Emerson Fisher 4195K Instruction Manual

Instruction Manual

D200160X012

4195K Controllers

December 2012

Fisherr 4195KA, KB, KC, and KS Gauge Pressure
Controllers

Contents

1. Introduction

Scope of Manual 4.............................

Description 4.................................

Specifications 4...............................

Educational Services 4.........................

2. Installation

Controller Mounting Orientation 9...............

Pipestand Mounting 9.........................

Panel Mounting 10............................

Wall Mounting 11.............................

Actuator Mounting 11.........................

Pressure Connections 12.......................

Process Pressure Connection 12..............

Supply Pressure Connection 12..............

Remote Set Point (suffix letter M)

Pressure Connection 13..................

External Feedback Pressure Connection

(4195KB Controllers Only) 13.............

Vent 14......................................

3. 4195KA Proportional‐Only Controllers

Adjustments for 4195KA Controllers 15...........

Manual Set Point Adjustment 15.............

Remote Set Point (suffix letter M)

Adjustment 16..........................

Proportional Band Adjustment (PB ADJ) 16.....

Changing Controller Action 16...............

Switching The Auto/Manual Station

(suffix letter E) 17.......................

Prestartup Checks for 4195KA Controllers 17......

Startup for 4195KA Controllers 18...............

Calibration of 4195KA Controllers 18.............

General Calibration Instructions 19...........

Process Indicator Zero and Span Calibration 19.
Remote Set Point (suffix letter M)

Zero and Span Calibration 21..............

Flapper Alignment 22......................

Principle of Operation for 4195KA Controllers 23...

Overall Operation 23.......................

Remote Set Point (suffix letter M)

Operation 24...........................

Auto/Manual Station (suffix letter E)

Operation 24...........................

4. 4195KB Proportional‐Plus‐Reset
Controllers and 4195KC
Proportional‐Plus‐Reset‐Plus‐Rate Controllers

Adjustments for 4195KB and KC Controllers 25.....

Manual Set Point Adjustment 25.............

Remote Set Point (suffix letter M)

Adjustment 26..........................

Proportional Band Adjustment (PB ADJ) 26.....

Changing Controller Action 26...............

Reset Adjustment 27.......................

Rate Adjustment 27........................

Anti‐Reset Windup (suffix letter F)

Adjustment 27..........................

Switching the Auto/Manual Station

(suffix letter E) 27.......................

Prestartup Checks for 4195KB and KC

Controllers 28..............................

Startup for 4195KB and KC Controllers 28.........

Calibration of 4195KB and KC Controllers 30.......

General Calibration Instructions 30...........

Process Indicator Zero and Span

Calibration 30..........................

Remote Set Point (suffix letter M)

Zero and Span Calibration 32..............

Flapper Alignment 33......................

Anti‐Reset Windup (suffix letter F)

Differential Relief Valve Calibration 35......

Principle of Operation for 4195KB and KC

Controllers 36..............................

Overall Operation 36.......................

Anti‐Reset Windup (suffix letter F)

Operation 39...........................

Remote Set Point (suffix letter M)

Operation 39...........................

Auto/Manual Station (suffix letter E)

Operation 40...........................

External Feedback Operation 41..............

5. 4195KS Differential Gap Controllers

Operating Information 42......................

Adjustments for 4195KS Differential Gap

Controllers 43..............................

Manual Set Point 43........................

Remote Set Point (Option M) 43.............

Proportional Band (Differential Gap) 43.......

Changing Controller Action 43...............

www.Fisher.com

4195K Controllers

December 2012

Instruction Manual

D200160X012

Contents (continued)

Auto/Manual Switching (Option E) 44.........

Prestartup Checks 44..........................

Startup 44...................................

Calibration 45................................

Process Zero and Span Adjustment 45........

Remote Set Point Zero and Span

(Option M) 45..........................

Setting Switching Points 46.................

Direct‐Acting Controllers 46.................

Reverse‐Acting Controllers 48...............

Principle of Operation 48.......................

Overall Operation 48.......................

Remote Set Point (Option M) 50.............

Auto/Manual Option 50.....................

