Instruction Manual 4194S Controllers D200158X012 December 2011 Fisherr 4194S Differential Pressure Controllers Contents 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Educational Services . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual 4194S Controllers December 2011 D200158X012 Contents (cont'd) Link Number 3 . . . . . . . . . . . . . . . . . . . . . . . . . Link Number 4 . . . . . . . . . . . . . . . . . . . . . . . . . Link Number 5 . . . . . . . . . . . . . . . . . . . . . . . . . Long Pivot Assembly . . . . . . . . . . . . . . . . . . . . . Short Pivot Assembly . . . . . . . . . . . . . . . . . . . . Process Drive Flexure . . . . . . . . . . . . . . . . . . . . Process Tubing . . . . . . . . . . . . . . . . . .
Instruction Manual 4194S Controllers D200158X012 December 2011 Table 1‐1. Specifications Available Configurations See table 1‐2 Sensing Element Range (Input Signal) Lower and Upper Range Limits: As shown in table 1‐3 Maximum Allowable Pressure: As shown in table 1‐3 Process Scale Matched to the range of the process differential pressure as standard.
Instruction Manual 4194S Controllers December 2011 D200158X012 Table 1‐2. Available Configurations for Fisher 4194S Controllers OPTIONS CONTROLLER(1) Internal Auto/Manual Station, Option E 4194S 4194SE 4194SM 4194SME Remote Set Point, Option M X X X X 1. Reverse‐acting constructions are designated by an R added to the type number Table 1‐3. Process Sensor (Capsular Element) Pressure Ratings and Materials DIFFERENTIAL SPAN UNITS CAPSULAR STANDARD RANGES UNITS Minimum(1) Maximum(2) Bar 0 to 4.
Instruction Manual 4194S Controllers D200158X012 December 2011 Specifications WARNING This product is intended for a specific current range, temperature range and other application specifications. Applying different current, temperature and other service conditions could result in malfunction of the product, property damage or personal injury. Specifications for 4194S controllers are listed in table 1‐1.
4194S Controllers December 2011 6 Instruction Manual D200158X012
Instruction Manual D200158X012 4194S Controllers December 2011 Section 2 Installation22‐2‐ The controllers should be mounted with the housing vertical (as shown in figure 2‐1) so that the vent points down. WARNING To avoid personal injury or property damage from sudden release of process pressure: D Always wear protective clothing, gloves, and eyewear when performing installation and maintenance procedures.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 2‐1. Typical Actuator Mounting Figure 2‐3. Wall Mounting SPACER SPOOLS CAP SCREWS AND LOCKWASHERS TOP VIEW 280 (10.25) 152 (6.00) 13 (0.50) MOUNTING BRACKET REAR VIEW 36A9761‐A A2759‐4 W5661 Figure 2‐2. Panel Mounting mm (INCH) Figure 2‐4. Pipestand Mounting TOP VIEW SIDE VIEW 308 (12.06) VERTICAL PIPE 14 (0.56)R 236 (9.
Instruction Manual 4194S Controllers D200158X012 December 2011 Pressure Connections WARNING Overpressuring any system component, including the capsular sensing element, could result in personal injury or property damage due to fire and explosion caused by venting or leakage of a hazardous supply pressure medium or process medium.
4194S Controllers December 2011 Instruction Manual D200158X012 Supply Pressure WARNING Severe personal injury or property damage may occur if the instrument air supply is not clean, dry and oil‐free, or noncorrosive gas.
Instruction Manual D200158X012 4194S Controllers December 2011 Section 3 Controller Operation33‐3‐ Operating Information This section includes descriptions of adjustments and procedures for prostrate and startup procedures. Location of adjustments are shown in figures 3‐1 and 3‐2. To better understand the adjustments and overall operation of the controller, refer to the Principle of Operation section and the schematic diagrams, figures 3‐4 and 3‐5.
Instruction Manual 4194S Controllers December 2011 D200158X012 When the automatic/manual switch is in AUTOMATIC, adjusting the loader knob has no effect on the controller output. When the automatic/manual switch is in MANUAL, changing the set point adjustment has no effect on the controller output. Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 3‐1. Location of Controller Parts and Adjustments (continued) SCREW 1 SCREW 2 SCREW 3 PROCESS SPAN ADJUSTMENT 35A7374‐B REMOTE SET POINT SPAN ADJUSTMENT SIDE VIEW OF SET POINT/PROCESS INDICATOR ASSEMBLY C0541 49A0771‐A SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 1. Connect supply pressure to the supply pressure regulator, and be sure it is delivering the proper supply pressure to the controller.
