Fisher 4195 KB Series, 4195 KC Series, 4195 KA Series Instruction Manual

Instruction Manual Form 5207 March 1997

4195KA, KB, and KC Series

4195KA,

KB, and K

C S

eries Gaug

Controllers

Contents

1. Introduction

Scope of Manual 1–3. Description 1–3 Specifications 1–3

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 2–1.

Process Pressure Connection 2–1. Supply Pressure Connection 2–3. Remote Set Point (suffix letter M)

Pressure Connection 2–3.

External Feedback Pressure Connection

(4195KB Series Controllers Only) 2–4.

Vent 2–4

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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 3–3.

General Calibration Instructions 3–3. Process Indicator Zero and Span

Calibration 3–3.

Remote Set Point (suffix letter M)

Zero and Span Calibration 3–4.

Flapper Alignment 3–6.

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e P

Principle of Operation for 4195KA Series

Controllers 3–6. Overall Operation 3–6. Remote Set Point (suffix letter M)

Operation 3–7.

Auto/Manual Station (suffix letter E)

Operation 3–7.

ressure

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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) 4–1. 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) 4–2.

Prestartup Checks for 4195KB and

KC Series Controllers 4–3.

Startup for 4195KB and KC Series

Controllers 4–3.

Calibration of 4195KB and KC Series

Controllers 4–4. General Calibration Instructions 4–4. Process Indicator Zero and Span

Calibration 4–4.

Remote Set Point (suffix letter M)

Zero and Span Calibration 4–6. Flapper Alignment 4–6. Anti-Reset Windup (suffix letter F)

Differential Relief Valve Calibration 4–8.

Principle of Operation for 4195KB and

KC Series Controllers 4–9. Overall Operation 4–9. Anti-Reset Windup (suffix letter F)

Operation 4–11.

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Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.

D200160X012

4195KA, KB, and KC Series

Contents

Remote Set Point (suffix letter M) Auto/Manual Station (suffix letter E) External Feedback Operation 4–12.

(continued)

Operation 4–12. Operation 4–12.

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5. Maintenance

Inspection and Maintenance 5–1. Troubleshooting 5–1 Replacing Common Controller Parts 5–1.

Replacing the Process Pressure Scale 5–1. Replacing the Relay 5–5. Replacing the Case and Cover 5–5. Replacing the Gauges 5–6. Replacing the Supply Gauge, Proportional,

Reset, and Reset Valve, Tubing Assemblies 5–6.

Replacing the Proportional Band Adjustment

Knob, Nozzle Assembly, and Set Point Beam Assembly 5–6.

Replacing the Flapper Assembly and

Flapper Flexure Pivot Assembly 5–10.

Replacing the Proportional or Reset

Bellows 5–13.

Replacing the Reset Restriction Valve

(4195KB Series) 5–15.

Replacing the Rate/Reset Valve Assembly

(4195KC Series) 5–15.

Replacing the Anti-Reset Windup

(suffix letter F) Differential Relief Valve 5–16.

Replacing the Anti-Reset Windup

(suffix letter F) Relief Valve Tubing Assembly 5–16.

Bourdon Tube Controller Maintenance

and Calibration 5–16. Replacing the Bourdon Tube 5–16. Replacing Bourdon Tube Controller Links 5–17.

Replacing Link 1 5–17.

Replacing Link 2 5–18.

Replacing Link 3 5–18.

Replacing Link 4 5–19. Bourdon Tube Travel Stop Installation

and Adjustment 5–20.

Bourdon Tube Controller Calibration:

Zero and Span Adjustment 5–21.

Capsular Element Controller Maintenance

and Calibration 5–23. Replacing the Capsular Element

Assembly 5–23.

Replacing Capsular Element Parts 5–23.

Replacing the Long Pivot Assembly 5–23.

Replacing the Short Pivot Assembly 5–24.

Replacing the Process Drive Flexure 5–24.

Replacing the Process Tubing 5–24. Replacing Capsular Element

Controller Links 5–25.

Replacing Link 1 5–25.

