Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Fisherr 4194HA, HB, and HC Differential Pressure Indicating Controllers Contents 1. Introduction Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Educational Services . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 4 4 2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Replacing Controller Parts . . . . . . . . . . . . . . . . . . . . Replacing the Process Differential Pressure Scale . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Relay . . . . . . . . . . . . . . . . . . . . . Replacing the Case and Cover . . . . . . . . . . . . . Replacing the Gauges . . . . . . . . . . . . . . . . . . . . Replacing the Links . . . . . . . . . . . . . . . . . . . . . . Link 1 . . . . . . . . . .
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Section 11‐1‐ Introduction Scope of Manual This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for the 4194HA, HB, and HC (high static pressure) differential pressure indicating controllers. Portions of this manual apply only to specific 4194HA, HB, and HC controller configurations.
194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Description The controllers described in this manual provide differential control with options as shown in table 1‐2. D 4194HA controllers: Proportional‐only control D 4194HB controllers: Proportional‐plus‐reset control D 4194HC controllers: Proportional‐plus‐reset‐plus‐rate control 4194HA, HB, or HC controllers show process differential pressure and set point on an easy‐to‐read process scale.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Table 1‐1. Specifications Remote Set Point Pressure Ranges Available Configurations See table 1‐2 0.2 to 1.0 bar (3 to 15 psig) or 0.4 to 2.0 bar (6 to 30 psig) Input Signal (Differential Pressure Sensing Element Range) Controller Adjustments Differential Pressure Range: See table 1‐3 Maximum Safe Working Pressure: See table 1‐3 Proportional Band: 5 to 500% of process scale range Reset: Adjustable from 0.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Table 1‐1. Specifications (continued) Hazardous Area Classification Complies with the requirements of ATEX Group II Category 2 Gas and Dust Housing Designed to NEMA 3 and IEC 529, IP54 specifications Mounting Controller is mounted on a pipestand. See figure 2‐1. Approximate Weight Controller: 4.5 kg (10 lb) without the differential pressure unit Differential Pressure Unit: 21.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Table 1‐3. Process Sensor (Barton 199) Range and Pressure Ratings DIFFERENTIAL PRESSURE RANGE(1) Psig (bar) Inches w.c. (mbar) 0 to 15 (0 to 1) 0 to 30 (0 to 2) 0 to 40 (0 to 2.8) 0 to 50 (0 to 3.4) 0 to 60 (0 to 4) 0 to 75 (0 to 5) 0 to 15 (0 to 1) 0 to 30 (0 to 2) 0 to 40 (0 to 2.8) 0 to 50 (0 to 3.4) 0 to 60 (0 to 4) 0 to 75 (0 to 5) 0 to 15 (0 to 1) 0 to 30 (0 to 2) 0 to 40 (0 to 2.8) 0 to 50 (0 to 3.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Section 2 2‐2‐ Installation, Mounting, and Connections WARNING To avoid personal injury or property damage resulting from the sudden release of pressure: D Always wear protective clothing, gloves, and eyewear when performing any installation operations. D Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 2‐1. Right Side View of Controller BARTON 199 DIFFERENTIAL PRESSURE UNIT 1/2 NPT PRESSURE CONNECTION 1/4 NPT PRESSURE CONNECTION 1 1 PIPESTAND MOUNTING BRACKET PIPESTAND SET SCREW (3 REQ'D) NOTE: 1 LOW PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT. W3635-1 Figure 2‐2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Process Pressure Connections Process pressures are piped to the connections on the ends of the differential pressure unit (figure 2‐3). Refer to the differential pressure unit instruction manual for the high and low pressure connections. Figure 2‐3.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Supply pressure must be clean, dry air or noncorrosive gas that meets the requirements of ISA 7.0.01. A maximum 40 micrometer particle size in the air system is acceptable. Further filtration down to 5 micrometer particle size is recommended. Lubricant content is not to exceed 1 ppm weight (w/w) or volume (v/v) basis. Condensation in the air supply should be minimized. Natural gas must be clean, dry, oil‐free, and noncorrosive.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 Section 3 3‐3‐ 4194HA Proportional‐Only Controllers Adjustments for 4194HA Controllers Note Some of the following procedures require adjusting the proportional band knob 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.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 3‐1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Remote Set Point (suffix letter M) Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point. Moving the set point indicator could damage the controller. If the controller is equipped with the remote set point option (figure 3‐2), 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.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 (0 to 15 psig). Then, at a proportional band setting of 100 percent DIRECT, the controller output goes from 3 to 15 psig as the process pressure differential goes from 0 to 15 psig. If the proportional band setting is subsequently changed to 50 percent DIRECT, the controller output would change from 3 to 15 psig as the process pressure differential changed from 0 to 7.5 psig.