4194S Controllers December 2011 Instruction Manual D200158X012 Calibration WARNING To avoid personal injury or property damage resulting from the sudden release of pressure, do not exceed the operating limits given in this manual. If the prestartup checks revealed faulty adjustment of the process indicator, perform the calibration procedures. These procedures are valid for either shop or field calibration, provided that open process loop conditions exist.
Instruction Manual 4194S Controllers D200158X012 1. 2. 3. 4. 5. 6. 7. 8. 9. December 2011 Refer to figures 3‐1 and 3‐2 for location of adjustments. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36). Set the proportional band between DIRECT and REVERSE. Adjust the set point pressure to the low limit of the input range.
Instruction Manual 4194S Controllers December 2011 D200158X012 The controller output signal will not return to zero pressure until decreasing process pressure passes the lower switching point. When making adjustments as described in the following steps, keep in mind that: D Changing the set point adjustment will move both switching points equally in the direction of adjustment.
Instruction Manual 4194S Controllers D200158X012 December 2011 6. Narrow the proportional band slowly until the output signal switches from zero pressure to full supply pressure. 7. Repeat steps 4 through 6 until the controller output switches at the desired points. 8. Observe the process pointer when the output switches at the upper switching point. The process pointer indication should be within $2 percent of the set point indication.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 3‐4.
Instruction Manual 4194S Controllers D200158X012 December 2011 Remote Set Point Option The capability to adjust the controller set point from a remote location is available with all 4194S controllers. This option is designated by the letter M in the type number. Auto/Manual Option Controllers with the auto/manual option (designated by the letter E in the type number) have piping on the output side of the relay as shown in figure 3‐5. Supply pressure to the relay is also applied to the manual loader.
4194S Controllers December 2011 20 Instruction Manual D200158X012
Instruction Manual D200158X012 4194S Controllers December 2011 Section 4 Maintenance44‐4‐ Parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and parts replacement depends upon the severity of the service conditions. When inspection or repairs are required, disassemble only those parts necessary to accomplish the job. Figure 4‐1 is a maintenance guide. It summarizes the information available in the maintenance procedures.
4194S Controllers December 2011 Instruction Manual D200158X012 Figure 4‐1. Maintenance Guide Troubleshooting If the controller is not operating properly, refer to the troubleshooting chart (table 4‐1). Then use the appropriate portions of the Maintenance section. Replacing Controller Parts Procedures describe replacement of parts in the controller and the input element.
Instruction Manual 4194S Controllers D200158X012 December 2011 Table 4‐1. 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 1.1 Flapper out of alignment 1.2 Process pointer not calibrated correctly 1.3 No supply pressure Check 1.1 Align flapper as necessary 1.2 Adjust as necessary 1.3 Check supply pressure 1.3 Provide correct supply pressure 1.
4194S Controllers December 2011 Instruction Manual D200158X012 Figure 4‐2. Changing Controller Action W3439 Replacing Common Controller Parts WARNING To avoid personal injury or property damage caused by the uncontrolled release of pressure, be sure any trapped process pressure is properly vented from the controller. Vent any supply pressure from the controller before disassembly. WARNING Refer to the Maintenance WARNING on page 21 before replacing any common controller parts.
Instruction Manual 4194S Controllers D200158X012 December 2011 4. To install the replacement scale, bend the lower part of the slot slightly so that the scale slides downward over the set point adjustment and under the process indicator. 5. Install and tighten the four screws on the scale. 6. A slight zero adjustment (see figure 3‐1) may be necessary so that the process indicator aligns with the 0 mark on the scale.
4194S Controllers Instruction Manual December 2011 D200158X012 Case and Cover CAUTION The case and cover are an integral unit; attempting to separate them will damage the hinge. If the cover needs to be replaced, replace the case also. 1. Remove the supply and output piping from the controller. Bleed away any process pressure, and carefully remove the process pressure piping from the controller. 2. Remove the controller from its mounting (see the Installation section) to a maintenance area. 3.
