Instruction Manual 4194HS Controllers D200157X012 October 2011 Fisherr 4194HS Differential Pressure Indicating Controllers Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Educational Services . . . . . . . . . . . . . . . . . . . .
Instruction Manual 4194HS Controllers October 2011 D200157X012 Contents (continued) Proportional Band Knob, Nozzle Pivot, and Set Point Beam Assembly . . . . . . . . . . . Flapper Flexure Pivot Assembly . . . . . . . . . . . Positive Feedback Bellows . . . . . . . . . . . . . . . Calibration After Controller Maintenance . . . Process Zero‐and‐Span Adjustment . . . . . . . Flapper Alignment . . . . . . . . . . . . . . . . . . . . . Replacing Remote Set Point (suffix letter M) Parts . . . . . . . . .
Instruction Manual 4194HS Controllers D200157X012 October 2011 Table 2. Specifications Controller Adjustments Available Configurations See table 1 Differential Gap Control: 1 to 100% of process scale range Set Point: Continuously adjustable from 0 to 100% of the scale range Input Signal (Sensing Element Range) Lower and Upper Range Limits: See tables 3 and 4 Maximum Allowable Operating Limits: See tables 3 and 4 Steady‐State Air Consumption(3,4) 0 to 1.4 Bar (0 to 20 Psig) Output: 0.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Table 2. Specifications (continued) Declaration of SEP with Sound Engineering Practice (SEP) and cannot bear the CE marking related to PED compliance. Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 of the Pressure Equipment Directive (PED) 97 / 23 / EC.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Do not install, operate, or maintain a 4194HS differential pressure indicating 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 of the contents of this manual, including all safety cautions and warnings.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Pipestand Mounting A 4194HS controller mounts on a pipestand and must be installed with the vent opening facing down. The coupling is secured to the pipestand by three set screws as shown in figure 2. Figure 2.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 3. Connections 1/4 NPT REMOTE SET POINT CONNECTION REMOTE SET POINT CONNECTION 1 1/2 NPT TOP VIEW 1/4 NPT OPTIONAL EXTERNAL FEEDBACK CONNECTION 1/4 NPT VENT 1/4 NPT 1 SUPPLY PRESSURE CONTROLLER OUTPUT PRESSURE 1/4 NPT 2 HOLES LEFT SIDE VIEW FRONT VIEW BOTTOM VIEW NOTE: 1 HIGH PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT 18A5903‐B A3000-1 Supply, output, vent, and remote set point connections are 1/4 NPT.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 4. Simplified Control Loop Diagram 2 LOW PRESSURE CONNECTIONS SUPPLY PRESSURE LOW PRESSURE PIPING HIGH PRESSURE CONNECTIONS OUTPUT SIGNAL HIGH PRESSURE PIPING 1 ORIFICE PLATE NOTE: 1 TO ALLOW A REAR VIEW OF THE CONTROLLER/ DIFFERENTIAL PRESSURE UNIT, THE SCHEMATIC SHOWS PROCESS FLOW FROM RIGHT TO LEFT. 2 SEE FIGURE 2 FOR LOW PRESSURE CONNECTIONS.
Instruction Manual D200157X012 4194HS Controllers October 2011 If a remote vent is not required, the vent opening (figure 3) 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. Supply Pressure WARNING Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oil‐free air or a non‐corrosive gas.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 5.
Instruction Manual D200157X012 4194HS Controllers October 2011 Adjustments Remote Set Point (suffix letter M) CAUTION Do not move the set point adjustment manually on controllers with remote set point. Moving the set point adjustment could damage the controller. If the controller is equipped with the remote set point option, 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.
4194HS Controllers October 2011 Instruction Manual D200157X012 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 manually or with remote set point pressure to move the ball into the switching zone.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Note If the controller has the auto/manual option, be sure the controller is in the automatic mode before performing calibration procedures. If the prestartup checks revealed faulty adjustment of the process indicator, perform the calibration procedures. These procedures are valid for either shop or field calibration, if open process loop conditions exist.