6. Maintenance

Inspection and Maintenance 51..................

Troubleshooting 51............................

Replacing Common Controller Parts 55...........

Replacing the Process Pressure Scale 55.......

Replacing the Relay 56.....................

Replacing the Case and Cover 56.............

Replacing the Gauges 57....................

Replacing the Supply Gauge, Proportional,

Reset, Reset Valve and Positive Tubing

Feedback Assemblies 58..................

Replacing the Proportional Band Adjustment

Knob, Nozzle Assembly, and Set Point

Beam Assembly 58......................

Replacing the Flapper Assembly and

Flapper Flexure Pivot Assembly 63.........

Replacing the Proportional or Reset

Bellows 68.............................

Replacing the Reset Restriction Valve

(4195KB Controllers) 70..................

Replacing the Rate/Reset Valve Assembly

(4195KC Controllers) 71..................

Replacing the Anti‐Reset Windup

(suffix letter F) Differential Relief Valve 72...

Replacing the Anti‐Reset Windup

(suffix letter F) Relief Valve Tubing

Assembly 72............................

Bourdon Tube Controller Maintenance

and Calibration 73..........................

Replacing the Bourdon Tube 73..............

Replacing Bourdon Tube Controller Links 74...

Replacing Link 1 74......................

Replacing Link 2 75......................

Replacing Link 3 76......................

Replacing Link 4 77......................

Bourdon Tube Travel Stop Installation

and Adjustment 78......................

Bourdon Tube Controller Calibration:

Zero and Span Adjustment 79.............

Capsular Element Controller Maintenance

and Calibration 82..........................

Replacing the Capsular Element

Assembly 82..........................

Replacing Capsular Element Parts 83........

Replacing the Long Pivot Assembly 83......

Replacing the Short Pivot Assembly 84......

Replacing the Process Drive Flexure 84......

Replacing the Process Tubing 85...........

Replacing Capsular Element

Controller Links 85....................

Replacing Link 1 86......................

Replacing Link 2 86......................

Replacing Link 3 87......................

Replacing Link 4 87......................

Replacing Link 5 88......................

Capsular Element Controller

Maintenance Calibration 88...............

Precalibration Procedure 89...............

Aligning the Drive Bracket Assembly

Setting the Travel Stops 89................

Aligning the Linkage 90...................

Capsular Element Controller

Zero and Span Adjustment 91.............

Remote Set Point (suffix letter M)

Maintenance 92............................

Replacing the Remote Set Point

Assembly 92............................

Replacing Remote Set Point

Assembly Parts 94.....................

Replacing Pivot Assembly A (key 114) 94....

Replacing Pivot Assembly B (key 115) 95....

Replacing the Drive Flexure 95.............

Replacing the Remote Set Point Tubing 96...

Replacing Link A 96......................

Replacing Link B 96......................

Remote Set Point (suffix letter M)

Maintenance Calibration 96..................

Precalibration Procedure 96.................

Aligning the Flexures 97....................

Setting the Travel Stops 97..................

Aligning the Linkage 98.....................

Remote Set Point Zero and Span

Adjustment 98..........................

Remote Set Point Linearity Adjustment 99.....

Auto/Manual Station (suffix letter E)

Maintenance 100...........................

Replacing the Auto/Manual Station 100.......

Replacing the Switch Body Assembly,

Lever O‐Ring, Switch Body O‐Ring,

and Tubing Assembly 101................

Replacing the Loader Range Spring,

Diaphragm Assembly, Ball Seat,

Tubing, and Ball 102.....................

Replacing the Loader Valve Plug and

Valve Plug Spring 103....................

89.....

2

Instruction Manual

D200160X012

Figure 1-1. Fisher 4195K Gauge Pressure Controllers

4195K Controllers

December 2012

W5663‐1

Contents (continued)

7. Parts

Parts Ordering 105............................

Parts Kits 105.................................

Parts List 105.................................

Abbreviations Used In The Parts List 105.......

Controller Common Parts 106...............

Process and Set Point Indicator

Assembly 114...........................

Indicator Assembly 116.....................

Capsular Element Assembly 118..............