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Replacing Link 2 5–25. Replacing Link 3 5–26. Replacing Link 4 5–26. Replacing Link 5 5–27.

Capsular Element Controller

Maintenance Calibration 5–27. Precalibration Procedure 5–27. Aligning the Drive Bracket Assembly 5–27. Setting the Travel Stops 5–28. Aligning the Linkage 5–28. Capsular Element Controller

Zero and Span Adjustment 5–29.

Remote Set Point (suffix letter M)

Maintenance 5–30.

Replacing the Remote Set Point

Assembly 5–30.

Replacing Remote Set Point

Assembly Parts 5–30. Replacing Pivot Assembly A (key 114) 5–30. Replacing Pivot Assembly B (key 115) 5–32. Replacing the Drive Flexure 5–32. Replacing the Remote Set Point Tubing 5–32. Replacing Link A 5–32. Replacing Link B 5–32.

Remote Set Point (suffix letter M)

Maintenance Calibration 5–33.

Precalibration Procedure 5–33. Aligning the Flexures 5–33. Setting the Travel Stops 5–33. Aligning the Linkage 5–33. Remote Set Point Zero and Span

Adjustment 5–34.

Remote Set Point Linearity Adjustment 5–34.

Auto/Manual Station (suffix letter E)

Maintenance 5–35.

Replacing the Auto/Manual Station 5–35. Replacing the Switch Body Assembly,

Lever O-Ring, Switch Body O-Ring,

and Tubing Assembly 5–35.

Replacing the Loader Range Spring,

Diaphragm Assembly, Ball Seat,

Tubing, and Ball 5–36.

Replacing the Loader Valve Plug and

Valve Plug Spring 5–37.

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6. Parts

Parts Ordering 6–1. Parts Kits 6–1. Parts List 6–1.

Abbreviations Used In The Parts List 6–1. Controller Common Parts 6–1. Process and Set Point Indicator

Assembly 6–5.

Indicator Assembly 6–6. Capsular Element Assembly 6–7. Type 83U Relay 6–7. Remote Set Point Assembly

(suffix letter M) 6–7.

Auto/Manual Station (suffix letter E) 6–8.

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1–2

4195KA, KB, and KC Series

W5663-1 / IL

Figure

1–1. 4195K Series Gauge Pressure Controllers

Contents

Internal/External Set Point Assembly Controller Mounting Parts 6–9.

Pipestand Mounting 6–9. Pipestand Mounting with Regulator 6–9. Panel Mounting 6–9. Wall Mounting 6–9. Controller Mounting Parts for Actuator

Controller Mounting Parts for Actuator

Regulator Mounting Parts 6–9.

Regulator Mounting Parts for Regulator Mounting Parts for

Regulator Mounting Parts for

Fittings 6–10

(continued)

(Option) 6–8.

with Casing-Mounted Controller 6–9. with Yoke-Mounted Controller 6–9.

Casing-Mounted Regulator 6–9. Yoke-Mounted Regulator (Mounting

Bracket Not Required) 6–9. Yoke-Mounted Regulator

(With Mounting Bracket) 6–9.

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W6831 / IL

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.

Only personnel qualified through training or experience should install, operate, and maintain this controller. If there are any questions concerning these instructions, contact your Fisher Controls sales representative or sales office before proceeding.

NAMEPLATE

Description

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

D 4195KA Series: Proportional-only control

Section 1 Introduction

Scope of Manual

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

D 4195KB Series: Proportional-plus-reset control D 4195KC Series: Proportional-plus-reset-plus-rate

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 the 4195KA, KB, and KC Series controllers are listed in table 1–1.

1–3

4195KA, KB, and KC Series

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

(1)

Reset

: Adjustable from 0.01 to more than 74 min-

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

(1)

Rate

: Adjustable from 0 to 20 minutes

Set Point: Adjustable from 0 to 100% of the scale

span

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: 3 to

15 psig or 6 to 30 psig (0.2 to 1.0 bar or 0.4 to 2.0 bar)

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 10 feet (3.05 m) of 1/4-inch (6.4 mm) tubing and 100 cubic inch (1639 cm3) vol-

ume Action: Field-reversible between direct(increasing sensed process pressure increases output pres-

sure) 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-inch NPT, female, stainless steel (all

input ranges)

Optional: 1/2-inch NPT. See table 1–5.