Instruction Manual 4194HS Controllers October 2011 D200157X012 5. Adjust the set point pressure to the upper limit of the input span. Note whether the pointer indication is above or below the upper limit of the process scale. 6. Adjust the span screw as follows: Clockwise to increase span for a low indication; counterclockwise to decrease span for a high indication. Adjust the span screw to correct one‐half the error. 7. Repeat steps 3 through 6 until the error is eliminated. 8.
Instruction Manual 4194HS Controllers D200157X012 October 2011 D Locate the 50 percent line on figure 7. Move along this line until you intersect the curve. Read the proportional band setting on the left hand axis. For this example, the setting is approximately 35 percent. 1. Using the curve in figure 7, determine the correct proportional band setting for the desired gap (expressed as a percent of the input span) between the switching points. 2.
Instruction Manual 4194HS Controllers October 2011 D200157X012 5. Increase the process differential pressure to the desired switching point at which the controller output signal switches from full supply pressure to zero pressure. 6. Narrow or widen the proportional band slowly until the output signal switches from full supply pressure to zero pressure. 7. Repeat steps 4 through 6 until the controller output switches at desired points. 8.
Instruction Manual 4194HS Controllers D200157X012 October 2011 The set point adjustment changes the proximity of the nozzle and flapper as does a change in process pressure except that, when the set point is changed, the nozzle moves with respect to the flapper. The set point adjustment moves both the upper and lower switching points. The proportional band knob positions the nozzle on the flapper. Increasing (widening) the proportional band moves the nozzle away from the input connection.
4194HS Controllers Instruction Manual October 2011 D200157X012 Before the auto/manual switch is operated, the output of the relay must equal the output of the manual loader 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.
Instruction Manual D200157X012 4194HS Controllers October 2011 Figure 10. Maintenance Guide Troubleshooting It the controller is not operating properly, refer to the troubleshooting chart (table 5). Then use the appropriate portions of the Maintenance section. Replacing Common Controller Parts Procedures describe replacement of controller parts. The procedures may be performed separately, but must be followed by maintenance calibration procedures.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Table 5. Troubleshooting Chart Fault 1. Output does not snap when process pointer and set point indicator are aligned 2. Controller output will not snap to full output pressure Possible Cause Correction 1.1 Refer to flapper alignment procedure 1.2 Process pointer not calibrated correctly 1.2 Refer to the process zero and span adjustment procedures 1.1 Align flapper as necessary 1.3 No supply pressure 1.3 Check supply pressure 1.
Instruction Manual D200157X012 4194HS Controllers October 2011 2. Lift the proportional band indicator cover as shown in figure 11. Figure 11. Changing Controller Action W3439 3. Rotate the proportional band knob (key 25) to the desired controller action. 4. Install the proportional band indicator cover (key 36) and tighten the two screws (key 6).
4194HS Controllers Instruction Manual October 2011 D200157X012 4. To separate the controller and differential pressure unit, open the cover, locate link number 1 (key 323) and disconnect it from the drive arm (key 322). CAUTION When reassembling the pivot bracket, it must be carefully aligned so it will not cause binding on the extension shaft (key 331). 5. Remove the pivot bracket (key 320) by removing the screws and washers (keys 329 and 332). 6.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Note Some of the following procedures require that the proportional band knob be adjusted to between DIRECT and REVERSE. If this is done, it will be necessary to set the proportional band knob to 400 (direct or reverse action) before replacing the proportional band indicator cover. Process Pressure Scale CAUTION Take care not to bend the process indicator or the set point adjustment while performing the following procedure. 1.
Instruction Manual 4194HS Controllers October 2011 D200157X012 4. Install the replacement relay, making sure the tabs on the relay line up with the tab on the frame (figure 13). Figure 13. Relay Features CLEAN‐OUT WIRE EXHAUST PORT (NO O‐RING USED) O‐RINGS RELAY TAB RELAY MOUNTING SCREWS W5744 5. Install and tighten the two screws that hold the relay in place. Case and Cover CAUTION The case and cover are an integral unit; trying to separate them will damage the hinge.