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 1. Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller. Provide a means of measuring the controller output pressure. Also, provide a means of applying process differential pressure to the differential pressure unit. 2. For a controller with remote set point (suffix letter M), connect regulated pressure of 0.2 to 1.0 bar (3 to 15 psig) or 0.4 to 2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 D remote set point: a. See figure 2‐2 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 of direct‐acting controllers. 3. Set the proportional band adjustment to 100 percent for fast processes.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Refer to figure 3‐1 for location of adjustments. 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band between DIRECT and REVERSE. 3. The process indicator should be aligned with the indicator subassembly as shown in figure 5‐6.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band between DIRECT and REVERSE. 3. Adjust the set point pressure to the low limit of the set point input range. Note the position of the set point indicator.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 This method should only be used if pressure is not available to drive the differential pressure unit to 50 percent. 3. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36). Adjust the proportional band adjustment between DIRECT and REVERSE. 4. The controller output should be 0.62 ±0.007 bar (9 ±0.1 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or 1.2 ±0.01 bar (18 ±0.2 psig) for a 0.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 The process differential pressure input element is connected to the process indicator and to the flapper by connecting links. As the process differential 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.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Section 44‐4‐ 4194HB Proportional‐Plus‐Reset Controllers And 4194HC Proportional‐Plus‐Reset‐Plus‐Rate Controllers Adjustments for 4194HB and HC Controllers This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustments is shown in figure 3‐1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 The white portion of the adjustment produces direct controller action. The black portion produces reverse controller action. After changing the action, tighten the screws on the proportional band indicator cover. Reset (suffix letter B) Adjustment Locate the reset adjustment. Rotate the adjustment clockwise to decrease the minutes per repeat or counterclockwise to increase the minutes per repeat.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 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 option (suffix letter E), be sure the controller is in the automatic mode before performing prestartup checks.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 proportional band percentage from the equation below: Proportional Band + 200 Adjustment Allowable Overshoot Pressure Span For example: 200 2 Psig ^ 13% 30 Psig 5. If the controller is used 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.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 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, if open process loop conditions exist. Unless otherwise noted, key numbers refer to figure 6‐1. Process Indicator Zero‐and‐Span Calibration Provide a regulated process differential pressure to the differential pressure unit.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 15. If the error is greater than ±1 percent, repeat steps 3 through 14. 16. Perform the flapper alignment procedure. Remote Set Point (suffix letter M) Zero‐and‐Span Calibration Refer to figure 3‐1 for location of adjustments. Refer to figures 6‐1 and 6‐3 for key number locations. Note Any adjustment of the remote set point span adjustment screw will require readjustment of the set point zero adjustment screw. See figure 3‐1.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 Flapper leveling screw numbers and adjustments are shown in figure 3‐1. Provide a regulated process differential pressure to the differential pressure unit. Also, plug the controller output connection and provide a regulated supply pressure to the controller. Do not exceed the normal operating pressure in table 1‐4.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 13. Adjust the proportional band to 100 percent direct action. 14. Apply differential pressure to the differential pressure unit or, if link 1 was disconnected, remove the tape from the process indicator and move the indicator until it aligns with the right‐hand edge of the set point indicator (as shown in figure 4‐1). Controller output should be within 0.14 bar (2 psig) of the supply pressure. 15.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Anti‐Reset Windup Valve (suffix letter F) Calibration Calibration for the anti‐reset windup valve to relieve on rising controller output pressure: 1. Plug the controller output connection or connect it to a pressure gauge if desired (open‐loop conditions must exist). 2. Set the reset adjustment to 0.01 minute per repeat (wide open) and the rate adjustment (4194HC controllers only) to the OFF position. 3.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 3. For a controller with manual set point, move the set point indicator to 50 percent of the scale range. For a controller with remote set point, adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range. 