Instruction Manual 4194S Controllers D200158X012 December 2011 Supply Tubing and Positive Feedback Tubing Assemblies Note The following procedure requires that the controller be removed from the case. Perform steps 1 through 3 of the replacing case and cover procedure. 1. Remove the nuts that hold the supply gauge tubing assembly (key 39) or the positive feedback tubing assembly (key 45) to the frame. Remove the tubing. 2. Install the replacement tubing assemblies. 3.
4194S Controllers December 2011 Instruction Manual D200158X012 15. Install the proportional band knob (key 25) on the set point beam assembly (key 23). 16. Install the retaining clip (key 26) on the three posts on the proportional band knob. 17. Install the nozzle assembly (key 21) through the set point beam assembly (key 23), the proportional band knob (key 25), and the retaining clip (key 26) into the cap, aligning the nozzle with the tab on the proportional band knob (shown in figure 4‐5). 18.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 4‐5.
Instruction Manual 4194S Controllers December 2011 Figure 4‐6. Proportional Band Adjustment Knob Setting D200158X012 Figure 4‐7. Nozzle‐Flapper Positioning TAB HOLE FLAPPER W3761 NOZZLE W3449 35. For direct acting controllers, adjust the proportional band knob to 5 percent direct acting. Adjust the set point adjustment or with remote set point pressure to 5 percent of the process scale range. WARNING In step 36, do not exceed the operating limits of the controller (refer to table 1‐3).
Instruction Manual D200158X012 4194S Controllers December 2011 42. If the output pressure snaps to supply pressure below 2 percent of set point, adjust the set point beam shoe (key 29) slightly toward the center of the nozzle pivot. If the output snaps to supply pressure above 2 percent of set point, adjust the set point beam shoe slightly away from the center of the pivot. 43.
Instruction Manual 4194S Controllers December 2011 D200158X012 1. Remove the two screws (key 6), and lift off the proportional band cover (key 36). 2. Disconnect link number 3 from the set point beam assembly (key 23). Refer to figure 4‐12 for link location. 3. Remove the set point beam bias spring (key 28), refer to figure 4‐5 for spring location. 4. Remove the screw and washer (keys 19 and 20) that hold the adjustable set point pivot assembly (key 17) to the frame. 5.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 4‐9. Exploded View of Flexure Pivot Assembly FOUR SCREWS (KEY 10) FLEXURE PIVOT ASSEMBLY INPUT FEEDBACK BEAM ASSEMBLY W3453 16. Move the flexure pivot assembly toward the relay as far as possible, and tighten the four screws (key 10). 17. Place the input feedback beam assembly (key 11) onto the flexure pivot assembly (key 9) with link 4 through the square hole in the frame. 18.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 4‐10. Link 2 Number Adjustment W3476 W3451 31. Install the pivot of the set point pivot assembly (key 17) in the hole in the set point beam. 32. Install washer (key 20) on screw (key 19). 33. Install the set point beam bias spring (key 28) into the frame (key 3) bore and onto the spring seat on the set point beam assembly (key 23). 34. Attach link number 3 to the set point beam assembly. 35.
Instruction Manual 4194S Controllers D200158X012 December 2011 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36). 2. Disconnect link 4 (key 65) from the bellows bracket (key 31). 3. Remove the screw (key 34), spring (key 33) and bellows adjustment bracket (key 32) from the bellows bracket (key 31). 4. Refer to figure 4‐11 for locations. Remove two screws (key 35) from the bellows assembly. Figure 4‐11.
4194S Controllers December 2011 Instruction Manual D200158X012 12. Apply the correct supply pressure, and check for leaks. Remove the supply pressure. If the length of link 4 (key 65) was not changed, proceed with step 14. 13. If the length of link 4 (key 65) was changed during this procedure, refer to the replacement procedures for the flapper flexure pivot assembly. Perform steps 36 through 38 of the procedure. 14. Replace link 4 on the bellows bracket. Make sure the link does not touch the frame.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 4‐12.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 4‐13. Process Pointer Alignment ALIGNED W3443‐1 ZERO ADJUSTMENT LOCKING SCREW MISALIGNED FINE ZERO ADJUSTMENT W3475‐1 Link Number 2 Note Link number 2 is made of aluminum for temperature compensation purposes. Do not replace it with a link of other material. 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 4194S Controllers D200158X012 December 2011 8. Connect link number 1 to the pivot arm. 9. Refer to the Maintenance Calibration and Flapper Alignment procedures. 10. Replace the proportional band indicator cover (key 36), and tighten two screws (key 6). 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.