Instruction Manual 4194HS Controllers D200157X012 October 2011 8. Mount the controller as described in the Installation section. 9. Connect the supply, output, and process pressure piping to the controller. 10. Perform necessary calibration steps. Gauges CAUTION Before performing this procedure, be sure the replacement gauges are the correct range so the gauges are not damaged by overpressure. 1. Unscrew the output gauge (key 46) or the supply gauge (key 47) from the frame (key 3). 2.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 14. Link Locations LINK 4 ADJUSTMENT LINK 4 LINK 2 W3442‐1 LINK 2 ADJUSTMENT LINK 3 ADJUSTMENT LINK 3 Link Number 2 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Note where the link is connected. Disconnect the link from process pointer assembly and from the input feedback beam assembly (key 11). Remove the link. 3.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 15. Process Pointer Alignment ZERO ADJUSTMENT LOCKING SCREW ALIGNED W3443‐1 MISALIGNED FINE ZERO ADJUSTMENT W3475‐1 Figure 16. Link Number 2 Adjustment CLINCH NUT FLAPPER LEVELING SCREW 3 W4191 W3451 1/2 OF PIN DIAMETER Link Number 3 1. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Note where the link is connected.
Instruction Manual 4194HS Controllers October 2011 D200157X012 3. Install the replacement link with the screw head toward set point beam assembly as shown in figure 17 and in the position as noted in step 2. Figure 17. Link Number 3 Adjustment LINK 3 ADJUSTMENT W4192‐1 LINK 2 DISCONNECT 4. Check that set point beam bias spring (key 28) is correctly located in frame bore and spring seat on the set point beam assembly as shown in figure 18. 5. Adjust the proportional band between DIRECT and REVERSE. 6.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Refer to figure 26 for key number locations. 1. Remove the nuts that hold the supply gauge tubing assembly (key 39) or the positive feedback tubing assembly (key 40) to the frame. Remove the tubing. 2. Install the replacement tubing assemblies. 3. Apply the correct supply pressure and check for leaks. Then remove pressure. 4. Install the controller assembly into the case.
4194HS Controllers Instruction Manual October 2011 D200157X012 19. Inspect the O‐ring on the relay nozzle tubing assembly (key 18) and replace it if necessary. Apply a suitable lubricant (key 318) to the O‐ring. 20. Install the relay nozzle tubing assembly (key 18) into the set point beam assembly. 21. Adjust the proportional band between DIRECT and REVERSE. Do this by aligning the tab on the proportional band knob with the hole in the set point beam assembly as shown in figure 20. 22.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 18.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 19. Position of Link Number 4 Adjustment Screws LINK 4 ADJUSTMENT SCREW HEADS Figure 20. Proportional Band Adjustment Knob Alignment ADJUSTABLE SET POINT PIVOT ASSEMBLY TAB HOLE SCREW AND WASHER (KEYS 19 AND 20) 2 SCREW AND WASHER (KEYS 19 AND 20) 1 NOTES: 1 SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY. 2 SCREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY. W3761 W4195 Figure 21.
Instruction Manual D200157X012 4194HS Controllers October 2011 37. If the output pressure snaps to supply pressure below 2 percent of set point, adjust flapper leveling screw number 3 clockwise (see figure 5 for location of screw). If the output pressure snaps to supply pressure above 2 percent of set point, adjust flapper leveling screw number 3 counterclockwise. 38. Repeat steps 36 and 37 until the output pressure snaps within "2 percent.
4194HS Controllers Instruction Manual October 2011 D200157X012 54. Install and tighten the nine mounting screws that hold the controller assembly in place. 55. Refer to the flapper alignment procedures. 56. Replace the proportional band indicator cover (key 36) and tighten two screws (key 6). Flapper Flexure Pivot Assembly Note The following procedure requires that the controller be removed from the case. Perform steps 1 through 7 in the replacing the differential pressure unit procedure.
Instruction Manual 4194HS Controllers D200157X012 October 2011 24. Adjust the proportional band between DIRECT and REVERSE. Do this by aligning the tab on the proportional band knob with the hole in the set point beam assembly as shown in figure 20. Figure 22. Flapper Assembly and Leveling Screws Figure 23.