Steady-State Air Consumption

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

m3/hr)

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

m3/hr)

Delivery Capacity

(3)

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

m3/hr)

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

m3/hr)

Exhaust Capacity

(3)

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

Supply and Output Connections

1/4-inch NPT, female

m3/hr)

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

m3/hr)

Supply Pressure Requirements

See table 1–6.

Operative Ambient Temperature Limits

–40 to 160_F (–40 to 71_C)

Remote Set Point Pressure Ranges

3 to 15 psig or 6 to 30 psig (0.2 to 1.0 bar or 0.4 to

2.0 bar)

Mounting

Controller can be mounted on actuator, panel, wall,

or pipestand.

Controller Adjustments

Proportional Band

(1)

: 5 to 500% of process input

span

1. These terms are defined in ISA Standard S51.1-1979.

2. Consult your Fisher sales office or sales representative for additional information.

3. Scfh—Standard cubic feet per hour (60_F and 14.7 psia). Normal m3/hr—Normal cubic meters per hour (0_C and 1.01325 bar, absolute).

4. Without auto/manual station. With auto/manual station, air consumption is 10.0 Scfh (0.28 normal m3/hr for either output range.

Approximate Weight

10 pounds (4.5 kg)

(1,3,4)

3.5 scfh (0.1

5.0 scfh (0.14

240 scfh (5.9 350 scfh (10.4

186 scfh (4.6

295 scfh (7.0

(1)

1–4

4195KA, KB, and KC Series

Table

1–2. A

vailable Configurations for 4195KA, 4195KB, and 4195KC Series Controllers

MODES OPTIONS

(1)

Proportional-

Only

(One-Mode

Controllers)

X X X X

– – – – – – – – – – – – – – – – – – – – – – – –

SERIES

4195KA

4195KB

4195KC

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

Proportional-

Plus-Reset (Two-Mode

Controllers)

– – – – – – – – – – – –

X X X X X X X X

– – – – – – – – – – – – – – – – – – – – – – – –

Proportional-

Plus-Reset-

Plus-Rate

(Three-Mode

Controllers)

– – – – – – – – – – – –

– – – – – – – – – – – – – – – – – – – – – – – –

X X X X X X X X

Internal

Auto/Manual

Station

– – –

Anti-Reset

Windup

– – – – – – – – – – – –

– – –

X – – – – – –

X – – –

– – –

X – – – – – –

Remote

Setpoint

– – – – – –

X X

– – – – – – – – – – – –

X X X X

– – – – – – – – – – – –

X X X X

1–5

4195KA, KB, and KC Series

CAPSULE

CAPSULAR

OPERATING

Positive pressure

Table 1–3. Process Sensor (Capsular Element) Pressure Ratings

CAPSULE CAPSULAR

MATERIAL

U.S. units

N09902

(Ni-Span C)

Metric units

ANDARD RANGES

Positive pressure

Vacuum

Compound

Positive pressure

Vacuum

Compound

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

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

-Continued-

(1)

SPAN

Min Max Min Max

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

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

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

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

OPERATING RANGE

–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 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

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

350 mbar 1 bar 1 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

OPERATING

(2)

LIMIT

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 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

1–6

4195KA, KB, and KC Series

CAPSULE

CAPSULAR

OPERATING

Positive pressure

Table 1–3. Process Sensor (Capsular Element) Pressure Ratings (Continued)

(1)

CAPSULE CAPSULAR

MATERIAL

U.S. units

S31600

(316 SST)

Metric 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 5 psig (0 to 350 mbar) sensing element is used and the minimum span of 2.5 psig (175 mbar) is set, the process indicaion can be calibrated to a range of –10 inch Hg to –6 inch Hg (–340 mbar to –203 mbar), 0 to 2.5 psig (0 to 172 mbar), 2.5 to 5 psig (172 to 345 mbar), 4.5 to 7 psig (305 to 480 mbar), 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.