4. Adjust the proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements. 5.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Pressure in the reset bellows opposes the action of the proportional bellows and slowly moves the flapper closer to the nozzle. The result of this interaction is that when the process differential pressure changes, proportional action temporarily reduces the gain of the controller for improved stability. The process differential pressure then slowly returns to set point, as pressure in both bellows equalizes via the reset action.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 4‐3.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 D Then, the low gain provided by the proportional action keeps the system stable. Finally, reset action slowly increases the gain and returns the process differential pressure toward the set point. Figure 4‐4.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 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 output of the manual loader is channeled through the auto/manual switch and becomes the output of the controller.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 4‐6.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Section 55‐5‐ Maintenance Inspection and Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance frequency depends on the severity of service conditions. When inspection or repairs are require, disassemble only those parts necessary to accomplish the job.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐1. Maintenance Guide Troubleshooting It the controller is not operating properly, refer to the troubleshooting chart (table 5‐1). 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 4194HA, HB, HC Controllers D200156X012 September 2014 Table 5‐1. Troubleshooting Chart Fault Possible Cause 1. Process wanders or cycles about set point. 1.1 Proportional band and reset settings. 1.1 Refer to the Start‐up section for controller settings. 1.1 If stable control cannot be attained, and all other elements of the loop are functionally correct, examine other possible causes related to the controller. 1.2 Supply pressure varying. 1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Table 5‐1. Troubleshooting Chart (Continued) Fault Possible Cause Check Correction 3. Controlling off set point but not reflected by process and set point indicators. 3.1 Out of calibration. 3.1 Refer to the calibration and flapper alignment procedures. 3.1 Adjust as necessary. 4. No reset action (4194HB and 4194HC controllers). 4.1 Reset valve is plugged. 4.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Table 5‐1. Troubleshooting Chart (Continued) Fault 7. Controller remains at full output. (continued) 8. Controller remains at zero output. Possible Cause Check Correction 7.5 Relay failure or restriction in nozzle passage. 7.5 Manually move flapper 1.6 mm (1/16‐inch) from the nozzle. 7.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 Figure 5‐2. Changing Controller Action W3439 Replacing the Differential Pressure Unit WARNING Refer to the Maintenance WARNING at the beginning of this section. Before performing any maintenance operations: D Shut off the supply pressure to the controller. D Disconnect any operating lines providing supply air pressure, a process input signal, or other pressure source to the controller.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Properly support the unit before trying to separate the controller and differential pressure unit. 4. To separate the controller and differential pressure unit, open the cover, locate link 1 (key 323, figure 6‐2) and disconnect it from the drive arm (key 322). 5. Remove the pivot bracket (key 320) by removing the screws and washers (keys 329 and 332). 6.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Refer to the installation procedures when reinstalling the unit. Note In the following procedures, adjust the proportional band knob between DIRECT and REVERSE. If this is done, it will be necessary to set the proportional band knob to 400 DIRECT or REVERSE (direct or reverse action) before replacing the proportional band indicator cover.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 2. Tip the relay slightly toward the side of the case to clear output pressure gauge and lift out the relay. 3. Make sure the replacement relay has three O‐rings as shown in figure 5‐4. The fourth port is for exhaust and does not require an O‐ring. 4. Install the replacement relay, making sure the tab on the relay lines up with the tab on the frame (figure 5‐4). 5. Install and tighten the two screws holding the relay in place.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 7. Reinstall the differential pressure unit using the proper procedures. 8. Mount the controller as described in the Installation section. 9. Connect the supply pressure and output piping to the controller. Connect the process differential pressure to the differential pressure unit. 10. Perform necessary calibration steps.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐5. Link Locations LINK 4 ADJUSTMENT LINK 4 LINK 2 LINK 2 ADJUSTMENT LINK 3 ADJUSTMENT LINK 3 W3442‐1 Link 1 Note Before performing the following link 1 maintenance steps, disconnect supply pressure from the controller. 