Remote Set Point Assembly

(suffix letter M) 119......................

Auto/Manual Station (suffix letter E) 120.......

Controller Mounting Parts 122...............

Pipestand Mounting 122..................

Pipestand Mounting with Regulator 122.....

W6831

NAMEPLATE

Panel Mounting 122......................

Wall Mounting 122.......................

Controller Mounting Parts for Actuator

with Casing‐Mounted Controller 122.....

Controller Mounting Parts for Actuator

with Yoke‐Mounted Controller 122.......

Regulator Mounting Parts 123...............

Regulator Mounting Parts for

Casing‐Mounted Regulator 123..........

Regulator Mounting Parts for

Yoke‐Mounted Regulator (Mounting

Bracket Not Required) 123..............

Regulator Mounting Parts for

Yoke‐Mounted Regulator

(With Mounting Bracket) 123............

Fittings 123...............................

3

4195K Controllers

December 2012

Instruction Manual

D200160X012

Section 1 Introduction

Scope of Manual

This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for
Fisher 4195KA, KB, KC, and KS gauge pressure indicating controllers.

Portions of this manual apply only to specific 4195K 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 type number.

Do not install, operate, or maintain a 4195K controller without being fully trained and qualified in valve, actuator, and
accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is important to
carefully read, understand, and follow all the contents of this manual, including all safety cautions and warnings. If you
have any questions about these instructions, contact your Emerson Process Management sales office before
proceeding.

Description

The controllers described in this manual provide gauge pressure control with the options as shown in table 1-2.

D 4195KA: Proportional‐only control

D 4195KB: Proportional‐plus‐reset control

D 4195KC: Proportional‐plus‐reset‐plus‐rate control

D 4195KS: 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.

Specifications

Specifications for 4195KA, KB, KC, and KS controllers are listed in table 1-1.

Educational Services

For information on available courses for 4195KA, 4195KB, 4195KC, and 4195KS 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: [phone] or
Phone: [phone]
FAX: [phone]
e‐mail: [e-mail]

4

Instruction Manual

D200160X012

Table 1-1. Specifications

4195K Controllers

December 2012

Available Configurations

See table 1-2

Input Signal (Process Sensor Range)

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

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

(1)

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

(2)

See table 1-6

Supply Pressure Medium

Air or natural gas
Air: Supply pressure must be clean, dry air that meets

the requirements of ISA Standard 7.0.01. A maximum
40 micrometer particle size in the air system is
acceptable. Further filtration down to 5 micrometer
particle size is recommended. Lubricant content is
not to exceed 1 ppm weight (w/w) or volume (v/v)
basis. Condensation in the air supply should be
minimized.

Natural Gas: Natural gas must be clean, dry, oil‐free,
and noncorrosive. H2S content should not exceed
20 ppm.

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)

Controller Adjustments

Proportional Band: 5 to 500% of process input span
Reset: Adjustable from 0.01 to more than 74 minutes

per repeat (from 100 to less than 0.0135 repeats per
minute)

Rate: Adjustable from 0 to 20 minutes
Differential Gap Controllers: Adjustable from 5 to
100% of process scale range
Set Point: Adjustable from 0 to 100% of the scale span

Controller Performance

Repeatability: 0.4% of output span
Dead Band: 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

Steady‐State Air Consumption

3 (

100 cubic inch) volume

(3)(4)

0.2 to 1.0 Bar (3 to 15 Psig) Output:

3

0.1 normal m

0.4 to 2.0 Bar (6 to 30 Psig) Output:

0.14 normal m

Delivery Capacity

0.2 to 1.0 Bar (3 to 15 Psig) Output:

5.9 normal m

0.4 to 2.0 Bar (6 to 30 Psig) Output:

10.4 normal m

Operative Ambient Temperature Limits

/hr (3.5 scfh)

3

/hr (5.0 scfh)

(3)

3

/hr (240 scfh)

3

/hr (350 scfh)

(2)(5)

-40 to 71_C (-40 to 160_F)

Exhaust Capacity

0.2 to 1.0 Bar (3 to 15 Psig) Output:

4.6 normal m

(3)

3

/hr (186 scfh)

0.4 to 2.0 Bar (6 to 30 Psig) Output:

7.0 normal m

3

/hr (295 scfh)

Hazardous Area Classification

Complies with the requirements of ATEX Group II
Category 2 Gas and Dust

-continued-

5

4195K Controllers

December 2012

Table 1-1. Specifications (continued)

Instruction Manual

D200160X012

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 (PED) 97 / 23 /

Mounting

Controller can be mounted on actuator, panel, wall,
or pipestand.