ANDARD RANGES

Positive pressure

Vacuum

Compound

Positive pressure

Vacuum

Compound

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

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

SPAN

Min Max Min Max

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

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

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

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

OPERATING RANGE

–5 inch Hg –10 inch Hg –20 inch Hg –30 inch Hg –30 inch Hg

–30 inch Hg

0 psig

–30 inch Hg –5 inch Hg

–10 inch Hg –20 inch Hg –30 inch Hg

–5 inch Hg –10 inch Hg –20 inch Hg

–30 inch Hg –30 inch Hg –30 inch Hg

–170 mbar –700 mbar –0.7 bar –1 bar –1 bar

–1 bar –1 bar

0 bar

–1 bar –170 mbar

–340 mbar –0.7 bar –0.7 bar –1 bar

–170 mbar –340 mbar –700 mbar –0.7 bar

–1 bar –1 bar –1 bar –1 bar

2.5 psig 5 psig 10 psig 15 psig 15 psig

20 psig 30 psig 30 psig

2.5 psig 5 psig 15 psig 15 psig

2.5 psig 5 psig 10 psig

15 psig 20 psig 30 psig

170 mbar 700 mbar

0.7 bar 1 bar 1 bar

1.4 bar 2 bar 2 bar 2 bar

170 mbar 340 mbar

0.7 bar

0.7 bar 1 bar

170 mbar 340 mbar 700 mbar

0.7 bar 1 bar

1.4 bar 2 bar 2 bar

OPERATING

(2)

LIMIT

3.75 psig

7.5 psig 15 psig

22.5 psig

22.5 psig 30 psig

45 psig 45 psig

3.75 psig

7.5 psig 15 psig

22.5 psig

3.75 psig

7.5 psig 15 psig

22.5 psig 30 psig 45 psig

255 mbar 1 bar 1 bar

1.5 bar

1.5 bar 2 bar

3 bar 3 bar 3 bar

255 mbar 510 mbar 1 bar 1 bar

1.5 bar 255 mbar

510 mbar 1 bar 1 bar

1.5 bar 2 bar 3 bar 3 bar

1–7

4195KA, KB, and KC Series

OPERATING

MATERIAL

U.S. units

PSIG INPUT

BAR INPUT

Psig

Bar

Table

1–4. Process Sensor (Bourdon T

(1)

15 30 50

100 150

300 750

1100 2200

3700 6000

7500

300 750

1100

10 20 20

76 160 250

420 520

1 2 2

3.5 7

SPAN

60 100 200

300 600

1000 1500

3000 5000

8000

10,000

600

1000 1500

2 4 4 7

70 100 200 350

550 700

70 100

BOURDON TUBES

Minimum Maximum Minimum Maximum

Psig Psig Psig Inch Hg Psig Psig

0 to 30 0 to 60 0 to 100 0 to 200

0 to 300 0 to 600 0 to 1000

U.S. units

0 to 1500 0 to 3000

0 to 5000 0 to 8000

0 to 10,000 0 to 600

0 to 1000 0 to 1500

0 to 1.6 0 to 2.5 0 to 4 0 to 6

0 to 10 0 to 16

Metric units

0 to 25 0 to 40

0 to 60 0 to 100 0 to 160 0 to 300

0 to 550 0 to 600

0 to 40 0 to 60 0 to 100

1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 30 psig (0 to 2 bar) sensing element is used and the minimum span of 15 psig (1 bar) is set, the process indication can be calibrated to a range of –30 inch Hg to 0 psig (–1 to 0 bar), 0 to 15 psig (0 to 1 bar), 15 to 30 psig (1 to 2 bar), 27 to 42 psig (2 to 3 bar) or any value between the operating range minimum and maxi mum 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 30 psig (0 to 2 bar) sensing element is calibrated for 10 to 30 psig (0.7 to 2 bar), the desired range. The minimum expected pressure is 0 psig and the maximum expected pressure is 40 psig (2.8 bar). Travel stops must be used to prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5% of the 20 psig (1.4 bar) span which is ±1 psig (70 mbar).