1. Note where the link is connected. Disconnect the link from the drive arm and from the process indicator assembly. Remove the link. Then, install the replacement link. 2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐6. Process Indicator Alignment ALIGNED W3443‐1 ZERO ADJUSTMENT LOCKING SCREW MISALIGNED FINE ZERO ADJUSTMENT W3475‐1 Link 2 Note Before performing the following link 2 maintenance steps, disconnect supply pressure from the controller. 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Note where the link is connected.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 7. Adjust the length of link 2 by turning the adjusting screw (see figure 5‐7) clockwise to increase length, or counterclockwise to decrease length so the pin on the end of the link is approximately one‐half of its diameter short of engaging with the hole in the flapper assembly as shown in figure 5‐9. This adjustment provides the proper tension on the link to eliminate lost motion. 8. Remove the tape from the process indicator. 9.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐8. Link Number 3 Adjustment LINK 3 ADJUSTMENT W4192‐1 LINK 2 DISCONNECT 5. Check the set point beam bias spring (key 28). Is it correctly located in the frame bore and spring seat on the set point beam assembly as shown in figure 5‐9? 6. Move the set point adjustment indicator to 50 percent of scale range. 7. Adjust the process differential pressure until the process indicator is at 50 percent of the scale range. 8.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 4. For controllers with reset (4194HB controllers) or rate and reset (4194HC controllers), disconnect the supply pressure and then adjust the rate (4194HC controllers, only) to OFF. The controller output pressure must be 0 bar. Adjust the reset to 0.01 minutes per repeat and wait 30 seconds. Then, turn the reset adjustment to the CLOSED (4194HB controllers) or OFF (4194HC controllers) position. The controller output must be 0 bar.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Replacing the Proportional Band Adjustment Knob, Nozzle Assembly, and Set Point Beam Assembly Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. Key numbers refer to figure 6‐1. Disassembly 1.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 5. 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. 6. Install the relay nozzle tubing assembly (key 18) by pushing it into the bore in the set point beam assembly. 7. Adjust the proportional band between DIRECT and REVERSE.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐9.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 Figure 5‐10. Proportional Band Adjustment Knob Alignment September 2014 Figure 5‐11. Nozzle‐Flapper Alignment TAB HOLE FLAPPER W3761 W3449‐1 NOZZLE TOP VIEW 20. Adjust the set point to the minimum value on the process scale. 21. Disconnect link 1 from the drive arm and tape the process indicator to the minimum scale value. Record the controller output pressure. Output pressure reading can be anywhere from 0.2 to 1.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 Replacing the Flapper Assembly and Flexure Pivot Assembly Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1. Perform the procedures required in the Note above. 2. Remove the two screws and lift off the proportional band indicator cover. 3.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 5‐12. Position of Link Number 4 Adjustment Screws LINK 4 ADJUSTMENT SCREW HEADS ADJUSTABLE SET POINT PIVOT ASSEMBLY SCREW AND WASHER (KEYS 19 AND 20) 2 Figure 5‐13. Flapper Assembly and Leveling Screws FLAPPER LEVELING SCREW NUMBER 2 FLAPPER INPUT FEEDBACK BEAM ASSEMBLY SCREW AND WASHER (KEYS 19 AND 20) 1 OBLONG HOLE IN FRAME NOTES: 1 SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 26. Position the proportional band knob, nozzle pivot, and set point beam assembly on frame. Install the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 5‐11. 27. Install the washer (key 20) on the screw (key 19). 28. Install the screw (key 19) through the frame (key 3) and into the relay nozzle tubing assembly (key 18). Tighten the screw.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Replacing the Proportional or Reset Bellows Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1. Perform the procedures required in the Note above. 2. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 16. Refer to steps 4 through 10 in the procedure for replacing link 4. If the controller is a proportional‐only (4194HA) controller, go to step 28. If the controller has reset (4194HB) or rate/reset (4194HC), continue with step 17 and the following note. 17. Disconnect link 1 from the drive arm. Figure 5‐15.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 22. Increase the process differential pressure very slowly until the output pressure stabilizes at 1.0 bar (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output signal range or 2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output signal range. Record the process differential pressure reading. 23.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1. Perform the procedures required in the Note above. 2. Remove the two machine screws (key 71) on the side of the rate/reset valve assembly (key 262). 3.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Refer to figure 6‐1 (4194HB or 4194HC controllers, suffix letter F) for key number locations. 