4194HS Controllers Instruction Manual October 2011 D200157X012 40. Determine the position of the set point beam shoe (key 29). D If the position of the set point beam shoe was changed during this procedure, relative to the set point beam assembly (key 23), refer to the procedure for replacing proportional band knob, nozzle pivot, and set point beam assembly. Perform steps 32 through 51 there.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 24. Bellows Assembly and Proportional Band Adjustment (Process Scale and Proportional Band Adjustment Cover Removed) FOUR SCREWS (KEY 6) RESET BELLOWS PROPORTIONAL BELLOWS WASHER (KEY 362) TWO SCREWS (KEY 35) BELLOWS BRACKET (KEY 31) LOCKING NUT ADJUSTABLE SET POINT PIVOT ASSEMBLY (KEY 17) LINK 4 SCREW AND WASHER (KEYS 19 AND 20) W4199 10. Install the two screws (key 35) through the bellows bracket (key 31) into the bellows.
4194HS Controllers October 2011 Instruction Manual D200157X012 Calibration After Controller Maintenance Process Zero‐and‐Span Adjustment If the prestartup checks procedures revealed faulty adjustment of the process indicator, perform the calibration procedures. These instructions are valid for either shop or field calibration, if open loop conditions exist. Note If the controller has the auto/manual station option, be sure the controller is in the automatic mode before performing calibration.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 25. Leveling Screws SCREW 1 SCREW 2 SCREW 3 56A9752‐S SHT 1 SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 1. For controllers with manual set point, move the set point adjustment to 50 percent of the scale range. For controllers with remote set point (suffix letter M), adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range. 2.
4194HS Controllers October 2011 Instruction Manual D200157X012 11. Carefully adjust the process differential pressure to 100 percent of the process scale range. Then, slowly decrease the process differential pressure until the output pressure snaps to supply pressure. The output pressure should snap to supply pressure within "2 percent of set point. 12. If the output pressure snaps to supply pressure below 2 percent of set point, adjust flapper leveling screw number 1 counterclockwise.
Instruction Manual 4194HS Controllers D200157X012 October 2011 10. Increase the remote set point pressure to 50 percent of input span. 11. Connect the drive flexure to the arm on the new pivot assembly, making sure it stays straight and horizontal. Before tightening down the drive flexure, set the pivot in the middle of the bushing end play. Tighten down the drive flexure to hold the pivot in that position. Do not kink or twist the flexure when tightening the screws.
4194HS Controllers Instruction Manual October 2011 D200157X012 2. Disconnect the pressure connection (key 93) into the pedestal assembly (key 105) and the connection to the case exterior at the top of the case. 3. Remove the tubing (key 104). 4. Install the replacement tubing and reconnect the two pressure connections. 5. Apply full remote set point pressure and check for leaks.
Instruction Manual 4194HS Controllers D200157X012 October 2011 2. Loosen the screw in the replacement link and adjust the length to match the link being replaced. Tighten the screw. 3. Attach both ends of the replacement link. Refer to figure 28 for correct orientation of the link and position the link as noted in step 1. 4. After replacing parts, refer to the various maintenance calibration procedures (process zero‐and‐span adjustment, flapper alignment). Pressure Control Block for Remote Set Point 1.
4194HS Controllers Instruction Manual October 2011 D200157X012 d. Set pivot A in the middle of the bushing end play. e. Tighten the screws that hold the drive flexure in place. 5. The guide flexure should also be straight. If not, loosen the screw (key 122) on the end of the flexure that is attached to the top of pivot A (key 114) and allow the flexure to straighten itself. Tighten the screw on the flexure. Setting Remote Set Point Travel Stops 1. Loosen the set screw in the travel stop nut (key 86).
Instruction Manual 4194HS Controllers D200157X012 October 2011 b. To increase the span further than the adjustment will allow, move both ends of link A to the right. Refer to figure 6 for link location. c. Make fine adjustments with the span adjustment screw. 6. To decrease the span, proceed as follows: a. Turn the span adjustment screw counterclockwise. (Adjust span to correct one‐half of the error). b. To decrease the span further than the adjustment will allow, move both ends of link A to the right.
