pin on the end of the link is approximately one-half
of its diameter short of aligning with the hole in the
flapper assembly as shown in figure 6-11. This
adjustment provides the proper tension on the link to
eliminate lost motion.
8. Connect link 2 to the flapper assembly.
9. Remove the tape from the process pointer and
reconnect link 1 to the hole in the short pivot clevis
assembly noted in step 6.
10. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Capsular Element Controller Link 3
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 3 from the set point indicator and
the set point beam assembly (key 23).
3. Adjust the replacement link to the same length as
the link removed.
4. Install the replacement link with the screw head
toward the set point beam assembly as shown in
figure 6-21.
5. Check that the set point beam bias spring (key
28) is correctly located in the frame bore and the
spring seat on the set point beam assembly as
shown in figure 6-3.
6. Move the set point indicator to the mid-scale
mark on the process scale.
7. Apply process pressure to position the process
pointer at the mid-scale mark on the process scale.
8. Adjust the proportional band to 5 percent
DIRECT. Turn flapper leveling screw 3 (the screw
nearest the nozzle) until the nozzle just touches the
flapper.
6-30
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Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
9. Adjust the proportional band to 5 percent
REVERSE. Turn flapper leveling screw 1 (the screw
nearest the nozzle) until the nozzle just touches the
flapper.
10. Flapper leveling screws 1 and 3 should protrude
the same distance from the clinch nuts. A clinch nut
is shown in figure 6-16.
11. If leveling screw 1 protrudes further than
leveling screw 3, turn the link 3 adjusting screw
counterclockwise. If leveling screw 3 protrudes
further than leveling screw 1, turn the link 3 adjusting
screw clockwise.
12. Repeat steps 8 through 11 until leveling screws
1 and 3 protrude an equal distance from the clinch
nuts.
13. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Capsular Element Controller Link 4
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Disconnect link 4 from the bellows bracket (key
31) and the flapper assembly (key 11).
3. Connect the replacement link to the flapper
assembly so that the two adjusting screws on the
link are nearest to the bellows bracket (key 31) and
so that the screw heads are facing the bottom of the
controller as shown in figure 6-21.
4. For controllers with reset (4195KB Series) or
reset and rate adjustments (4195KC Series), turn
the reset adjustment to the CLOSED (4195KB) or
OFF (4195KC) position. Turn the rate adjustment
(4195KC Series) to the OFF position.
The controller output must be 0 bar (0 psig). To be
sure the controller output is at 0 bar (0 psig), remove
supply pressure, set the reset adjustment to 0.01
minutes per repeat and wait 30 seconds; then, turn
the reset adjustment to the CLOSED (4195KB) or
OFF (4195KC) position.
5. Adjust the proportional band to 5 percent
REVERSE and move the set point indicator to the
process scale upper limit.
6. Disconnect link 1 from the pivot arm. Tape the
process pointer to the process scale lower limit (the
last mark on the left side of the scale).
7. Apply the correct supply pressure to the
controller. The output of the controller should be
within 0.14 bar (2 psig) of supply pressure. If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle) until the output is within 0.14 bar (2 psig)
of supply pressure.
8. Loosen the two adjusting screws on link 4.
Connect the free end of the link to the bellows
bracket and allow the link to find its free length.
9. Tighten the two adjusting screws on the link.
10. Raise link 4 out of the hole in the bellows
bracket (key 31) and ensure that it drops back into
the hole under its own weight. If not, repeat steps 8
and 9.
11. For a controller with reset, adjust the reset
adjustment to 0.01 minutes per repeat. The rate
adjustment (4195KC) should remain in the OFF
position.
12. The controller output should be within 0.14 bar
(2 psig) of the supply pressure. If not, adjust flapper
leveling screw 1 (the screw nearest the nozzle) until
the output is within 0.14 bar (2 psig) of supply
pressure.
13. Remove the tape from the process pointer and
connect link 1 to the pivot arm.
14. Perform the controller calibration procedures
and, if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Replacing Capsular Element Controller Link 5
1. Remove the two screws (key 6), and lift off the
proportional band indicator cover (key 36).
2. Note the location of the connection holes and
disconnect both ends of link 5 (key 88) from the
lever arms of the two pivot assemblies. Refer to
figure 6-22 for parts locations.
3. Loosen the adjustment screw on the replacement
link and adjust the length to match the original link.
Tighten the adjustment screw.
4. Attach the replacement link to the two lever arms
in the same holes noted in step 2.
5. Move the set point indicator, either manually or
with remote set point pressure, to the mid-scale
mark on the process scale and set the proportional
band between DIRECT and REVERSE.
6. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the process pointer zero adjustment to align the
process pointer and pointer subassembly. Tighten
the zero adjustment locking screw.
7. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate the mid-scale ±3 percent of
the scale span. If not, loosen the screw in link 1 or
6-31
Page 76
4195KA, KB, KC, and KS Controllers
link 5, and move the process pointer to the
mid-scale mark of the process scale span. Tighten
the screw.
8. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Capsular Element Controller Maintenance Calibration
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Precalibration Procedure
DIAPHRAGM
ASSEMBLY
EXTENSION
Instruction Manual
VIEW A-A
VIEW A-A
Form 5207
April 2007
TRAVEL
STOP
NUT
DRIVE
BRACKET
TRAVEL
STOP
NUT
1. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
2. Set the proportional band adjustment between
DIRECT and REVERSE.
3. Remove the two screws (key 103) and remove
the tie bar (key 97) from the capsular element
assembly.
Aligning the Drive Bracket Assembly
Refer to figures 6-22 and 7-5.
1. With an Allen wrench, loosen the set screw in the
hex nut of the drive bracket assembly (key 84).
2. Loosen the screw (key 98) that holds the guide
flexure to the tab on the mounting plate (key 77).
The guide flexure location is shown in figure 6-22.
3. Apply process pressure equal to 75 percent of
the capsular element range.
4. Slide the drive bracket assembly (key 84) along
the diaphragm capsule extension (key 82) until the
guide flexure is aligned with the center of the long
pivot clevis assembly (key 78).
GUIDE
FLEXURE
LONG
PIVOT
58A0708-E
A6946 / IL
SHORT
PIVOT
DRIVE
FLEXURE
A
A
LINEARITY
ADJUSTMENT
TRAVEL
STOP
LINK 5
LINK 1
5. Tighten the machine screw (key 98) and the set
screw in the hex nut to fasten the drive bracket
assembly in that position.
Setting the Capsular Element Travel Stops
1. For the full span stop—Apply process pressure
equal to 5 percent greater than capsular element
range. Then perform the following as appropriate:
6-32
Figure 6-22. Process Input Capsular Element Assembly Part
and Adjustment Locations (Positive and Compound Pressure
Element Shown)
Page 77
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
D For positive or compound pressure with a
three-capsule stack, loosen the machine screws
(key 139) that secure the travel stop (key 83) to the
mounting plate (key 77). Slide the travel stop until it
is just touching the end of the capsule stack. Tighten
the travel stop mounting screws to lock it into
position. Decrease the input pressure to 100 percent
of the capsular element range and make sure the
capsule stack is not contacting the travel stop (key
83).
D For positive or compound pressure with a
two-capsule stack, loosen the set screw (key 87) in
the travel stop nut (key 86) between the travel stop
(key 83) and the capsule stack. Slide the nut along
the diaphragm capsule extension (key 130) until it
just touches the travel stop (key 83). Tighten the set
screw to lock the travel stop nut in position.
Decrease the input pressure to 100 percent of the
capsular element range and make sure the travel
stop nut is not contacting the travel stop (key 83).
D For vacuum pressure, loosen the set screw
(key 87) in the travel stop nut (key 86) on the end of
the diaphragm capsule extension (key 132 or 133).
The nut is located on the opposite side of the travel
stop (key 83) from the capsule. Slide the nut along
the diaphragm capsule extension until it just touches
the travel stop (key 83). Tighten the set screw to
lock the travel stop nut in position. Decrease the
vacuum to 100 percent of the capsular element
range and make sure the travel stop nut is not
contacting the travel stop (key 83).
2. For the zero stop—perform the following as
appropriate:
D If the lower limit of the capsular element range
is 0 bar (0 psig), adjust the process pressure to 0
bar (0 psig). Slide the zero travel stop nut (key 86)
along the diaphragm assembly extension until it is
approximately 0.4 mm (1/64-inch) away from the
travel stop. Tighten the set screw to lock the travel
stop nut in position.