1. Perform the procedures required in the Note above. 2. Loosen the nuts at both ends of the relief valve tubing (key 44) and remove the tubing. 3. Install the replacement relief valve tubing and tighten the tubing nuts at both ends. 4. Apply the proper supply pressure to the controller. Check for leaks. 5.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 7. The process indicator should point out 50 ±3 percent of the input scale range. If not, loosen the screws in link 1 and move the process indicator to 50 ±3 percent. Tighten the screws. 8. The controller output pressure should be: c. For 4194HA controllers — 0.6 ±0.1 bar (9 ±1 psig) for a 0.2 to 1 bar (3 to 15 psi) output or 1.2 ±0.1 bar (18 ±2 psig) for a 0.4 to 2 bar (6 to 30 psi) output. d. For 4194HB and HC controllers — 0.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 Flapper leveling screw numbers and adjustments are shown in figure 3‐1. Provide a means of applying supply pressure to the controller and plug the output connection. After performing the flapper alignment procedure, go to the appropriate startup procedure. 4194HA Proportional‐Only Controllers 1. For controllers with manual set point, move the set point adjustment to 50 percent of the process scale range.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 2. For a controller with manual set point, move the set point adjustment to 50 percent of the scale range. For a controller with remote set point, adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range. 3. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36). 4. Adjust the reset adjustment to 0.01 minute per repeat. 5.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 18. Pressure the differential pressure unit or, if disconnected, position the process indicator to align with the left‐hand edge of the set point indicator. The controller output should be within 0.14 bar (2 psig) of supply pressure. 19. If the controller does not perform as indicated in steps 13 through 18, the flapper is not correctly aligned.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 12. If the differential pressure calculated in step 11 is incorrect for the application, the differential can be adjusted by turning the anti‐reset windup valve adjustment screw (see figure 3‐1). Turning the screw clockwise will decrease the differential pressure. Turning the screw counterclockwise will increase the differential pressure.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Remote Set Point Assembly Replacement Use the following procedures to replace the remote set point assembly. Refer to figure 6‐3 for key number locations. Note Remove the supply pressure gauge before attempting to remove the remote set point capsular element assembly. 1. Decrease the remote set point pressure to 0 psig. 2. Remove the supply pressure gauge. 3.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 3. Note where link A (key 116) is connected. Disconnect the link from the lever arm on the pivot assembly. 4. Disconnect the drive flexure (key 79) from the adjustment arm of the pivot assembly. Be careful not to bend or kink the drive flexure. 5. Remove the screw (key 122), the washer (key 123) and the nut (key 124) holding the guide flexure to the top of the pivot assembly. 6.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 6. Attach links A and B (keys 116 and 126) to the arms of the replacement pivot assembly B in the positions noted in step 2. 7. Perform the remote set point maintenance calibration procedure in this section. Also, perform the appropriate controller calibration procedure in Section 3 or 4. Drive Flexure CAUTION Avoid bending or kinking the drive flexure during this procedure.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 Link B 1. Note where link B (key 126) is connected (figure 6‐3). Disconnect both ends of the link from the pivot arm and from the set point indicator assembly. 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 6‐3 for correct orientation of the link and position the link as noted in step 1. 4.
Instruction Manual D200156X012 4194HA, HB, HC Controllers September 2014 Note The adjustment arm of pivot A turns on a bushing at each end of the shaft supporting the adjustment arm. In the next step, position the shaft so both bushings ”float” inside the bearings and do not rest against the end of either bearing. d. Set pivot A in the middle of the bushing end play. e. Tighten the screws holding the drive flexure in place. 5. The guide flexure should also be straight.
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 1. Decrease remote set point pressure to the lower range limit. 2. Loosen the adjustment screw on link A (key 116) and adjust the length so the set point indicator points to the lower limit of the process scale. Tighten the screw. 3. Make fine zero adjustments by loosening the zero adjustment locking screw (key 102) and turning the zero adjustment screw (key 108). Tighten the locking screw (key 102).
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 6. Repeat steps 1 through 4 until lower, middle, and upper indications are within ±1 percent of the process scale markings. Replacing Auto/Manual Station (suffix letter E) Parts Disassembly of the Auto/Manual Station Note This procedure also permits replacement of the switch manifold O‐rings (key 312), the auto/manual tubing assembly (key 138), and the frame gaskets (keys 4 and 5).