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.

ube) Pressure Ratings and Materials

84 140 280

420 840

1300 1950

3900 6000

9600

12,000

840

1300 1950

90 135 270 420

670 830

90 135

(2)

(3)

OPERATING

LIMITS

3 6 6

OPERATING RANGE

–30 –30 –30 –30

–30

0 0 0

0 0

0 0 0

Bar

–1 –1 –1 –1

–1 –1

0 0

0 0 0 0

0 0

0 0 0

96 160 320

480 960

1500 2250

4500 7000

11,200 14,000

960

1500 2250

3.3

6.6

6.6 11

22 33 66 66

103 155 310 482

772 965

103 155

(4)

STANDARD

MATERIAL

S31600 (316 SST)

N09902 Nickel Alloy

(Ni-Span C)

K-Monel

(for NACE)

S31600 (316 SST)

N09902 Nickel Alloy

(Ni-Span C)

K-Monel

(for NACE)

Table

1–5. Optional Process Connections

PSIG INPUT BAR INPUT

RANGE

Up to 0 to 5000

0 to 5000 to 0 to 10,000

RANGE

Up to 0 to 400

0 to 400 to 0 to 600

J 1/2-inch NPT male

or J 1/2-inch NPT female

1/2-inch NPT female Stainless steel

1/2-inch NPT male Stainless steel

CONNECTION

Size Material

1–8

J Steel or J stainless

steel

able 1–6. Supply Pressure Data

Output Signal

Range

Psig

3 to 15 20 40

Normal Operating

Supply Pressure

Maximum Pressure

(1)

6 to 30 35 40

Bar

0.2 to 1.0 1.4 2.8

0.4 to 2.0 2.4 2.8

1. If this pressure is exceeded, control may be impaired.

2. If this pressure is exceeded, damage to the controller may result.

Limit

(2)

4195KA, KB, and KC Series

Section 2 Installation

Controller Mounting Orientation

Mount the controller with the housing vertical, as shown in figure 2–1, so the vent points down.

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.

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.

TYPE 67FR FILTER REGULATOR

W5661 / IL

Figure

2–1. Typical Actuator Mounting

Pressure Connections

WARNING

MOUNTING PLATE

TYPE 657 ACTUATOR

TYPE 4195K CONTROLLER

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.

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.

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 enginnering practices.

Refer to figure 2–5 for pressure connection locations. Supply, output, remote set point, external feedback, and vent connections are 1/4-inch NPT, female. Process pressure connections are 1/4- or 1/2-inch 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.

2–1

4195KA, KB, and KC Series

49A3196-A A6732 / IL

HEX HEAD CAP SCREW (KEY 66)

LOCKWASHER (KEY 67)

HEX NUT (KEY 364)

LOCKWASHER (KEY 363)

PIPE CLAMP (KEY 69)

 

LOCKWASHER (KEY 363)

HEX NUT (KEY 364)

HEX HEAD CAP SCREW (KEY 66)

LOCKWASHER (KEY 67)

 

HEX HEAD CAP SCREW (KEY 362)

BRACKET (KEY 68)

ELBOW (KEY 365)

HEX HEAD CAP SCREW (KEY 362)

PIPE CLAMP (KEY 69)

BRACKET (KEY 68)

ELBOW (KEY 365)

REGULATOR

LOCK WASHER (KEY 67)

HEX HEAD CAP SCREW (KEY 66)

BRACKET (KEY 68)

ROUND HEAD MACHINE SCREW (KEY 70)

36A9760-A A6733 / IL

 

0.50 (13)

 

3.29 (84)

2.49 (63)

2.43 (62)

   

0.56 R (14)

9.31 (236)

Figure

2–2. Pipestand Mounting

12.06 (306)

INCH (mm)

0.50 (13)

36A9761-B A6734 / IL

6.00 (152)

 

10.25 (260)

0.50 (13)

 

6.35 (161)

2.43 (62)

LOCKWASHER (KEY 67)

HEX HEAD CAP SCREW (KEY 66)

BRACKET (KEY 68)

INCH (mm)

Figure

2–3. Panel Mounting

2–2

Figure

2–4. Wall Mounting

4195KA, KB, and KC Series

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 1 inch per foot (83 millimeters per m).