4194S Controllers Instruction Manual December 2011 D200158X012 4. Adjust the process differential pressure to 0 psid. Adjust the proportional band to 5 percent direct acting, and move the set point manually or with the remote set point pressure to 100 percent of process scale range. Controller output should be 0 psig. 5. With zero pressure in the feedback bellows, loosen the two adjustment screws on the link.
Instruction Manual D200158X012 4194S Controllers December 2011 2. Disconnect links 1 and 5 (keys 88 and 90) from the pivot assembly (key 89). Note which holes they connect to. Remove the two screws (key 102) attaching the pivot assembly to the mounting plate (key 77), and remove the pivot assembly. 3. Set the linearity adjustment screw to approximately the same location as the old assembly. 4. Insert the replacement pivot assembly on the mounting plate, and attach it with the two mounting screws. 5.
4194S Controllers December 2011 Instruction Manual D200158X012 5. Lift out the capsular element assembly by holding the plate (key 77), travel stop (key 83), or pedestal (key 81). 6. Align the replacement capsular element assembly over the mounting screw holes. Install and tighten the mounting screws. 7. Reconnect link 1 (key 90) to the pointer subassembly in the same hole noted in step 3. 8. Reconnect the process pressure connections. 9.
Instruction Manual 4194S Controllers D200158X012 December 2011 2. Full span stop—Adjust process differential pressure to 5 percent greater than full span pressure. Loosen the screws (key 139) mounting the travel stop (key 83) to the mounting plate. Slide the travel stop until it is just touching the end of the capsule stack. Tighten the travel stop mounting screws to lock it into that position. 3. Zero stop—Adjust pressure input to 0 percent of the full span.
4194S Controllers Instruction Manual December 2011 D200158X012 a. Turn the span adjustment screw clockwise. (Adjust the span to correct one‐half the error). b. To increase the span further than the adjustment will allow, move both ends of link 5 (key 88) down one set of holes. Refer to figure 4‐12 for link location. c. Make fine adjustments with the span adjustment screw. 8. To decrease the span, proceed as follows: a. Turn the span adjustment screw counterclockwise.
Instruction Manual D200158X012 4194S Controllers December 2011 WARNING In step 4, do not exceed the operating limits for the controller (refer to table 1‐3). Personal injury or equipment damage may result from overpressure. 4. Slowly increase the process differential pressure from zero until the output pressure snaps to supply pressure. The output pressure should snap to supply pressure within $2 percent of set point. 5.
4194S Controllers Instruction Manual December 2011 D200158X012 Pivot Assembly A (Key 114) CAUTION Avoid bending or kinking the drive flexure during the following procedure. Bending or kinking the drive flexure can result in product damage, as well as impaired performance. 1. Decrease the remote set point pressure to 0 psig. 2. Remove the tie bar (key 106). 3. Note where link A (key 116) is connected. Disconnect the link from the lever arm on the pivot assembly. 4.
Instruction Manual D200158X012 4194S Controllers December 2011 8. Refer to the Maintenance Calibration procedure. Drive Flexure 1. Disconnect the flexure (key 79) from the drive bracket (key 121) and from the adjustment arm of pivot assembly A. Remove the screws and washer (key 12 and 13); remove the flexure. 2. Set remote set point pressure at 50 percent of input span. CAUTION Avoid bending or kinking the drive flexure.
4194S Controllers Instruction Manual December 2011 D200158X012 5. Lift out the capsular element assembly by holding the plate (key 111), travel stop (key 83), or pedestal assembly (key 105). 6. Align the replacement assembly with the mounting screw holes. Replace the mounting screws. 7. Reconnect the process pressure connection union (key 93). Apply remote set point pressure, and check for leaks. 8. Connect the link (key 126) to the pivot hole on the set point indicator assembly. 9.
Instruction Manual D200158X012 4194S Controllers December 2011 3. Apply 50 percent of full span remote set point pressure. 4. The drive flexure (key 79) should be straight. If not, proceed as follows: a. Loosen the screw on the adjustment arm on pivot assembly A (key 114) and the screws holding the drive flexure. b. Set the length of the adjustment arm so that the drive flexure is parallel to the centerline of the capsules. c. Tighten the screw on the adjustment arm. d.