Approximate Weight

4.5 kg (10 pounds)

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.

1. Consult your Emerson sales office for additional information.

2. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded.

3. Normal m

4. Without auto/manual station. With auto/manual station, air consumption is 0.28 normal m

5. Also use these temperatures for transportation and storage limits.

3

/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).

3

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.

/hr (10.0 Scfh) for either output range.

Table 1-2. Available Configurations for Fisher 4195KA, 4195KB, 4195KC, and 4195KS Controllers

MODES OPTIONS

Proportional‐

Plus‐Reset‐

Plus‐Rate

(Three‐Mode

Controllers)

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - ­X

X
X
X
X
X
X
X

- - -

- - -

- - -

- - -

Differential

Gap Controller

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - ­X

X
X
X

Internal

Auto/Manual

Station

E

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

- - ­X

(1)

Proportional‐

Only

(One‐Mode

Controllers)

X
X
X
X

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

CONTROLLER

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)

- - -

- - -

- - -

- - -

X
X
X
X
X
X
X
X

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

Anti‐Reset

Windup

F

- - -

- - -

- - -

- - -

- - -

- - ­X
X

- - -

- - ­X
X

- - -

- - ­X
X

- - -

- - ­X
X

- - -

- - -

- - -

- - -

Remote

Setpoint

M

- - -

- - ­X
X

- - -

- - -

- - -

- - ­X
X
X
X

- - -

- - -

- - -

- - ­X
X
X
X

- - -

- - ­X
X

6

Instruction Manual

D200160X012

4195K Controllers

December 2012

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)

7

4195K Controllers

December 2012

Instruction Manual

D200160X012

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

(2)

10
20

30
60
60

90
135
270
420

42

84
140
280

420
840

1300
1950

3900
6000

OPERATING

(3)

3
6
6

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 Range Signal

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

(1)

Maximum

Pressure Limit

(2)

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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

preventive measures are not taken. Preventive measures may include, but are not limited to, one or more of the
following: 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 14.

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.

Figure 2‐1. Typical Actuator Mounting

67CFR
FILTER
REGULATOR

W8462-1

FISHER 657 ACTUATOR

4195K

CONTROLLER

MOUNTING
PLATE

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.

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4195K Controllers

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Figure 2‐2. Pipestand Mounting

HEX HEAD
CAP SCREW
(KEY 66)

LOCKWASHER
(KEY 67)

HEX NUT
(KEY 364)

LOCKWASHER
(KEY 363)

Instruction Manual

D200160X012

REGULATOR

HEX HEAD
CAP SCREW
(KEY 362)

BRACKET
(KEY 68)

49A3196‐A
A6732

PIPE CLAMP
(KEY 69)

VERTICAL PIPE

LOCKWASHER
(KEY 363)

HEX NUT
(KEY 364)

HEX HEAD
CAP SCREW
(KEY 66)

LOCKWASHER
(KEY 67)

ELBOW
(KEY 365)

HEX HEAD
CAP SCREW
(KEY 362)

PIPE CLAMP
(KEY 69)

BRACKET
(KEY 68)

ELBOW
(KEY 365)

HORIZONTAL PIPE

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.

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Figure 2‐3. Panel Mounting

LOCK
WASHER
(KEY 67)

36A9760‐A
A6733

TOP VIEW

84

(3.29)

63

(2.49)

HEX HEAD
CAP SCREW
(KEY 66)

BRACKET
(KEY 68)

ROUND
HEAD
MACHINE
SCREW
(KEY 70)

13
(0.50)

REAR VIEW

62

(2.43)

(9.31)

DIMENSIONS OF

PANEL CUTOUT

306

(12.06)

14
(0.56 R)

236

mm

(INCH)

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.