4194HA, HB, HC Controllers September 2014 Instruction Manual D200156X012 5. Apply air pressure to the controller and check for leaks. 6. Install the controller assembly in the case. Slide the controller frame down to assure an O‐ring seal at the pressure connections. Hold the frame in place. 7. Install and tighten the nine screws holding the controller assembly in the case. 8. Refer to the flapper alignment procedure.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 3. Position the closing plate gasket (key 306) and the closing plate (key 307). Secure with two screws (key 308). 4. Place the balls (key 296), switch body springs (key 295), and O‐rings (keys 292, 293, and 294) in the switch body (key 291). Note In the following step, the ends of the springs must be in the counterbored spring seats before compression. 5.
4194HA, HB, HC Controllers Instruction Manual September 2014 D200156X012 3. Position the ball (key 279), the tube (key 278), and the ball seats (key 280) between the ears of the loader assemblies (keys 282 and 274); position the diaphragm assembly (key 281) between the main halves of the loader assemblies. Note The tube (key 278) must be well‐seated in the cups of the ball seats (key 280). 4. Bolt the loader assembly halves together using the four screws (key 289).
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Section 6 6‐6‐ Parts Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment, always mention the controller serial number. When ordering replacement parts, refer to the 11‐character part number of each required part number as found in the following part list. WARNING Use only genuine Fisher replacement parts.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Key Description Part Number Note Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Key Description SST 57 58 Pressure control block, CF8M (316 SST Casting) 1 req'd for remote set pt 1 req'd for ext fdback Cap screw, hex hd, SST (Maximum qty req'd: 6) Key 46/47 Pressure Gauge(1) RANGE GAUGE MATERIAL Brass Dual Scale Gauge 0 to 30 psig/ 0 to 2 kg/cm2 11B8577X042 11B8583X032 0 to 60 psig/ 0 to 4 kg/cm2 11B8577X052 --- Triple Scale Gauge 0 to 30 psig/ 0 to 200 kpa/ 0 to 2 bar 0 to 60 psig/ 0 to 400 k
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Key Description 101 Indicator ass'y Part Number Key Description 262 Rate/reset valve ass'y For 4194HC controllers only Brass bellows 0.2 to 1.0 bar (3 to 15 psig) 0.4 to 2.0 bar (6 to 30 psig) SST bellows 0.2 to 1.0 bar (3 to 15 psig) 0.4 to 2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐1. Controller Assembly Drawings (Continued) VIEW F‐F F F VIEW E SUFFIX B 49A0770‐A VIEW F‐F F F VIEW E SUFFIX BF SECTION B‐B APPLY LUB/ADHESIVE NOTES: 1 KEY 4 GASKET, IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD. 2 KEY 5, GASKET, IS USED BETWEEN FRAME MANIFOLD AND POSITIVE FEEDBACK TUBING MANIFOLD.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐1.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐2.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐3. Remote Set Point Assembly APPLY LUB/SEALANT 36A6988‐C Remote Set Point Assembly (key 62) (figure 6‐3) Key Description 12 Cap screw, hex socket, 18‐8 SST (2 req'd) Plain washer, 18‐8 SST (3 req'd) Drive flexure, SST 13 79 80 83 86 87 93 99 102 103 104 88 Diaphragm capsule ass'y (for 4194HAM, HAME, HBRM, HBFME, HBM, and HBME) 1 req'd for use in remote set pt ass'y (key 62) N09902 0.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐4.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐5.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Figure 6‐5.
Instruction Manual 4194HA, HB, HC Controllers D200156X012 September 2014 Key Description 300 301 302 303* 304 305 Clip, SST Lever spring seat, SST Lever spring, K08500 (pl steel) Groove pin, SST Switch lever, polycarbonate/SST Switch lever cover plate, aluminum/chromate 306* Closing plate gasket, chloroprene 307 Closing plate, SST 308 309 Machine screw, pan hd, 18‐8 SST, (2 req'd) Tubing ass'y, SST 310 311 Lithium grease (not furnished with controller) Anti‐seize sealant (not furnished with contr