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

4.00

5.80 (147)

(102)

2.00

5/16

(51)

UNC-28 3 HOLES (MOUNTING)

3.44 (87)

10.04 (255)

1/4 NPT REMOTE SET POINT CONNECTION

INCH (mm)

10.25 (260)

   

1/4-18 NPT CONTROLLER OUTPUT CONNECTION

1/4-18 NPT VENT CONNECTION

   

NOTES:

1/4-18 NPT PROCESS CONNECTION (MARKED A) FOR ALL BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.

1/4-18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND PRESSURE APPLICATIONS.

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 / IL

Figure

5.13 (130)

13.00 (330)

1/4-18 NPT SUPPLY PRESSURE CONNECTION

2.56 (66)

1.22 (31)

1/4 NPT 4 HOLES

2–5. Connection Locations

WARNING

Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oilfree, or a non-corrosive gas. Industry instrument air quality standards describe acceptable dirt, oil, and moisture content. Due to the variability in nature of the problems these influences can have on pneumatic equipment, Fisher Controls has no technical basis to recommend the level of filtration equipment required to prevent performance degradation of pneumatic equipment. A filter or filter regulator capable of removing particles 40 microns in diameter should suffice for most applications. Use of suitable filtration equipment and the establishment of a maintenance cycle to monitor its operation is recommended.

Supply pressure must be clean, dry air or noncorrosive gas that meets the requirements of ISA Standard S7.3-1975 (R1981). 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 3 to 15 psig (0.2 to 1.0 bar) remote set point pressure range for a 3 to 15 psig (0.2 to 1.0 bar) controller output signal range or a 6 to 30 psig (0.4 to 2.0 bar) remote set point pressure range for a 6 to 30 psig (0.4 to 2.0 bar) 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.

2–3

4195KA, KB, and KC Series

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).

Vent

WARNING

If a flammable, toxic, or reactive gas is to be used as the supply pressure medium, personal injury and property damage could result from fire or explosion of accumulated gas or from contact with a toxic or reactive gas. The controller case and cover assembly do not form a gas-tight seal, and when the assembly is enclosed, a remote vent line, adequate ventilation, and necessary safety measures should be used. However, a remote vent pipe alone cannot be relied upon to remove all 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 3/4 inches (19 mm) for runs up to 20 feet (6.1 meters) and a minimum inside diameter of 1 inch (25 mm) for runs from 20 to 100 feet (6.1 to

30.5 meters). 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.

2–4

4195KA, KB, and KC Series

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

SET POINT INDICATOR

PROCESS POINTER

PROPORTIONAL BAND ADJUSTMENT

PROPORTIONAL BAND INDICATOR COVER

OUTPUT PRESSURE GAUGE

W3679 / IL

 

  

knob clockwise to increase the process set point and counterclockwise to decrease the process set point.

Remote Set Point (suffix letter M) Adjustment

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 5–24.

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.

If the controller is equipped with the optional internal or external set point adjustment, turn the 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.

3–1

4195KA, KB, and KC Series

W3439 / IL

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 porportional band in the black portion provides reverse controller action.

Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure

 For direct control action:

An increasing sensed pressure increases output pressure.

 For reverse control action:

An increasing sensed pressure decreases output pressure.

Capsular Element Controllers for Vacuum Pressure

 For direct control action:

An increasing sensed vacuum increases output pressure.

 For reverse control action:

An increasing sensed vacuum decreases output pressure.

After changing the action, tighten the screws on the proportional band indicator cover.

Figure

3–2. Changing Controller Action

(4195KA Series Controllers)

Switching The Auto/Manual Station (suffix letter E)

CAUTION

Switching the controller between automatic and manual mode without balancing 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 Series Controllers

Refer to figure 3–1 for adjustment locations and refer to figure 5–24 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 3 to 15 psig (0.2 to

3–2

4195KA, KB, and KC Series

1.0 bar) or 6 to 30 psig (0.4 to 2.1 bar) 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 psig.