4194S Controllers Instruction Manual December 2011 D200158X012 3. Make fine zero adjustments by loosening the zero adjustment locking screw and turning the zero adjustment screw (key 108). Tighten the locking screw. Refer to figure 5‐3 for location of the screws. 4. Apply 100 percent of the remote set pressure input span. 5. To increase the span, proceed as follows: a. Turn the span adjustment screw clockwise. (Adjust span to correct one‐half the error). b.
Instruction Manual D200158X012 4194S Controllers December 2011 Replacing the Auto/Manual Station Refer to figures 4‐19, 5‐4, and 5‐5 for key number locations. Note This procedure also permits replacement of the switch manifold O‐rings (key 312), the auto/manual tubing assembly (key 138), and the frame gaskets (keys 4 and 5). Disassembly 1. Perform steps 1 through 3 of the replacing case and cover procedure. 2.
4194S Controllers Instruction Manual December 2011 D200158X012 Disassembly 1. Perform steps 1 through 3 of the replacing case and cover procedure. 2. Remove the auto/manual station from the controller frame as described in steps 1 through 4 of the Replacing the Auto/Manual Station procedure. 3. Loosen the two screws (key 288) and remove the lever cover plate (key 305). WARNING The lever spring (key 302) is under preload.
Instruction Manual 4194S Controllers D200158X012 December 2011 5. Compress the switch body springs with the loader assembly (key 282), and bolt the switch (key 291) to the loader assembly with the two screws (key 290). 6. Reconnect the tubing assembly (key 309). 7. Locate the lever spring (key 302) and the spring seat (key 301) on the switch lever (key 304) and position these parts in the opening of the loader assembly (key 282). 8.
4194S Controllers December 2011 Instruction Manual D200158X012 4. Bolt the loader assembly halves together using the four screws (key 289). Note Be sure that the supply and exhaust seats of the loader are correctly aligned. Misalignment will impair loader performance. 5. Attach the tubing assembly (key 309). 6. Perform the Assembly portion of the Replacing the Auto/Manual Station procedure. Replacing the Loader Valve Plug and Valve Plug Spring Refer to figure 5‐5 for key number location. 1.
Instruction Manual 4194S Controllers D200158X012 December 2011 Section 5 Parts Ordering5 Whenever corresponding with your Emerson Process Management sales office about this equipment, always mention the controller serial number. When ordering replacement parts, refer to the 11‐character part number of each required part as found in the following parts list. WARNING Use only genuine Fisher replacement parts.
Instruction Manual 4194S Controllers December 2011 D200158X012 Key Description 27 28 29 30 31 32 33 34 35 36 E‐ring, pl steel Set Point Beam Bias Spring, zn pl steel Set Point Beam Shoe, zn pl steel Machine Screw, pl steel (2 req'd) Bellows Bracket, aluminum Bellows Adjustment Bracket, zn pl steel Bellows Adjustment Spring, zn pl steel Machine Screw, pl steel (2 req'd) Machine screw, pl steel (2 req'd) Proportional Band Indicator Cover, polyester/plastic Self‐Tapping Screw, steel (4 req'd)
Instruction Manual 4194S Controllers D200158X012 December 2011 Mounting Parts Key Description Description Actuator Yoke Mounting Pipestand Mounting 66 67 68 69 Spacer Spool, steel (3 req'd) Cap Screw, pl steel (3 req'd) Lockwasher, pl steel (5 req'd) Mounting Bracket, steel Spacer Spool, steel (2 req'd) Cap Screw, pl steel (2 req'd) Cap Screw, pl steel (3 req'd) Lock Washer, pl steel (7 req'd) Bracket, pl steel Clamp, pl steel (2 req'd) Panel Mounting 66 67 68 70 Cap Screw, pl steel (3 re
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 5‐1.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 5‐1. Controller Assembly Drawing (Continued) Figure 5‐2.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 5‐3.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 5‐4.
Instruction Manual 4194S Controllers December 2011 D200158X012 Figure 5‐5.
Instruction Manual 4194S Controllers D200158X012 December 2011 Figure 5‐6.
4194S Controllers December 2011 Instruction Manual D200158X012 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. Fisher is a mark owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co.