Figure 2‐4. Wall Mounting

260

(10.25)

HEX HEAD
CAP SCREW
(KEY 66)

161

36A9761‐B
A6734

TOP VIEW

(6.35)

LOCKWASHER
(KEY 67)

13

(0.50)

152

(6.00)

13
(0.50)

REAR VIEW

62

(2.43)

BRACKET
(KEY 68)

mm

(INCH)

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.

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.

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Instruction Manual

D200160X012

Pressure Connections

WARNING

To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any 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.

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, 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.

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 micrometers 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 7.0.01. A maximum 40
micrometer particle size in the air system is acceptable. Further filtration down to 5 micrometer particle size is
recommended. Lubricant content is not to exceed 1 ppm weight (w/w) or volume (v/v) basis. Condensation in the air
supply should be minimized. Natural gas must be clean, dry, oil‐free, and noncorrosive. H2S content should not
exceed 20 ppm.

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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

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.

External Feedback Pressure Connection (4195KB 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).

Figure 2‐5. Connection Locations

102

260

(10.25)

130

(5.13)

(4.00)

51

(2.00)

5/16
UNC‐28
3 HOLES
(MOUNTING)

3.44

330

(13.00)

66

REAR VIEW

147

(5.80)

FRONT VIEW

1/4‐18 NPT CONTROLLER
OUTPUT CONNECTION

1/4‐18
NPT VENT
CONNECTION

1/4‐18 NPT
SUPPLY PRESSURE
CONNECTION

(2.56)

31

(1.22)

1/4 NPT 4 HOLES

BOTTOM VIEW

NOTES:
11/4‐18 NPT PROCESS CONNECTION (MARKED A) FOR ALL BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR
ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.
21/4‐18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND PRESSURE APPLICATIONS.
3FOR THE EXTERNAL FEEDBACK CONNECTIONS (4195KB CONTROLLERS ONLY), EITHER THE A OR B CONNECTION IS USED, DEPENDING ON THE
LOCATION OF THE PROCESS CONNECTION.

46A9765‐A
A2892‐4

(87)

10.04
(255)

1/4 NPT
REMOTE SET POINT CONNECTION

TOP VIEW

mm

(INCH)

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4195K Controllers

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Instruction Manual

D200160X012

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.

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Section 3 4195KA Proportional‐Only Controllers

Adjustments for 4195KA 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.

Figure 3‐1. Fisher 4195KA Controller Adjustment Locations

METAL BALL

SWITCHING
ZONE
INDICATOR

LOADER KNOB

AUTO/MANUAL
SWITCH

SET POINT
INDICATOR

PROCESS POINTER

PROPORTIONAL BAND
ADJUSTMENT

PROPORTIONAL BAND
INDICATOR COVER

OUTPUT PRESSURE GAUGE

W6832

W3679

AUTO/MANUAL STATION

(SUFFIX LETTER E)

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.

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Instruction Manual

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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.

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 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.

Figure 3‐2. Changing Controller Action on Fisher 4195KA Controllers

W3439

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.

Capsular Element Controllers for Vacuum Pressure

D For direct control action—An increasing sensed vacuum increases output pressure.

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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)

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 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.

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 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.

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.

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4195K Controllers

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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.

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 calibration procedure for recalibration.

Instruction Manual

D200160X012

Startup for 4195KA 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 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:

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 x2).

5. Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring
the process.

200 Allowable Overshoot

Pressure Span

200 0.14 bar

2.1 bar

^ 13%

Calibration of 4195KA 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.

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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.

Refer to figures 3‐1 and 3‐3 for adjustment locations.

Note

Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment.

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4195K Controllers

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Figure 3‐3. Fisher 4195KA Controller Calibration Adjustment Locations

REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)

Instruction Manual

D200160X012

POINTER ZERO
ADJUSTMENT

POINTER ZERO
ADJUSTMENT
LOCKING SCREW

W6832

39A1126‐B

PROCESS
POINTER SPAN
ADJUSTMENT

REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)

FRONT VIEW

REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)

PROCESS POINTER
SPAN ADJUSTMENT

SCREW 1

SCREW 2

SCREW 3

56A9752‐S SHT 1

20

A6730

SIDE VIEW OF SET POINT/

PROCESS INDICATOR ASSEMBLY

SIDE VIEW OF CONTROLLER

SHOWING FLAPPER LEVELING SCREWS

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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.

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.

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.

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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.

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.

11. If link 1 was disconnected, remove the tape and reconnect link 1 to the input element.

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12. Set the proportional band to 400 percent in the desired controller action and replace the proportional band
indicator cover.

Principle of Operation for 4195KA Controllers

Overall Operation

Refer to the schematic diagram in figure 3‐4.

Figure 3‐4. Fisher 4195KA Controller Schematic

SET POINT INDICATOR

PROCESS POINTER

REMOTE SET POINT
CONNECTED HERE

INPUT ELEMENT
CONNECTED HERE

CONNECTING
LINK

SUPPLY PRESSURE

OUTPUT PRESSURE

PROPORTIONAL PRESSURE

NOZZLE PRESSURE

46A9764‐A
B1489‐2

BEAM

RESET BELLOWS (VENTED)

PROPORTIONAL
BELLOWS

FLAPPER

NOZZLE

PROPORTIONAL
BAND ADJUSTMENT

FEEDBACK
LINK

FEEDBACK
MOTION

DIRECT ACTION
QUADRANT

SUPPLY
PRESSURE

REVERSE ACTION
QUADRANT

FLAPPER PIVOT

INPUT
MOTION

FLAPPER DETAIL

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

RELAY

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.

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 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.

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Remote Set Point (suffix letter M) Operation

The capability to adjust the controller set point from a remote location is available with all 4195KA 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.

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.

Figure 3‐5. Fisher 4195KA Auto/Manual Station Schematic

AUTOMATIC
POSITION

AUTO/MANUAL
SWITCH

MANUAL LOADER

MANUAL
LOADER KNOB

PLASTIC
TUBE

METAL
BALL

MANUAL POSITION

AUTO/MANUAL
SWITCH

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

48A5230‐A
A2999‐1

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

RELAY

SUPPLY PRESSURE

RELAY OUTPUT PRESSURE

SUPPLY PRESSURE

MANUAL LOADER OUTPUT PRESSURE

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.

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Section 4 4195KB Proportional‐Plus‐Reset Controllers and
4195KC Proportional‐Plus‐Reset‐Plus‐Rate Controllers

Adjustments for 4195KB and KC 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.

Figure 4‐1. Fisher 4195KB and KC Controller Adjustment Locations

METAL BALL

SWITCHING
ZONE
INDICATOR

LOADER KNOB

AUTO/MANUAL
SWITCH

SET POINT
INDICATOR

PROCESS POINTER

W3679

AUTO/MANUAL STATION

(SUFFIX LETTER E)

PROPORTIONAL BAND
ADJUSTMENT

ANTI‐RESET WINDUP
DIFFERENTIAL RELIEF
VALVE (SUFFIX LETTER F)

SUPPLY
PRESSURE GAUGE

W6833

RESET
ADJUSTMENT

TYPICAL ADJUSTMENTS

4195KB SHOWN

OUTPUT PRESSURE GAUGE

RATE
ADJUSTMENT

W3599-1

4195KC RESET AND RATE ADJUSTMENTS

RESET
ADJUSTMENT

Manual Set Point Adjustment

Adjust the set point by opening the controller cover and 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.

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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.

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.

Figure 4‐2. Changing Controller Action on Fisher 4195KB and KC Controllers

W3439

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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.

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 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.

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.

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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 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.

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 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 controllers).

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.

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 calibration procedure
for recalibration.

Startup for 4195KB and KC 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.

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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. +

200 Allowable Overshoot

Pressure Span

For example:

200 0.14 bar

2.1 bar

^ 13%

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.

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 controllers), 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 controllers.

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Calibration of 4195KB and KC 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 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.

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