4194HS Controllers Instruction Manual October 2011 D200157X012 Disassembly Refer to figures 29 and 30 for key number location. 1. Loosen the screw (key 316) that holds the auto/manual station (key 273) to the controller frame. 2. Loosen the two screws (keys 314 and 315) that hold the auto/manual station to the auto/manual tubing assembly (key 138). 3. Remove the auto/manual station from the controller frame. 4. Remove the switch manifold O‐rings (key 312). 5.
Instruction Manual 4194HS Controllers D200157X012 October 2011 When removing the groove pin, hold onto the switch lever and slowly pull the switch lever from the lever assembly shaft (key 297). Then, remove the lever spring and lever spring seat. 3. Using a 1.5 mm (1/16‐inch) punch, push the groove pin (key 303) out of the lever assembly shaft. 4. Remove the switch lever (key 304), lever spring (key 302), and lever spring seat (key 301). 5. Remove the tubing assembly (key 309).
4194HS Controllers Instruction Manual October 2011 D200157X012 6. Reconnect the tubing assembly (key 309). 7. Locate the lever spring (key 302) and the spring seat (key 301) on the switch lever (key 304) and position these parts in the opening of the loader assembly (key 282). 8. Push the switch lever down, using the lever spring seat (key 301) and the lever assembly (key 297) to preload the spring. Make sure the notch of the switch lever engages the pin of the lever assembly. 9.
Instruction Manual 4194HS Controllers D200157X012 October 2011 5. Attach the tubing assembly (key 309). 6. Perform the assembly portion in the replacing the auto/manual station procedure. Replacing the Auto/Manual Station Loader Valve Plug and Valve Plug Spring Refer to figure 30 for key number location. 1. Loosen the spring seat screw (key 275). 2. Remove the valve plug spring (key 276) and the valve plug (key 277). 3. Inspect the parts and replace as necessary. 4.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Controller Parts (figure 26) Note Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office.
Instruction Manual 4194HS Controllers D200157X012 Key Description 58 Cap screw, hex hd, SST for use w/pressure control block (key 57), w/remote set pt (2 req'd) 61 62 Process scale, aluminum for indicator ass'y 0‐5 psid 0‐10 psid 0‐15 psid 0‐20 psid 0‐30 psid 0‐40 psid 0‐50 psid 0‐60 psid 0‐75 psid 0‐250 mbar differential 0‐0.6 bar differential 0‐1.4 bar differential 0‐1.6 bar differential 0‐2.0 bar differential 0‐20 in. w.c. differential 0‐25 in. w.c.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Key Description Key Description 140 Machine screw, fill hd, 18‐8 SST For 4194HSM and HSME only.
Instruction Manual 4194HS Controllers D200157X012 Key Description 375 Set pt indicator ass'y, A93003 (aluminum) for controllers w/remote set pt for controllers w/o remote set pt Dial Bracket, G10080 (steel) Dial bracket, G10080 (steel) Screw, self‐tapping, 18‐8 SST (2 req'd) 376 377 378 October 2011 Part Number Auto/Manual Station (suffix letter E) (figure 28) 138 273 274 275 276 277* 278 279 280 281 282 283 284 285 286* 287 288 289 290 291 292* 293* 294* 295 296 297 298* 299 Auto/manual tubin
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 26.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 26. Controller Assembly Drawings (Continued) APPLY LUB/SEALANT SECTION B-B 49A0770‐A NOTES: 1 2 KEY 4, GASKET, IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD KEY 5, GASKET, IS USED BETWEEN FRAME MANIFOLD AND POSITIVE FEEDBACK TUBING MANIFOLD.
4194HS Controllers October 2011 Figure 27.
Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 28.
Instruction Manual 4194HS Controllers October 2011 D200157X012 Figure 28.
Instruction Manual D200157X012 4194HS Controllers October 2011 Figure 29.
4194HS Controllers October 2011 Instruction Manual D200157X012 Figure 30. Process and Set Point Indicator Assembly (Manual Set Point) 39A1126‐H Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