8. Rotate the proportional band to 5 percent REVERSE.

9. The controller output should be within 2 psig (0.14 bar) 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 Series calibration procedure for recalibration.

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 ×2).

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

200  Allowable Overshoot

Pressure Span

200  2psig

30 psig

 13%

Calibration of 4195KA Series Controllers

General Calibration Instructions

Note

Startup for 4195KA 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 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.

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 5–24.

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:

 Provide a regulated process pressure to the controller and a means of measurement external to the controller.

 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.

3–3

4195KA, KB, and KC Series

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.

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 5–24 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 midrange 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 ajustment 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.

3–4

REMOTE SET POINT ZERO ADJUSTMENT (SUFFIX LETTER M)

4195KA, KB, and KC Series

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

4195KA, KB, and KC Series

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 5–24.

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 9 ±0.10 psig (0.62 ±0.007 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or 18 ±0.2 psig (1.2 ±0.01 bar) for a 6 to 30 psig (0.4 to

2.0 bar) 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 9 ±0.25 psig (0.62 ±0.02 bar) or 18 ±0.5 psig (1.2 ±0.04 bar). If not, ad- just flapper leveling screw 3 (the screw nearest the nozzle).

8. Set the proportional band to 30 percent REVERSE.

9. The controller output should be 9 ±0.25 psig (0.62 ±0.02 bar) or 18 ±0.5 psig (1.2 ±0.04 bar). If not, ad- just 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.

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 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.

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.

3–6

4195KA, KB, and KC Series

SET POINT INDICATOR RESET BELLOWS (VENTED)

PROPORTIONAL BELLOWS

PROCESS POINTER

REMOTE SET POINT CONNECTED HERE

INPUT ELEMENT CONNECTED HERE

CONNECTING LINK

BEAM

FLAPPER

SUPPLY PRESSURE

OUTPUT PRESSURE

PROPORTIONAL PRESSURE

NOZZLE PRESSURE

46A9764-A B1489-2 / IL

NOZZLE

Figure

3–4. 4195KA Series Controller Schematic

PROPORTIONAL BAND ADJUSTMENT

FEEDBACK MOTION

DIRECT ACTION QUADRANT

SUPPLY PRESSURE

FEEDBACK LINK

 

REVERSE ACTION QUADRANT

INPUT MOTION

OUTPUT PRESSURE TO FINAL CONTROL ELEMENT

RELAY

FLAPPER PIVOT

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.

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.

3–7

4195KA, KB, and KC Series

AUTOMATIC POSITION

AUTO/MANUAL SWITCH

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

PLASTIC TUBE

METAL BALL

RELAY

SUPPLY PRESSURE

OUTPUT PRESSURE TO FINAL CONTROL ELEMENT

3–5. Auto/Manual Station Schematic (4195KA Series)

MANUAL POSITION

AUTO/MANUAL SWITCH

3–8

SUPPLY PRESSURE GAUGE

W6833 / IL

RESET ADJUSTMENT

 

 

Figure

4–1. 4195KB and KC Series Controller Adjustment Locations

OUTPUT PRESSURE GAUGE

4195KA, KB, and KC Series

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

 

  

RATE ADJUSTMENT

W3599–1 / IL

    

RESET ADJUSTMENT

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 5–24.

Manual Set Point Adjustment

Adjust the set point by opening the controller cover and moving the set point indicator until the line on theset 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.

If the controller is equipped with the optional internal or external set point adjustment, turn the adjustment knob clockwise to increase the process set point and counterclockwise to decrease the process set point.

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

4–1

4195KA, KB, and KC Series

W3439 / IL

marked in percentages of process pressure required to drive the controller from zero output to full output.

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

(4195KB and KC Series Controllers)

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 5 psig (0.3 bar). Maximum relief pressure is 7 psig (0.5 bar). The minimum is 2 psig (0.1 bar).

Turn the adjusting screw counterclockwise to increase differential relief pressure, clockwise to decrease it.

Switching the Auto/Manual Station (suffix letter E)

Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure

 For direct control action:

An increasing sensed pressure increases output pressure.