D If the lower limit of the capsular element range
is other than 0 bar (0 psig), adjust the process
pressure to 5 percent below the capsular element
range lower limit and slide the travel stop nut (key
86) along the diaphragm extension until it just
touches the travel stop (key 83). Tighten the set
screw. Increase the input pressure to the capsular
element range lower limit and make sure the travel
stop nut is not contacting the travel stop (key 83).
Aligning the Capsular Element Linkage
1. Adjust the process pressure to 75 percent of the
capsular element range. The drive flexure (key 79)
should be straight and horizontal. If it is not, proceed
as follows:
a. Loosen the screw on the pivot adjustment arm
on the long pivot clevis assembly (key 78) and
the two screws mounting the drive flexure.
b. Adjust the length of the pivot adjustment arm
so that the drive flexure is parallel to the
centerline of the capsules. Tighten the screw to
set the length of the pivot adjustment arm in that
position.
Note
See figure 6-20. The adjustment arm of
the long pivot clevis assembly is
connected to a shaft that turns on
bushings at each end of the shaft. In
the next step, position the shaft so
that both bushings ‘‘float’’ inside the
bearings and do not rest against the
end of either bearing.
c. Before retightening the drive flexure screws,
hold the long pivot clevis assembly shaft in the
middle of the bushing end play. Be sure neither
bushing is resting against the inside end of either
bearing.
d. Tighten the drive flexure screws to hold the
pivot clevis assembly shaft in position.
2. Set the linearity adjustment screw on the short
pivot clevis assembly so the two arms of the short
pivot clevis assembly are parallel. The linearity
adjustment screw should be near the center of its
slot.
3. Make certain that the process pointer and pointer
subassembly are aligned as shown in figure 6-15. If
not, loosen the zero adjustment locking screw and
adjust the process pointer zero adjustment screw to
align the process pointer and pointer subassembly.
Tighten the zero adjustment locking screw.
4. Adjust the process pressure to 50 percent of the
capsular element range.
5. Loosen the screw on link 5 (key 88) and adjust
the link length so that the pivot arms of the short
pivot clevis assembly (key 89) and the long pivot
clevis assembly (key 78) are parallel. Tighten the
screw.
6. Complete the maintenance calibration by
performing the zero and span adjustments in the
following procedure.
6-33
Page 78
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Capsular Element Controller Zero and Span Adjustment
Note
For routine zero and span calibration,
refer to the appropriate procedures in
Section 3, 4, or 5. Use the following
maintenance zero and span
adjustment procedure only if difficulty
is encountered with the routine
procedure or if nonlinearity occurs.
Provide a means of applying process pressure to the
sensing element and a regulated supply pressure
adjusted to the normal operating pressure (see table
1-6). Plug the controller output or connect it to a
gauge. Monitoring the controller output is not
necessary. However, the flapper should not contact
the nozzle at any time while performing this
procedure. If it does, adjust flapper screw 2 (the one
nearest the nozzle) to provide clearance. Refer to
figure 6-19 for the adjustment locations. Refer to
figure 7-1 for the key number locations.
Note
Any adjustment of the process pointer
span adjustment screw requires
readjustment of the process pointer
zero adjustment screw.
1. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Adjust the reset (4195KB and KC Series only) to
0.01 minutes per repeat.
4. Adjust the rate (4195KC Series only) to OFF.
5. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point,
adjust the remote set point pressure until the set
point indicator is at the mid-scale mark on the
process scale.
6. Apply process pressure equal to the mid-scale
value of the process scale span.
7. The process pointer should be aligned with the
pointer subassembly as shown in figure 6-15. If not,
loosen the zero adjustment locking screw and adjust
the zero adjustment screw to align the process
pointer with the pointer subassembly. Tighten the
zero adjustment locking screw.
8. The process pointer should indicate mid-scale ±3
percent of the process scale span. If not, loosen the
screw on either link 1 or link 5 and adjust the length
so that the process pointer points to the mid-scale
mark on the process scale. Tighten the screw.
9. Apply process pressure equal to the process
scale lower limit.
10. The process pointer should indicate the process
scale lower limit. If not, loosen the zero adjustment
locking screw and adjust the zero adjustment screw
until the process pointer indicates the lower limit.
Tighten the zero adjustment locking screw.
11. Apply process pressure equal to the process
scale upper limit.
12. The process pointer should indicate the process
scale upper limit. If not, proceed as follows:
a. If the pointer indicates less than the process
scale upper limit, rotate the pointer span
adjustment clockwise to increase the span.
Adjust the span adjustment screw to correct for
one-half of the error.
b. If the pointer indicates greater than the
process scale upper limit, rotate the pointer span
adjustment counterclockwise to decrease the
span. Adjust the span adjustment screw to
correct for one-half of the error.
13. Repeat steps 9 through 12 until the zero and
span indications are within ±1 percent of the scale
limits with no further adjustment. If proper span is
achieved, proceed to step 16. If the span adjustment
screw is adjusted to its limit and the span is still too
short or too long, proceed with step 14.
14. Within the process pointer subassembly, there
are three holes for the connection of link 1. Use
procedure (a.) or (b.) below to make the coarse
span adjustment with link 1.
a. If the span is short (process pointer indication
is less than the process scale upper limit),
disconnect link 1 from the process pointer
subassembly, move the link to the lowest hole
(the hole nearest the pointer pivot), and return to
step 9. If the link is already in the lowest hole,
proceed to step 15.
b. If the span is long, (process pointer indication
is greater than the process scale upper limit),
disconnect link 1 from the process pointer
subassembly, move the link to the highest hole
(the hole furthermost from the pointer pivot), and
return to step 9. If the link is already in the
highest hole, proceed to step 15.
6-34
Page 79
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
PIVOT
ASSEMBLY A
36A9751-C
B1668-4 / IL
GUIDE
FLEXURE
TIE BAR
REMOTE SET POINT ZERO ADJUSTMENT SCREW
ZERO ADJUSTMENT LOCKING SCREW
MOUNTING
SCREW
LINK A
MOUNTING
SCREW
ADJUSTMENT
SCREW
LINK B
LINEARITY
ADJUSTMENT
PIVOT
ASSEMBLY B
UPPER TRAVEL
STOP
CAPSULES
DRIVE FLEXURE
LOWER TRAVEL
STOP
Figure 6-23. Remote Set Point (suffix letter M) Parts and Adjustment Locations
SIDE VIEWFRONT VIEW
15. At either end of link 5, there are four holes in
which the link may be connected. A coarse span
adjustment can be made by moving both ends of link
5 up or down.
a. If the span is short (process pointer indication
is less than the process scale upper limit),
disconnect both ends of link 5, move the link
down one set of holes, and return to step 6.
b. If the span is long (process pointer indication
is greater than the process scale upper limit),
disconnect both ends of link 5, move the link up
one set of holes, and return to step 6.
16. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate mid-scale ±2 percent of the
scale span. If the process pointer error is ±2 percent
or less, proceed to step 17. If the process pointer
error exceeds ±2 percent, the linearity can be
improved with the linearity adjustment. See figure
6-22 for the linearity adjustment screw location.
a. If the error at mid-scale is high (process
pointer is to the right side of the mid-scale mark),
loosen the linearity adjustment screw and slide it
upward in the curved slot. Tighten the screw and
return to step 6.
b. If the error at mid-scale is low (process
pointer is to the left side of the mid-scale mark),
loosen the linearity adjustment screw and slide it
downward in the curved slot. Tighten the screw
and return to step 6.
17. Adjust the process pointer to within ±1 percent
of the mid-scale mark by loosening the zero
adjustment locking screw and adjusting the zero
adjustment screw. Tighten the zero adjustment
locking screw. This distributes the error over the
entire process scale and keeps all points within ±1
percent of the process scale span.
6-35
Page 80
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
18. Adjust the process pressure to the lower and
upper limits of the scale span to make sure the
process pointer is still within ±1 percent of the lower
and upper scale limits.
19. Perform the flapper alignment procedure and, if
necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
Remote Set Point (suffix letter M) Maintenance
Replacing the Remote Set Point Assembly
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Use the following procedures to replace the remote
set point assembly. Figure 6-23 shows the part
locations. Refer to figure 7-6 for key number
locations.
CAUTION
In the following step, do not lift out
the remote set point assembly by
holding the capsular element or
linkages. These parts may be
damaged.
6. Lift out the remote set point assembly by holding
the tie bar (key 106), mounting plate (key 111),
travel stop (key 83), or pedestal assembly (key 105).
7. Align the replacement assembly with the
mounting screw holes. Replace the mounting
screws.
8. Reconnect the remote set point pressure
connection union (key 93). Apply full remote set
point pressure and check for leaks.
9. Connect link B (key 126) to the connecting hole
on the set point indicator.
10. Replace the supply pressure gauge.
11. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedure in Section 3, 4, or 5.
Replacing Remote Set Point Assembly Parts
WARNING
Note
Remove the supply pressure gauge
before attempting to remove the
capsular element assembly.
1. Decrease the remote set point pressure to 0 bar
(0 psig).
2. Remove the supply pressure gauge.
3. Remove the pressure connection (key 93) at the
pedestal assembly (key 105). Use two 5/16 inch
wrenches.
4. Disconnect link B (key 126) from the connection
hole on the set point indicator.
5. Remove the three mounting screws (keys 120
and 140) that attach the remote set point assembly
to the process/set point indicator assembly. Figure
6-23 shows the mounting screw locations.
6-36
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
Avoid bending or kinking the drive
flexure during the following
procedures. Bending or kinking the
drive flexure can result in product
damage, as well as impaired
performance.
Figure 6-23 shows the parts and adjustment
locations. Refer to figure 7-6 for key number
locations.
Replacing Pivot Assembly A (Key 114)
1. Decrease the remote set point pressure to 0 bar
(0 psig).
2. Remove the two screws (key 103) and remove
the tie bar (key 106).
Page 81
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
3. Note where link A is connected. Disconnect link
A (key 116) from the lever arm on pivot assembly A
(key 114).
4. Disconnect the drive flexure (key 79) from the
adjustment arm of pivot assembly A. Be careful not
to bend or kink the drive flexure.
5. Remove the screw (key 122), washer (key 123),
and nut (key 124) that attach the guide flexure (key
119) to the top of the pivot assembly.
6. Remove the pivot screw and spring washer (keys
109 and 112) and the mounting screw (key 102)
attaching the pivot assembly to the mounting plate
(key 111). Lift out pivot assembly A.
7. Loosen the adjustment screw (key 118) on the
adjustment arm of the replacement pivot assembly,
and set the arm to the same length as the arm on
the pivot assembly being replaced. Tighten the
screw.
8. To replace the pivot assembly, first put the spring
washer (key 112) on the screw (key 109). Then,
insert the screw through the replacement pivot
assembly and into the mounting plate and tighten.
Install the mounting screw (key 102) and tighten.
9. Connect the guide flexure (key 119) to the top of
the replacement pivot assembly with the screw (key
122), washer (key 123), and nut (key 124) as it was
before. The guide flexure should be straight and
horizontal as shown in figure 6-23. If not, loosen the
screws (key 122) and retighten to eliminate any
bowing. Loosen the screws (key 139) and raise or
lower the pedestal assembly (key 105) to get the link
horizontal. Retighten the screws (key 139) and
ensure the diaphragm assembly extension (key 134)
is centered in the upper travel stop (key 83) hole.
10. Apply remote set point pressure equal to 50
percent of the remote set point input range.
Note
See figure 6-20. The adjustment arm of
the remote set point pivot assembly A
turns on a bushing at each end of the
shaft supporting the adjustment arm.
In the next step, position the shaft so
both bushings ‘‘float’’ inside the
bearings and do not rest against the
end of either bearing.
11. Connect the drive flexure (key 79) to the arm on
the replacement pivot assembly, making sure it
stays straight and vertical. Adjust the length of the
pivot arm, if necessary, until the flexure is vertical.
Before tightening the drive flexure screws, hold the
pivot assembly shaft in the middle of the bushing
end play. Be sure neither bushing is resting against
the inside end of either bearing. Tighten the drive
flexure screws to hold pivot assembly A in this
position. Do not bend or twist the flexure when
tightening the screws.
12. Decrease the remote set point pressure to 0 bar
(0 psig).
13. Connect the end of link A (key 116) to the pivot
lever arm in the same holes noted in step 3.
14. Replace the tie bar (key 106).
15. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedures in Section 3, 4, or 5.
Replacing Pivot Assembly B (Key 115)
1. Decrease the remote set point pressure to 0 bar
(0 psig).
2. Note the holes where links A and B are
connected. Disconnect links A and B (keys 116 and
126) from the arms of pivot assembly B (key 115).
3. Remove the two screws (key 102) that attach
pivot assembly B to the mounting plate (key 111).
Remove the pivot assembly.
4. Loosen the linearity adjustment screw on the
replacement pivot assembly and set it in the same
position as the adjustment on the original pivot
assembly. Tighten the screw.
5. Set the replacement pivot assembly on the
mounting plate, and attach it with the two machine
screws.
6. Attach links A and B (keys 116 and 126) to the
arms of the replacement pivot assembly in the same
holes noted in step 2.
7. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedures in Section 3, 4, or 5.
Replacing the Drive Flexure
1. Using an Allen wrench, remove the cap screws
(key 12) and washers (key 13) to disconnect the
drive flexure (key 79) from the drive bracket (key
121) and from the adjustment arm of pivot assembly
A. Remove the drive flexure.
2. Set the remote set point pressure to 50 percent
of the remote set point input range.
6-37
Page 82
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Note
See figure 6-20. The adjustment arm of
the remote set point pivot assembly A
turns on a bushing at each end of the
shaft supporting the adjustment arm.
In the next step, position the shaft so
both bushings ‘‘float’’ inside the
bearings and do not rest against the
end of either bearing.
3. Connect the new drive flexure making sure it
stays straight and vertical. Adjust the length of the
pivot arm, if necessary, until the drive flexure is
straight. Before tightening the drive flexure screws,
hold the pivot assembly A shaft in the middle of the
bushing end play. Be sure neither bushing is resting
against the inside end of either bearing. Tighten the
drive flexure screws to hold the pivot shaft in this
position. Do not bend or twist the flexure when
tightening the screws.
4. Decrease the remote set point pressure to 0 bar
(0 psig).
5. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedure in Section 3, 4, or 5.
Replacing the Remote Set Point Tubing
1. Decrease the remote set point pressure to 0 bar
(0 psig).
2. Using two 5/16-inch open-end wrenches,
disconnect the pressure connection union (key 93)
from the pedestal assembly (key 105) and the
connection to the case exterior at the top of the
case.
3. Remove the tubing (key 104).
4. Install the replacement tubing, and reconnect the
two pressure connections.
5. Apply full remote set point pressure, and check
for leaks.
Replacing Link A
This procedure describes link A (key 116)
replacement in the remote set point assembly.
Figure 6-23 shows the link location.
1. Note the holes where link A is connected.
Disconnect link A (key 116) from the lever arms on
pivot assembly A and pivot assembly B.
2. Loosen the screw in the replacement link A and
adjust the length to match the link being replaced.
Tighten the screw.
3. Refer to figure 6-23 for the correct link
orientation. Attach the replacement link A to the two
lever arms in the same holes noted in step 1.
4. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedures in Section 3, 4, or 5.
Replacing Link B
This procedure describes link B (key 126)
replacement in the remote set point assembly.
Figure 6-23 shows the link location.
1. Note the holes where link B is connected.
Disconnect link B (key 126) from the pivot arm and
from the set point indicator.
2. Loosen the screw in the replacement link B and
adjust the length to match the link being replaced.
Tighten the screw.
3. Refer to figure 6-23 for the correct link
orientation. Attach the replacement link B to the
pivot arm and to the set point indicator in the same
holes as noted in step 1.
4. Perform the remote set point maintenance
calibration procedure. Perform the appropriate
process indicator zero and span calibration and
flapper alignment procedures in Section 3, 4, or 5.
Remote Set Point (suffix letter M) Maintenance Calibration
Refer to figure 6-23 for parts and adjustment
locations. Refer to figures 7-1 and 7-6 for key
number locations.
Precalibration Procedure
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band adjustment between
DIRECT and REVERSE.
3. Remove the two screws (key 103) and remove
the tie bar (key 106) from the remote set point
assembly.
6-38
Page 83
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Aligning the Flexures
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Apply remote set point pressure equal to 50
percent of the remote set point pressure range.
2. The guide flexure (key 119) should be straight
and horizontal. If not, straighten the flexure by
loosening the machine screw (key 122) on the end
of the flexure that is attached to the top of the pivot
assembly A (key 114) and allow the flexure to
straighten itself. Tighten the machine screw.
3. If the flexure is not horizontal, loosen the two
machine screws (key 139) and raise or lower the
pedestal assembly (key 105) until the guide flexure
is horizontal. Retighten the machine screws (key
139) and ensure the diaphragm assembly extension
(key 134) is centered in the upper travel stop (key
83) hole.
4. The drive flexure (key 79) should be straight. If
not, proceed as follows:
a. Loosen the screw (key 118) on the adjustment
arm of pivot assembly A (key 114) and loosen
the screws holding the drive flexure.
b. Set the length of the adjustment arm so that
the drive flexure is parallel to the centerline of the
diaphragm capsule assembly (key 80).
Setting the Travel Stops
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Loosen the set screw (key 87) in the travel stop
nut (key 86).
CAUTION
Make sure the loose travel stop nut
does not bind on the diaphragm
capsule extension (key 134) when
pressurizing the capsules (key 80).
Damage to the capsules may result.
2. Full span stop—Adjust the remote set point
pressure to 2-1/2 percent of span greater than the
remote set point input range upper limit.
Loosen the two screws (keys 139 and 140) that
secure the travel stop (key 83) to the mounting plate
(key 111). Slide the travel stop until it is just touching
the end of the capsule stack. Tighten the travel stop
mounting screws to lock it into position.
3. Zero Stop—Adjust the remote set point pressure
to 2-1/2 percent of span less than the remote set
point input range lower limit.
Slide the travel stop nut (key 86), along the
diaphragm capsule extension (key 134) until it is just
touching the travel stop (key 83). Tighten the set
screw (key 87) to lock the travel stop nut in position.
c. Tighten the screw (key 118) on the
adjustment arm.
Note
See figure 6-20. The adjustment arm of
the remote set point pivot assembly A
turns on a bushing at each end of the
shaft supporting the adjustment arm.
In the next step, position the shaft so
both bushings ‘‘float’’ inside the
bearings and do not rest against the
end of either bearing.
d. Hold the pivot assembly A shaft in the middle
of the bushing end play. Be sure neither bushing
is resting against the inside end of either bearing.
e. Tighten the screws that hold the drive flexure
in place.
Aligning the Linkage
WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Adjust the remote set point pressure to 50
percent of the remote set point input range.
2. Set the linearity adjustment screw in the center of
the slot on the lever arm of pivot clevis assembly B
(key 115). See figure 6-23 for the linearity
adjustment location.
3. Set the length of link A (key 116) so the lever
arms of pivot assembly A and pivot assembly B are
parallel and link A is perpendicular to them.
4. Set the length of link B (key 126) so the set point
indicator indicates mid-scale on the process scale
span.
6-39
Page 84
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
5. Replace the tie bar (key 106) and install the two
screws (key 103).
Remote Set Point Zero and Span Adjustment
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Note
For routine remote set point zero and
span calibration, refer to the
appropriate procedures in Section 3,
4, or 5. Use the following maintenance
remote set point zero and span
adjustment procedures only if
difficulty is encountered with the
routine procedure or nonlinearity
occurs.
Refer to figures 6-19 and 6-23 for adjustment
locations.
1. Decrease the remote set point pressure to 0
percent of the remote set point input range.
2. The set point indicator should indicate the lower
limit of the process scale span. If not, loosen the
adjustment screw on link A (key 116), and adjust the
length so the set point indicator points to the lower
limit of the process scale. Tighten the screw.
3. Make fine zero adjustments by loosening the
zero adjustment locking screw (key 102) and turning
the zero adjustment screw (key 108). Tighten the
locking screw. Refer to figure 6-23 for the screw
locations.
4. Apply remote set point pressure equal to 100
percent of the remote set point input range.
5. The set point indicator should indicate the upper
limit of the process scale span.
6. To increase the span, proceed as follows:
a. Turn the remote set point span adjustment
screw clockwise.
b. To increase the span further than the
adjustment screw allows, move both ends of link
A (key 116) to the right.
c. Make fine adjustments with the remote set
point span adjustment screw.
7. To decrease the span, proceed as follows:
a. Turn the remote set point span adjustment
screw counterclockwise.
b. To decrease the span further than the
adjustment screw allows, move both ends of link
A (key 116) to the left.
c. Make fine adjustments with the remote set
point span adjustment screw.
8. Repeat the adjustments until the upper and lower
indications are aligned with the upper and lower
limits on the process scale.
9. Adjust the remote set point pressure for 50
percent of the remote set point input range.
10. The set point indicator should indicate mid-scale
±2 percent of the process scale span. If the error is
within ±2 percent, proceed to step 11. If the error is
greater than ±2 percent of the scale span, proceed
to the remote set point linearity adjustment
procedure.
11. Adjust the set point indicator to mid-scale ±1
percent of the process scale span by loosening the
zero adjustment locking screw and turning the zero
adjustment screw. Tighten the locking screw.
12. Adjust the remote set point pressure to the
upper and lower limits of the remote set point input
range and make sure the set point indicator is still
within ±1 percent at the lower and upper limits of the
process scale.
13. Perform the appropriate flapper alignment
procedure and, if necessary, the process indicator
zero and span calibration procedure in Section 3, 4,
or 5.
6-40
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Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Remote Set Point Linearity Adjustment
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Adjust the linearity by loosening and repositioning
the linearity adjustment screw in the curved slot on
the lever arm of pivot assembly B (key 115).
Adjusting the linearity affects the zero and span
adjustment.
1. Adjust the remote set point pressure to 50
percent of the remote set point input range. The set
point indicator should indicate mid-scale ±1 percent
of the process scale span. If not, make fine
adjustments by loosening the zero adjustment
locking screw and turning the zero adjustment
screw.
2. Adjust the remote set point pressure to 0 percent
of the remote set point input range and note the
indicator position relative to the process scale lower
limit.
3. Adjust the remote set point pressure to 100
percent of the remote set point input range and note
the indicator position relative to the process scale
upper limit.
4. If the greatest misalignment is positive (the set
point indicator is to the right of the process scale
limits), loosen the linearity screw and move it
clockwise in the slot. If the misalignment is negative,
move the linearity screw counterclockwise in the
slot.
Auto/Manual Station (suffix letter E)
Maintenance
Replacing the Auto/Manual Station
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figures 7-1 and 7-7 for key number
locations.
Note
This procedure also permits
replacement of the switch manifold
O-rings (key 312), the auto/manual
tubing assembly (key 138), and the
frame gaskets (keys 4 and 5).
Disassembly
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Loosen the screw (key 316) that holds the
auto/manual station (key 273) to the controller
frame.
3. Loosen the two screws (keys 314 and 315) that
hold the auto/manual station to the auto/manual
tubing assembly (key 138).
4. Remove the auto/manual station from the
controller frame.
5. Remove the switch manifold O-rings (key 312).
6. Carefully loosen the nut on the relay nozzle
tubing assembly (key 18) where it connects to the
auto/manual tubing assembly (key 138). Loosen
three screws (keys 34 and 131) and remove the
tubing assembly and frame gaskets (keys 4 and 5).
7. Inspect the gaskets (keys 4 and 5) and O-rings
(key 312) for wear. Replace if necessary.
Assembly
5. If the misalignment is greater than 1 percent of
the process scale span at the lower and upper limits,
with one positive and the other negative, perform the
remote set point zero and span adjustment
procedure to correct a span error.
6. Repeat steps 1 through 4 until lower, middle, and
upper indications are within ±1 percent of the
process scale markings.
1. Install the gaskets and tubing assembly to the
frame. Start, but do not tighten, the three screws
(keys 34 and 131) and the nut on the relay nozzle
tubing assembly (key 18).
2. Install the switch manifold O-rings (key 312) and
secure the auto/manual station to the controller
frame with the screw (key 316) and to the tubing
assembly (key 138) with the two screws (keys 314
and 315). Do not tighten any screws.
6-41
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4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
CAUTION
In the next step, take care to tighten
the two screws (keys 314 and 315)
evenly. Uneven tightening could
damage the tubing assembly.
3. Position the auto/manual station as far down on
the frame and toward the scale as possible.
Carefully tighten the two screws (keys 314 and 315)
so that the auto/manual station contacts the three
pads on the tubing assembly.
4. Carefully tighten the remaining screws and nuts.
5. Plug the controller output connection and apply
supply pressure to the controller. Check for leaks.
6. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
7. Perform the appropriate calibration procedure in
Section 3, 4, or 5.
Replacing the Switch Body Assembly, Lever O-Ring, Switch Body O-Ring, and Tubing Assembly
WARNING
3. Using a 1/16-inch (1.5 mm) punch, push the
groove pin (key 303) out toward the surface of the
lever cover plate.
4. Remove the switch lever (key 304), lever spring
(key 302), and lever spring seat (key 301).
5. Remove the tubing assembly (key 309).
WARNING
The switch body springs (key 295) are
under preload. To avoid personal
injury or losing parts, carefully
separate the switch body assembly
from the loader assembly.
6. Loosen the two screws (key 290) and separate
the switch body assembly (key 291) from the loader
assembly (key 282).
7. Remove the O-rings (keys 292, 293, and 294),
switch body springs (key 295), and balls (key 296).
8. Loosen two screws (key 308), and remove the
closing plate (key 307) and the closing plate gasket
(key 306).
9. Pull the clip (key 300) from its engagement with
the lever assembly shaft (key 297).
10. Pull the lever assembly from the switch body
assembly (key 291) and rocker (key 299).
11. Remove the O-ring (key 298).
12. Inspect the O-rings and gaskets for damage or
wear; replace if necessary.
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 7-7 for key number location.
Disassembly
1. Remove the auto/manual station from the
controller as described in steps 1 through 4 of the
replacing the auto/manual station procedure.
2. Loosen the two screws (key 288) and remove the
lever cover plate (key 305).
WARNING
The lever spring (key 302) is under
preload. To avoid personal injury or
losing parts, carefully disassemble the
auto/manual station.
6-42
Assembly
1. Insert the lever assembly (key 297) into the
switch body assembly (key 291) and hold the rocker
(key 299) with the flats on the lever assembly shaft.
2. Insert the clip (key 300) in the groove of the lever
assembly shaft to hold the lever assembly (key 297)
in the switch body assembly (key 291).
3. Position the closing plate gasket (key 306) and
the closing plate (key 307). Secure with two screws
(key 308).
Note
After assembly in step 3, be sure the
side of the closing plate marked OUT
is visible.
4. Place the balls (key 296), switch body springs
(key 295), and O-rings (keys 292, 293, and 294) in
the switch body assembly (key 291).
Page 87
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Note
In the following step, the ends of the
springs must be in the counterbored
spring seats before compression.
5. Compress the switch body springs with the
loader assembly (key 282), and bolt the switch body
assembly (key 291) to the loader assembly with the
two screws (key 290).
6. Reconnect the tubing assembly (key 309).
7. Locate the lever spring (key 302) and the spring
seat (key 301) on the switch lever (key 304) and
position these parts in the opening of the loader
assembly (key 282).
8. Push the switch lever down, using the lever
spring seat (key 301) and the lever assembly (key
297) to preload the spring. Make sure the notch of
the switch lever engages the pin of the lever
assembly.
9. Drive in the groove pin (key 303) to hold the
switch lever.
10. Replace the lever cover plate (key 305) and
attach with two screws (key 288).
11. Perform the assembly portion of the replacing
the auto/manual station procedure.
Replacing the Loader Range Spring, Diaphragm Assembly, Ball Seat, Tubing, and Ball
arrow) to relieve pressure on the
spring.
3. Loosen the four screws (key 289), and separate
the upper loader assembly (key 282) and the lower
loader assembly (key 274).
4. Remove the loader range spring (key 283), range
spring cup (key 284), and diaphragm assembly (key
281).
5. Remove the tube (key 278), ball seats (key 280)
and ball (key 279).
Assembly
1. Turn the loader knob (key 287) counterclockwise
to back the spring adjustment screw (key 285) all
the way out to eliminate loading the range spring.
2. Position the range spring cup (key 284), range
spring (key 283), and the diaphragm assembly (key
281) on the upper loader assembly (key 282).
3. Position the ball (key 279), the tube (key 278),
and the ball seats (key 280) between the ears of the
loader assemblies (keys 282 and 274); position the
diaphragm assembly (key 281) between the main
halves of the loader assemblies.
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 7-7 for key number locations.
Disassembly
1. Remove the auto/manual station from the
controller as described in steps 1 through 4 of the
replacing the auto/manual station procedure.
2. Remove the tubing assembly (key 309).
WARNING
To avoid personal injury caused by
preload from the range spring (key
283), turn the loader knob (key 287)
counterclockwise (opposite to the
Note
The tube (key 278) must be well seated
in the cups of the ball seats (key 280).
4. Bolt the loader assembly halves together using
the four screws (key 289).
Note
Be sure that the supply and exhaust
seats of the loader are correctly
aligned. Misalignment will impair
loader performance.
5. Attach the tubing assembly (key 309).
6. Perform the assembly portion of the replacing the
auto/manual station procedure.
6-43
Page 88
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Replacing the Loader Valve Plug and Valve Plug Spring
WARNING
Refer to the Maintenance WARNING
on page 6-1.
Refer to figure 7-7 for key number location.
1. Remove the controller assembly from the case
by performing steps 1 through 3 of the case and
cover replacement procedure.
2. Loosen the spring seat screw (key 275).
3. Remove the valve plug spring (key 276) and the
valve plug (key 277).
4. Inspect the parts and replace as necessary.
5. Install the valve plug spring and valve plug.
6. Tighten the spring seat screw.
7. Temporarily apply supply pressure and process
pressure and check for leaks.
8. Position the controller assembly in the case and
start, but do not tighten the nine mounting screws.
Slide the controller assembly down to assure an
O-ring seal at the pressure connections along the
bottom of the case. Hold the controller assembly in
place while tightening the nine mounting screws.
9. Mount the controller as described in the
Installation section.
10. Connect the external piping to the controller.
6-44
Page 89
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Section 7 Parts
Parts Ordering
Whenever corresponding with your Emerson
Process Management sales office about this
equipment, always mention the controller serial
number. When ordering replacement parts, refer to
the 11-character part number of each required part
as found in the following parts list.
WARNING
Use only genuine Fisher replacement
parts. Components that are not
supplied by Emerson Process
Management should not, under any
circumstances, be used in any Fisher
instrument. Use of components not
supplied by Emerson will void your
warranty, might adversely affect the
performance of the instrument, and
could give rise to personal injury and
property damage.
Note
Description Part Number
4190 Series Relay Replacement Kit
Contains Relay Assembly (includes keys 13 and 15)
and key 10
0.2 to 1.0 bar (3 to 15 psig) RRELAYX83C2
0.4 to 2.0 bar (6 to 30 psig) RRELAYX83D2
Type 4195KBF Anti-Reset Windup Retrofit Kit,
SST tubing, Contains keys 44 and 55 R4190X00S22
Parts List
Abbreviations Used In Parts List
adj: adjustment
alt desgntn: alternative designation
ass’y: assembly
conn(s): connection(s)
diff: differential (as in process differential
pressure)
fdback: feedback
fill hd: fillister head (as in fillister head cap screw)
ext: external
hd: head (as in machine screw head)
int: internal
OD: outside diameter
p/o part of (as in part of another assembly)
pl: plated (as in plated steel)
pt: point (as in set point)
qty: quantity
SST: stainless steel
w/: with
w/o: without
Key Description Part Number
Neither Emerson, Emerson Process
Management, nor any of their affiliated
entities assumes responsibility for the
selection, use, and maintenance of
any product. Responsibility for the
selection, use, and maintenance of
any product remains with the
purchaser and end-user.
Parts Kits
Description Part Number
4190 Series Auto/Manual Repair Kit
Contains keys 277, 278, 279, 281, 292,
293, 294, 298, 306, 312 R4190X0AM12
4190 Series Auto/Manual Retrofit Kit, SST tubing,
Contains keys 138, 273, 312, 313,
314, 315, 316 R4190X00S12
4190 Series Case Handle Kit
Contains lever and mounting hardware R4190X00H12
4190 Series Controller Repair Kit
Contains keys 4, 5, 7, 8, 24, 52 R4190X00C12
4190 Series Pointer and Bracket Repair Kit
Contains pointer and bracket ass’y,
three machine screws, three washers R4190X00P12
Controller Common Parts (figure 7-1)
Note
Figure 7-1 shows key numbers for the common
construction of all controller types. Figure 7-1
continues over several pages. Be sure to check all
pages of figure 7-1 to find the common key
numbers.
1 Case and cover ass’y
For use w/o remote set pt 46A5903X012
For use w/remote set pt 46A5902X012
2 Nameplate, A91100 (aluminum) - - 3 Frame, A03600 (aluminum) 56A7001X012
4* Frame gasket, chloroprene
For use between frame and frame
manifold (key 135) 18A0749X012
5* Gasket, chloroprene
4195KA, KB, and KS (1 req’d)
4195KC (2 req’d) 18A0742X012
6 Machine screw, fill hd, 18−8 SST (9 req’d)
2 req’d to mount the prop band ind cover
to the frame
4 req’d to mount bellows bracket
(key 31) to bellows beam (key 49)
2 req’d to attach process scale
brackets (keys 376, 377) to frame 1P4373X0012
*Recommended spare parts
7-1
Page 90
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Key Description Part Number
7* O-Ring, nitrile
Used between frame and case at conns: process pressure,
either 1/4-18 NPT internal or 1/2-14 NPT external; output
and supply; remote set point; and external feedback
3 req’d w/o remote set pt and w/o ext fdback
4 req’d w/remote set pt or ext fdback
5 req’d w/remote set pt and ext fdback 1C376206992
8* O-Ring, nitrile
Used between frame and case on
mounting bosses extending from the frame
through the back of the case (3 req’d) 16A6903X012
9 Flexure pivot ass’y, sapphire/SST 29A4340X012
10 Machine screw, fill hd, 18−8 SST
Used to attach the flexure pivot ass’y
(key 9) to the frame (4 req’d) 18B0008X012
11* Flapper ass’y 29A9518X012
12 Machine screw, hex socket, 18−8 SST
For flapper ass’y (key 11) (2 req’d) 10B0700X012
17 Adjustable set pt pivot ass’y, SST 19A1121X012
18 Relay nozzle tubing ass’y, SST 18A0765X012
19 Machine screw, fill hd, 18−8 SST
1 req’d to attach adjustable set pt pivot
ass’y (key 17) to frame
For 4195KC Series
3 req’d to attach relay nozzle tubing
ass’y (key 18) to frame 1C8990X0012
20 Plain washer, 18-8 SST
Used w/key 19 (2 req’d) 1K261028992
21 Nozzle ass’y, SST 26A6904X012
22 Washer, plastic (2 req’d) 16A9767X012
23 Set pt beam ass’y, aluminum/SST 16A6939X012
24* O-ring, nitrile
1 req’d for nozzle tubing ass’y (key 18)
1 req’d for nozzle ass’y (key 21) 1E222606992
25 Proportional band knob, polycarbonate 36A6911X012
26 Retaining clip, S30200 (302 SST) 16A6913X012
27 E-ring, SST 1V5929X0012
28 Set pt beam bias spring, pl steel 16A6909X012
29 Set pt beam shoe, G10100 (pl steel) 16A6910X012
30 Machine screw, 18-8 SST
Used w/key 29 (2 req’d) 19A1155X022
31 Bellows bracket, A95052 (aluminum) 26A6932X012
32 Bellows adj bracket, G10100 (pl steel) 16A6933X012
33 Bellows adj spring, pl steel 16A6934X012
34 Machine screw, fill hd, 18-8 SST
Used to attach frame manifold (key 135) to
frame and for reset gain adjustment (2 req’d) 18B0009X012
35 Machine screw, hex hd, 18−8 SST
Used to attach bellows bracket (key 31)
to each bellows ass’y (key 48) (2 req’d) 16A6935X022
Key Description Part Number
40 Proportional tubing ass’y, SST
For 4195KA or KB Series 28A0766X022
For 4195KC Series 27A3217X022
41 Plug, S30300 (303 SST)
For all 4195KA, KB, and KS Series (1 req’d)
For 4195KC, KCM, KCE, and KCME (2 req’d)
For 4195KCF, KCFM, KCFE, and
KCFME (1 req’d) 1P2796X0012
42 Reset valve tubing ass’y, SST
For 4195KB Series w/o ext feedback, SST 16A6949X022
43 Reset tubing ass’y, SST
For all 4195KB Series 26A6950X022
For all 4195KC Series 28A0764X022
44 Relief valve tubing ass’y, SST
For Types 4195KBF, KBFE, KBFM,
and KBFME only 16A6951X022
For Types 4195KCF, KCFE, KCFM,
45 Posititve Feedback Tubing Assembly, SST
and KCFME only 18A0763X022
For 4195KS Series only 18A0769X022
Note
One type of pressure gauge is used for both output
pressure and supply pressure indication.
46* Pressure gauge (2 req’d) See Key 46 table
Key 46* Pressure Gauge
RANGE
0 to 30 psig/
0 to 2 kg/cm
0 to 60 psig/
0 to 4 kg/cm
0 to 30 psig/
0 to 200 kPa/
0 to 2 bar
0 to 60 psig/
0 to 400 kPa/
0 to 4 bar
1. One type of pressure gauge is used for both output pressure and supply
pressure indication.
2
2
(1)
GAUGE MATERIAL
Brass SST
Dual Scale Gauge
11B8577X042 11B8583X032
11B8577X052 − − −
Triple Scale Gauge
11B8577X012 11B8583X012
11B8577X022 11B8583X022
36 Proportional band indicator cover,
ABS w/polyester label 36A6936X012
37 Self-tapping screw, 18−8 SST
4 req’d to attach process scale (key 61)
to process scale bracket (key 376) 16A6938X022
38 Self-tapping screw, 18−8 SST
Used to attach frame inside case (9 req’d) 16A6959X022
39 Supply gauge tubing ass’y, SST 16A6952X022
7-2
*Recommended spare parts
Page 91
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Key Description Part Number
48* Bellows ass’y (2 req’d)
Brass 16A6953X012
SST 16A6953X022
49 Bellows beam, A96061 (aluminum)
0.2 to 1.0 bar (3 to 15 psig) 16A6957X012
0.4 to 2.0 bar (6 to 30 psig) 16A6958X012
51 Relief valve cover plate, A03600 (aluminum) 2V597308012
52* O-ring, nitrile 1C853806992
Used w/key 51 (2 req’d)
53 Machine screw, fill hd, 18−8 SST
Used w/key 51 (2 req’d)
4195KA, KB, and KS Series
4195KC Series (7 req’d) 1U8842X0012
54 Reset restriction valve (4195KB Series only) 19A4361X032
55 Differential relief valve
For all 4195KB and KC Series w/suffix
letter F, anti-reset windup 21A6447X0A2
Key 56 Process and Set Point Indicator Assembly with Bourdon T ube
BAR RANGE PSIG RANGE
With S31600 (316 SST) Bourdon Tube
0 to 1.6 or 0 to 2
0 to 4 or 0 to 2.5
0 to 6
0 to 10
0 to 16
0 to 40 or 0 to 25
0 to 60
0 to 100
0 to 160
0 to 250 or 0 to 300
0 to 30
0 to 60
0 to 100
0 to 200
0 to 300
0 to 600
0 to 1000
0 to 1500
0 to 3000
0 to 5000
Key Description Part Number
56 Process and set pt indicator ass’y w/sensing element
The part numbers in the Key 56 tables are for the complete
process and set pt indicator ass’y with a process sensing
element. Individual indicator ass’y parts are listed in two
subsections of this parts list: the Process and Set Point
Indicator Assembly (key 56) subsection and the Indicator
Assembly (key 101) subsection. Key numbers for individual
indicator parts also appear in figures 7-2 and 7-3.
Process and set pt indicator ass’y
w/Bourdon tube sensing element See Key 56 tables
Process and set pt indicator ass’y
w/capsular element ass’y See Key 56 tables
ASSEMBLY PART NUMBER
W/O Remote Set Point W/Remote Set Point
32B1532X012
32B1532X022
32B1532X032
32B1532X042
32B1532X052
32B1532X062
32B1532X072
32B1532X082
32B1532X092
32B1532X102
32B1532X142
32B1532X152
32B1532X162
32B1532X172
32B1532X182
32B1532X192
32B1532X202
32B1532X212
32B1532X222
32B1532X232
Key 56 Process and Set Point Indicator Assembly with Capsular Element Assembly
ASSEMBLY PART NUMBER
W/O Remote Set Point W/Remote Set Point
N09902 N09902
Positive and Compound Element
36A6986X082
36A6986X092
36A6986X102
36A6986X112
36A6986X302
36A6986X122
36A6986X132
36A6986X142
Vacuum Element
36A6987X052
36A6987X062
36A6987X072
36A6987X082
U.S. Units
U.S. Units
RANGE
0 to 60 inch wc
0 to 5 psig
0 to 10 Psig
0 to 12 Psig
0 to 15 Psig
0 to 20 Psig
0 to 24 Psig
0 to 30 Psig
−5 to 0 Inch Hg
−10 to 0 Inch Hg
−20 to 0 Inch Hg
−30 to 0 Inch Hg
36A6986X222
36A6986X232
36A6986X242
36A6986X252
36A6986X322
36A6986X262
36A6986X272
36A6986X282
36A6987X132
36A6987X142
36A6987X152
36A6987X162
*Recommended spare parts
7-3
Page 92
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
Key Description Part Number
57 Pressure control block, CF8M (316 SST Casting)
1/4-18 NPT Internal Process Connection
1 req’d for all types w/o remote set pt and
w/o ext fdback, except none required
for units with Bourdon tube isolator 26A6962X012
2 req’d for all types w/remote set pt and
w/o ext fdback, except 1 req’d for units
with Bourdon tube isolator 26A6962X012
2 req’d for all types w/ext fdback and
w/o remote set pt, except 1 req’d for
units with Bourdon tube isolator 26A6962X012
3 req’d for all types w/ext fdback and
w/remote set pt, except 2 req’d for units
with Bourdon tube isolator 26A6962X012
1/2-14 NPT External Process Connection
For all types w/o remote set pt
and w/o ext fdbck (1 req’d) 20B7911X012
Pressure control block, CF8M (316 SST Casting)
1/4-18 NPT Internal Process Connection
1 req’d for all types w/o remote set pt and
w/o ext fdback, except none required
for units with Bourdon tube isolator 26A6962X012
For all types w/remote set pt
and w/o ext fdbck
(1 req’d) 26A6962X012
(1 req’d) 20B7911X012
For all types w/ext fdback and
w/o remote set pt
(1 req’d) 26A6962X012
(1 req’d) 20B7911X012
For all types w/ext fdback and
w/remote set pt
(2 req’d) 26A6962X012
(1 req’d) 20B7911X012
58 Cap screw, hex hd, SST
2 req’d for use w/each pressure
control block (key 57) 1A352538992
59 Hex reducing nipple, (use only when specified)
1/2 NPT external
All ranges up to 0-345 bar (0-5000 psig)
Steel 16A6992X012
SST 16A6992X022
60 Reducing adaptor, (use only when specified)
1/2 NPT internal
All ranges up to 0-345 bar (0-5000 psig)
Steel 16A6993X012
SST 16A6993X022
61 Process scale, aluminum
For indicator ass’y (key 101) See Key 61 tables
Key Description Part Number
62 Remote set pt ass’y (suffix letter M)
The part numbers listed for key 62 are for the complete remote
set point (suffix letter M) ass’y. Individual assembly parts are
listed in the Remote Set Point Assembly subsection of the
parts list. Key numbers for individual ass’y parts also appear in
figure 7-6.
Remote set pt ass’y (suffix letter M)
N09902 (Nickel Alloy)
0.8 bar (12 psig) span 36A6988X032
1.7 bar (24 psig) span 36A6988X042
SST
0.8 bar (12 psig) span 36A6988X012
1.7 bar (24 psig) span 36A6988X022
64 Machine screw, fill hd, 18−8 SST
4 req’d to attach process and set pt
indicator ass’y (key 56) to frame 1J8415X0012
65 Feedback link ass’y, aluminum/brass/SST 16A7036X012
71 Machine screw, fill hd, 18−8 SST
For all 4195KA, KB, and KS Series (4 req’d)
For all 4195KC Series (6 req’d) 1P4743X0012
72 Blowout plug, silicone 2V766005312
Note
Key numbers 73 through 76 are only for use
with a 4195K Series controller with a Bourdon
tube element. Travel stops are required when
the calibration starting point is greater than 0
psig. Use only when specified.
73 Upper travel stop, G10100 (steel)
Use only when specified. See Note above. 26A9768X012
74 Lower travel stop, G10100 (steel)
Use only when specified. See Note above. 27B0400X012
75 Machine screw, fill hd, 18−8 SST
Use only when specified. See Note above.
If only upper travel stop installed, none req’d − − −
If both upper and lower travel stop installed,
2 req’d to mount upper travel stop 1H2676X0012
76 Machine screw, fill hd, 18−8 SST
Use only when specified. See Note above.
If only upper travel stop installed,
2 req’d to mount upper travel stop 1V413038982
If both upper and lower travel stop installed,
2 req’d to mount lower travel stop 1V413038982
120 Machine screw, fill hd, 18−8 SST
2 req’d to attach remote set pt ass’y (suffix
letter M) to indicator ass’y base plate 1J8415X0012
127 Machine screw, fill hd, 18−8 SST
(4 req’d) 1J8415X0012
131 Machine screw, fill hd, S30400 (304 SST)
2 req’d to attach rate/reset manifold
(key 136) to frame manifold (key 135) 1C101535042
135 Frame manifold, A03600 (aluminum)
For all types except w/suffix letter E,
auto/manual station 28A0756X012
7-4
Page 93
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
Key 61 Process Scale, Positive Pressure
Scale Range Part Number
0 to 150 mbar
0 to 400 mbar
0 to 0.6
0 to 1
0.2 to 1
0 to 1.4
0 to 1.6
0 to 2
0.4 to 2
Bar Scales
0 to 2.5
0 to 4
0 to 6
0 to 10
0 to 16
0 to 25
0 to 40
0 to 60
0 to 100
0 to 160
0 to 250 1R0003X0542
0 to 60 inch wc
0 to 5
0 to 10
3 to 15
0 to 15
0 to 20
6 to 30
0 to 30
Psig Scales
0 to 60
0 to 100
0 to 200
0 to 300
0 to 600
0 to 1000
0 to 1500
0 to 3000
0 to 5000
0 to 200
0 to 400
0 to 700
0 to 1400
kPa Scales
0 to 2000
0 to 4000
0 to 7000
0 to 10,000
0 to 20,000
0 to 35,000
Key 61 Process Scale, All Controllers
Scale Range Part Number
0 to 100%
0 to 10 Square Root
0 to 100 Square Root
1R0003X1562
1R0003X0422
1R0003X0402
1R0003X0432
1R0003X1602
1R0003X1612
1R0003X0442
1R0003X1652
1R0003X1622
1R0003X0452
1R0003X0462
1R0003X0472
1R0003X0482
1R0003X0492
1R0003X0572
1R0003X0502
1R0003X0512
1R0003X0522
1R0003X0532
1R0003X0202
1R0003X0212
1R0003X0222
1R0003X0172
1R0003X0232
1R0003X0242
1R0003X0182
1R0003X0032
1R0003X0042
1R0003X0052
1R0003X0062
1R0003X0072
1R0003X0082
1R0003X0092
1R0003X0102
1R0003X0112
1R0003X0122
1R0003X0922
1R0003X0932
1R0003X0942
1R0003X0702
1R0003X0952
1R0003X0962
1R0003X0972
1R0003X0712
1R0003X0982
1R0003X0992
1R0003X1042
1R0003X1172
1R0003X1292
Key 61 Process Scale, Vacuum and Compound Pressure
SCALE RANGE PART
Vacuum Pressure
150 to 0 mbar
Bar Scales
In Scales
Bar Scales
Psig Scales
400 to 0 mbar
0.6 to 0
1 to 0
5 to 0
10 to 0
20 to 0
30 to 0
Compound Pressure
−50 to +100 mbar
−150 to +250 mbar
−0.2 to +0.4
−0.4 to +0.6
−0.6 to +0.8
−1 to +0.6
−1 to +1
30 inches wc vac. to 30 inches wc
5 inches Hg vac. to 2.5 psig
10 inches Hg vac. to 5 psig
15 inches Hg vac. to 7.5 psig
20 inches Hg vac. to 10 psig
30 inches Hg vac. to 15 psig
Key Description Part Number
136 Rate/reset manifold, A03600 (aluminum)
For all types except 4195KC Series 28A0747X012
137 Rate tubing ass’y (for 4195KC Series only)
SST/aluminum 28A0762X042
138 Auto/manual tubing ass’y
Use w/suffix letter E, auto/manual station only
SST/aluminum 38A2859X022
140 Machine screw, fill hd, 18−8 SST
Used to attach remote set pt ass’y (suffix
letter M) to indicator ass’y (key 56) 16A7007X022
162 Machine screw, hex hd, 18−8 SST
Used to attach the reset valve (4195KB Series)
or rate/reset valve (4195KC Series) to the frame
For 4195KB and KC Series only 1B8480X0012
262 Rate/reset valve ass’y (for 4195KC Series only)
Brass bellows
0.2 to 1.0 bar (3 to 15 psig) 39A6013X052
0.4 to 2.0 bar (6 to 30 psig) 39A6013X072
SST bellows
0.2 to 1.0 bar (3 to 15 psig) 39A6013X062
0.4 to 2.0 bar (6 to 30 psig) 39A6013X082
273 Auto/manual station (suffix letter E) 48A2905X012
The part number listed for key 273 is for the complete
auto/manual station (suffix letter E). Individual ass’y parts are
listed in the Auto/Manual Station subsection of the parts list.
Key numbers for individual ass’y parts also appear in figure
7-7.
NUMBER
1R0003X1632
1R0003X0592
1R0003X0602
1R0003X0612
1R0003X0322
1R0003X0332
1R0003X0342
1R0003X0192
1R0003X1572
1R0003X0632
1R0003X0642
1R0003X0652
1R0003X1582
1R0003X0662
1R0003X1592
1R0003X0252
1R0003X0352
1R0003X0362
1R0003X0262
1R0003X0372
1R0003X0272
*Recommended spare parts
310 Lithium grease (not furnished with controller)
311 Anti-seize sealant (not furnished with controller)
312* O-ring, nitrile
For all types w/suffix letter E,
auto/manual station (3 req’d) 1P8453X0022
7-5
Page 94
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
SEE VIEW H SEE VIEW G
K
K
SEE VIEW M
D
SEE VIEW L
C
C
B
D
B
SECTION B-B
SEE VIEW E
SECTION D-D
APPLY LUB/ SEALANT
56A9752-U SHT 1 and 2 / DOC
Figure 7-1. Controller Assembly Drawings
Key Description Part Number
313 Auto/Manual Scale, plastic
For all types w/suffix letter E,
314 Machine screw, fill hd, 18−8 SST
315 Machine screw, fill hd, 18−8 SST
auto/manual station 38A2901X012
For all types w/suffix letter E,
auto/manual station 1C101535042
For all types w/suffix letter E,
auto/manual station 1B9925X0012
7-6
VIEW C-C 4195KA SERIES
Key Description Part Number
316 Machine screw, SST
For all types w/suffix letter E,
auto/manual station 1U8841X0012
317 Silicone based lubricant, (not furnished with controller)
318 Lubricant, silicone, not furnished with controller)
339 External feedback ass’y, SST tubing
For controllers w/Bourdon tube or
vacuum capsule 28A7285X022
For controllers w/positive or
w/compound capsules 29A5715X022
362 Spring retaining washer, SST 1B196138992
365 Washer, 18−8 SST 11B6501X012
VIEW C-C 4195KS SERIES
Page 95
Instruction Manual
Form 5207
April 2007
VIEW F-F VIEW F-F
FF FF
4195KA, KB, KC, and KS Controllers
56A9752-U SHT 4 / DOC
VIEW K-K
PROCESS CONNECTION
ADAPTORS
4195KB SERIES
56A9752-U SHT 2 / DOC
VIEW E
4195KB SERIES
VIEW C-C
VIEW E
4195KB SERIES WITH
ANTI-RESET WINDUP
(SUFFIX LETTER F)
VIEW C-C
4195KB SERIES WITH
ANTI-RESET WINDUP
(SUFFIX LETTER F)
Figure 7-1. Controller Assembly Drawings (cont’d)
7-7
Page 96
4195KA, KB, KC, and KS Controllers
VIEW F-F
Instruction Manual
Form 5207
April 2007
VIEW F-F
FF
VIEW E 4195KC SERIES
F
VIEW E 4195KC SERIES WITH
ANTI-RESET WINDUP (SUFFIX LETTER F)
F
56A9752-U SHT 3 / DOC
7-8
VIEW C-C 4195KC SERIES
Figure 7-1. Controller Assembly Drawings (cont’d)
VIEW C-C 4195KC SERIES WITH
ANTI-RESET WINDUP
(SUFFIX LETTER F)
Page 97
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
56A9752-U SHT 2 / DOC
SECTION B-B
4195KA SERIES
56A9752-U SHT 4 / DOC
VIEW L
56A9752-U SHT 3 / DOC
SECTION B-B
4195KB SERIES
CONTROLLERS WITH AUTO/MANUAL STATION
SECTION B-B
4195KC SERIES
(SUFFIX LETTER E)
Figure 7-1. Controller Assembly Drawings (cont’d)
56A9752-U SHT 2 / DOC
VIEW B-B
4195KS SERIES
7-9
Page 98
4195KA, KB, KC, and KS Controllers
56A9752-U SHT 4 / DOC
VIEW H
CONTROLLERS WITH REMOTE SET POINT
(SUFFIX LETTER M)
Instruction Manual
Form 5207
April 2007
VIEW G
BOURDON TUBE
TRAVEL STOPS
7-10
56A9752-U SHT 3 / DOC
VIEW M
EXTERNAL FEEDBACK FOR
4195K SERIES BOURDON TUBE
AND VACUUM PRESSURE CONTROLLERS
Figure 7-1. Controller Assembly Drawings (cont’d)
56A9752-U SHT 5 / DOC
VIEW M
EXTERNAL FEEDBACK FOR
4195K SERIES POSITIVE AND
COMPOUND PRESSURE CONTROLLERS
Page 99
Instruction Manual
Form 5207
April 2007
4195KA, KB, KC, and KS Controllers
32B1532-A / DOC
Figure 7-2. Process and Set Point Indicator Assembly for Bourdon Tube Controllers
Process and Set Point Indicator
Assembly (key 56) (figures 7-2 and 7-3)
Key Description Part Number
With capsular element ass’y
101 Indicator ass’y
The part numbers listed here for key 101 are for the indicator
ass’y only. Individual part numbers are listed in the Indicator
Assembly and the Capsular Element Assembly subsections of
this parts list. Key numbers for individual ass’y parts also
appear in figures 7-4 and 7-5.
For use w/o remote set pt 39A1126X012
For use w/remote set pt 39A1126X022
113 Capsular element ass’y See Key 113 table
The part numbers listed in the key 113 table are for the
complete capsular element ass’y. Individual ass’y parts are
listed in the Capsular Element Assembly subsection of this
parts list. Key numbers for individual ass’y parts also appear in
figure 7-4.
Key Description Part Number
127 Machine screw, fill hd, 18−8 SST
4 req’d to attach the capsular element ass’y
to the indicator ass’y (key 101) 1J8415X0012
With Bourdon tube
101 Indicator ass’y
The part numbers listed here for key 101 are for the indicator
ass’y only. Individual part numbers are listed in the Indicator
Assembly subsection of this parts list. Key numbers for
individual ass’y parts also appear in figure 7-4.
For use w/o remote set pt 39A1126X012
For use w/remote set pt 39A1126X022
379 Process Tube Retainer, S30400 (304 SST) 18A8870X012
380 Machine screw, pan hd, 18−8 SST 1H2674X0012
381 Process tubing ass’y, SST 12B4951X012
382 Link ass’y, steel/SST 22B0469X012
383* Bourdon tube See Key 383 table
384 Screw, self-tapping, pl steel (2 req’d) 16A9772X022
*Recommended spare parts
7-11
Page 100
4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
7-12
36A6986-C / DOC
Figure 7-3. Process and Set Point Indicator Assembly for Capsular Element Controllers
(Positive and Compound Pressure Shown)
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