 For reverse control action:

An increasing sensed pressure decreases output pressure.

Capsular Element Controllers for Vacuum Pressure

 For direct control action:

An increasing sensed vacuum increases output pressure.

 For reverse control action:

4–2

CAUTION

Switching the controller between automatic and manual mode without balancing 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.

4195KA, KB, and KC Series

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 5–24 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.

2. For a controller with remote set point (suffix letter M), connect regulated pressure of 3 to 15 psig (0.2 to

1.0 bar) or 6 to 30 psig (0.4 to 2.1 bar) 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 psig, a pressure source is not required.

9. The controller output pressure should be 0 psig.

10. Rotate the proportional band to 5 percent REVERSE.

11. The controller output should be within 2 psig (0.14 bar) 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 Series calibration procedure for recalibration.

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:

For example:

4–3

4195KA, KB, and KC Series

P.B. 

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.

200  Allowable Overshoot

Pressure Span

200  2psig

30 psig

 13%

Calibration of 4195KB and KC Series 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 5–24.

Process Indicator Zero and Span Calibration

Before starting this procedure:

 Provide a regulated process pressure to the controller and a means of measurement external to the controller.

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 5–13 or 5–21 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.

 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.

4–4

W6833 / IL

REMOTE SET POINT ZERO ADJUSTMENT (SUFFIX LETTER M)

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

   

RESET ADJUSTMENT

4195KA, KB, and KC Series

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)

RATE ADJUSTMENT

W3599–1 / IL

 

RESET ADJUSTMENT

PROCESS POINTER SPAN ADJUSTMENT

REMOTE SET POINT SPAN ADJUSTMENT (SUFFIX LETTER M)

  

 

 

59A9752-S SHT 1

  

39A1126-B A6731 / IL

Figure

4–3. 4195KB and KC Series Controller Calibration Adjustment Locations

 

  

SCREW 1

SCREW 2

SCREW 3

4–5

4195KA, KB, and KC Series

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 5–24 for key number locations.

5. Apply remote set point pressure equal to the upper range limit.

7. Repeat steps 3 through 6 until the error is eliminated.

8. Adjust the remote set point pressure to the midrange 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

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.

4–6

Flapper leveling screw numbers and adjustments are shown in figure 4–3. Key number locations are shown in figure 5–24.

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.

4195KA, KB, and KC Series

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 midscale mark on the process scale. If 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.

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.

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 2 psig (0.14 bar) 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 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 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 2 psig (0.14 bar) of the supply pressure.

20. If the controller does not perform as indicated in steps 14 through 19, the flapper is not correctly aligned. This may occur because the output was not

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4195KA, KB, and KC Series

W4039 / IL

 

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 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.

6. Provide a regulated supply pressure to the controller. Do not exceed the normal operating pressure in table 1–6.

Note

W4038 / IL

Figure

4–4. Alignment of the Process Pointer with the Set

 

Point Indicator

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. If the controller has the external feedback option, disconnect the outside tubing which connects the external feedback connection to the output connection.

23. 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.

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 6 psig (0.4 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output range or 12 psig (0.8 bar) for a 6 to 30 psig (0.4 to 2.0 bar) 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 0.5 psig (0.04 bar)) 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 0.5 psi (0.04 bar) 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.

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4195KA, KB, and KC Series

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 5 psi (0.4 bar) differential pressure.

13. Repeat steps 7 through 12 until the required differential pressure is obtained.

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.

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.

Note

7. Increase the process pressure (or vacuum for a vacuum controller) to the controller until the controller output pressure balances at 12 psig (0.8 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output range or 24 psig (1.6 bar) for a 6 to 30 psig (0.4 to 2.0 bar) 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 0.5 psig (0.04 bar)) by changing the process pressure to the controller or by 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 0.5 psi (0.04 bar) 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 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.

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 5 psi (0.4 bar) differential pressure.

13. Repeat steps 7 through 12 until the required differential pressure is obtained.

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.

Pressure in the reset bellows opposes the action of the proportional bellows and slowly moves the flapper

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Fisher 4195 KB Series, 4195 KC Series, 4195 KA Series Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual