4195S Controller Instruction Manual

Instruction Manual Form 5583 June 1983

4195S Series Incorporates Errata Sheet Dated October 1990–See Page 5-10

4195S Series Gauge Pressure Controllers 1. Introduction Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2. Installation Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Pipestand Mounting . . . . . . . . . . . . . . . . . . . . . . . 2–1 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Remote Set Point (Option M) . . . . . . . . . . . . . . . 2–3

3. Controller Operation Operating Information . . . . . . . . . . . . . . . . . . . . .

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Prestartup Checks . . . . . . . . . . . . . . . . . . . . . . .

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Remote Set Point Zero and Span (Option M) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Direct-Acting Controllers . . . . . . . . . . . . . . . . .

Reverse-Acting Controllers . . . . . . . . . . . . . . .

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

Overall Operation . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3–1 3–1 3–1 3–1 3–1 3–1 3–1 3–1 3–2 3–2 3–3 3–3 3–4 3–4 3–5 3–6 3–6 3–6 3–6

4. Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

Changing Controller Action . . . . . . . . . . . . . . . . . 4–1 Replacing Common Controller Parts . . . . . . . . . 4–1 Process Pressure Scale . . . . . . . . . . . . . . . . . . 4–1 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Case and Cover . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Pressure Control Block . . . . . . . . . . . . . . . . . . . 4–4 Supply Tubing and Positive Feedback Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Proportional Band Knob, NozzleAssembly, and Set Point Beam Assembly . . . . . . . . . . . . . . . . . . 4–5 Flapper Flexure Pivot Assembly . . . . . . . . . . . 4–8 Positive Feedback Bellows . . . . . . . . . . . . . . . 4–10 Bourdon Tube Controllers . . . . . . . . . . . . . . . . . 4–11 Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Bourdon Tube . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Maintenance Calibration . . . . . . . . . . . . . . . . . 4–15 Calibration Procedures–100 Percent of Bourdon Tube Range . . . . . . . . . . . . . . . . . . . . . . . . 4–16 Calibration Procedures–Less Than 100 Percent of Bourdon Tube Range . . . . . . . . . . . . . . . . 4–17 Travel Stop Installation and Adjustment . . . . 4–16 Capsular Element Controllers . . . . . . . . . . . . . 4–16 Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . 4–15 Long Pivot Assembly . . . . . . . . . . . . . . . . . . . 4–17 Short Pivot Assembly . . . . . . . . . . . . . . . . . . 4–17 Process Drive Flexure . . . . . . . . . . . . . . . . . . 4–17 Process Tubing . . . . . . . . . . . . . . . . . . . . . . . 4–17 Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18 Maintenance Calibration . . . . . . . . . . . . . . . . . 4–19 Precalibration Procedures . . . . . . . . . . . . . . 4–19 Aligning the Drive Bracket Assembly . . . . . 4–19 Setting Travel Stops . . . . . . . . . . . . . . . . . . . 4–19 Adjusting Linkage . . . . . . . . . . . . . . . . . . . . . . 4–20 Zero and Span Adjustment . . . . . . . . . . . . . . 4–20 Linearity Adjustment . . . . . . . . . . . . . . . . . . . 4–21 Flapper Alignment . . . . . . . . . . . . . . . . . . . . . . . . 4–21 Remote Set Point (Option M) . . . . . . . . . . . . . . 4–22 Pivot Assembly A (key 114) . . . . . . . . . . . . . 4–22 Pivot Assembly B (key 115) . . . . . . . . . . . . . 4–22 Drive Flexure . . . . . . . . . . . . . . . . . . . . . . . . . 4–22 Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22

D200161X012

Contents

4195S Series Remote Set Point Capsular Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .

Link A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Link B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Calibration . . . . . . . . . . . . . . . . .

Precalibration Procedure . . . . . . . . . . . . . . .

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

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

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

Zero and Span . . . . . . . . . . . . . . . . . . . . . . . .

Linearity Adjustment . . . . . . . . . . . . . . . . . . .

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

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

Replacing the Switch Body Assembly, Lever O-Ring, Switch Body O-Ring, and Tubing Assembly . . . . . . . . . . . . . . . . .

Replacing the Loader Range Spring, Diaphragm Assembly, Ball Seat,

ii

4–23 4–23 4–23 4–23 4–23 4–24 4–24 4–24 4–24 4–24 4–25 4–25 4–25

Tubing, and Ball . . . . . . . . . . . . . . . . . . . . . . 4–26 Replacing the Loader Valve Plug and Valve Plug Spring . . . . . . . . . . . . . . . . . . . . 4–27

5. Parts List Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Controller Parts and Bourdon Tubes .

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

Remote Set Point Assembly . . . . . . . . . . . . . . . .

Internal Auto/Manual Station . . . . . . . . . . . . . . . .

Mounting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipestand Mounting . . . . . . . . . . . . . . . . . . . . .

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . .

Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuator Casing Mounting . . . . . . . . . . . . . . .

Actuator Yoke Mounting . . . . . . . . . . . . . . . . .

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–1 5–1 5–6 5–6 5–7 5–7 5–7 5–8 5–8 5–8 5–8 5–8 5–8

4195KS Series 1-1. They 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.

Section 1 Introduction Scope of Manual This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for the 4195S Series gauge pressure indicating controllers.

Portions of this manual apply only to specific configurations in the 4195S Series product line. These configurations are indicated by letter suffixes in the type number that correspond to the mode and option designated in table 1-1. Refer to table 1-1 for the definition of each 4195S Series type number. The type number of the controller is on the nameplate. Refer to figure 1-1 for the nameplate.

Description The controllers described in this manual provide differential gap control with the options as shown in table

Use qualified personnel when installing, operating, and maintaining this controller. If there are any questions concerning these instructions, contact your Fisher Controls sales representative or sales office before proceeding.

Specifications Specifications for the 4195S Series controllers are listed in table 1-2.

Table 1-1. Available configurations for 4195S Series Controllers OPTIONS Internal Auto/Manual Station, Option E

TYPE NUMBER(1) 4195S 4195SE 4195SM 4195SME

Remote Set Point, Option M

X X

X X

1. Reverse-acting constructions are designated by an R suffix added to the type number.

NAMEPLATE

W5663-1 / IL

W6831 / IL

Figure 1–1. 4195 Series Gauge Pressure Controllers

1–1

4195S Series Table 1–2. Specifications

Available Configurations See table 1-1 Process(1) Sensor Range (Input Signal(1)) Lower and Upper Range Limits: As shown in tables 1–3 and 1–4 Maximum Allowable Pressure: As shown in tables 1–3 and 1–4 Process Scale Matched to the range of the process sensor as standard. Optional(2) scales are available.

Process Connections Standard: 1/4-inch NPT female stainless steel (all input ranges) Optional: 1/2-inch NPT female (see table 1–5) Output Signal(1) Differential Gap Range: 0 and 20 psig (0 and 1.4 bar) or 0 and 35 psig (0 and 2.4 bar) Action: Field-reversible between direct(increasing sensed pressure increases output pressure) or reverse(increasing sensed pressure decreases output pressure).

Supply and Output Connections 1/4-inch NPT female Supply Pressure Requirements See table 6.

Remote Set Point Pressures 3 to 15 psig or 6 to 30 psig (0.2 to 1.0 bar or 0.4 to 2.0 bar) 1.

2.

3.

4.

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

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

Scfh at 60 F, 14.7 psia (m3/hr at 0 C and 1.01325 bar absolute).

Also for transportation and storage limits.

1–2

Controller Adjustments Differential Gap Control1): 5 to 100% of process scale range Set Point: Adjustable from 0 to 100% of the scale range Steady-State Air Consumption(1,3) 0 and 20 Psig (0 and 1.4 Bar) Output: 3.5 scfh (0.1 m3/hr) 0 and 35 Psig (0 and 2.4 Bar) Output: 5.0 scfh (0.14 m3/hr) Delivery Capacity(3) 0 and 20 Psig (0 and 1.4 Bar) Output:: 210 scfh (5.6 m3/hr) 0 and 35 Psig (0 and 2.4 Bar) Output: 370 scfh (9.9 m3/hr) Exhaust Capacity(3)

3 to 15 Psig (0.2 to 1.0 Bar) Output: 170 scfh (4.6 m3/hr) 0 and 35 Psig (0 and 2.4 Bar) Output: 260 scfh (7.0 m3/hr) Operative Ambient Temperature Limits(4) –40 to 160 F (–40 to 70 C) Housing Controller is weatherproof per NEMA 3 (IEC 529 IP54) Mounting Controller can be mounted on actuator, panel, wall, or pipestand.

Approximate Weight 10 pounds (4.5 kg)

4195S Series Table 1-3. Process Sensor (Capsular Element) Pressure Ratings and Materials CAPSULAR STANDARD RANGES

English units

Metric units

SPAN(1) Min

OPERATING RANGE Max

Min

Max

OPERATING ( ) LIMIT(2)

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 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

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

–10 inch Hg –14 inch Hg –30 inch Hg –30 inch Hg –30 inch Hg –30 inch Hg 0 psig –30 inch Hg –10 inch Hg –14 inch Hg –30 inch Hg –30 inch Hg

5 psig 7 psig 15 psig 20 psig 20 psig 25 psig 30 psig 35 psig 5 psig 7 psig 15 psig 20 psig

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

–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 0.4 to 2 bar 0 to 2 bar –150 to 0 mbar –400 to 0 mbar –0.6 to 0 bar –1 to 0 bar

30 inch wc 2.5 psig 5 psig 7.5 psig 10 psig 15 psig 75 mbar 175 mbar 0.35 bar 0.4 bar 0.5 bar 0.7 bar 0.8 bar 1 bar 85 mbar 0.35 mbar 0.35 bar 0.5 bar

60 inch wc 5 psig 10 psig 15 psig 20 psig 30 psig 150 mbar 350 mbar 0.7 bar 0.8 bar 1 bar 1.4 bar 1.6 bar 2 bar 170 mbar 0.7 bar 0.7 bar 1 bar

–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 –340 mbar –1 bar –1 bar –1 bar

5 psig 7 psig 15 psig 20 psig 25 psig 35 psig 350 mbar 1 bar 1 bar 1.4 bar 1.4 bar 1.7 bar 2 bar 2.4 bar 350 mbar 1 bar 1 bar 1.4 bar

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 bar 3.5 bar 510 mbar 1.5 bar 1.5 bar 2 bar

–50 to 100 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 1 bar

75 mbar 0.35 bar 0.35 bar 0.5 bar 0.7 bar 1 bar

150 mbar 0.7 bar 0.7 bar 1 bar 1.4 bar 2 bar

–350 mbar –480 mbar –1 bar –1 bar –1 bar –1 bar

350 mbar 480 mbar 1 bar 1.4 bar 1.7 bar 2.4 bar

510 mbar 724 mbar 1.5 bar 2 bar 2.5 bar 3.5 bar

AVAILABLE MATERIAL

Ni-Span-C (standard) or Stainless steel (optional)

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 indication can be calibrated to a range of –14 in. Hb to –9 in. Hg (–480 mbar to –305 mbar), 0 to 2.5 psig (0 to 175 mbar), 2.5 to 5 psig (175 to 350 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.

1–3

4195S Series Table 1-4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials BOURDON TUBES TUBES Psig

English units

SPAN(1)

OPERATING RANGE(2)

Minimum

Maximum

Minimum

Maximum(3)

OPERATING ( ) LIMITS(4)

Psig

Psig

Psig

Psig

Inch Hg

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

15 30 50 100

30 60 100 200

–30 –30 –30 –30

42 84 140 280

48 96 160 320

0 to 300 0 to 600 0 to 1000 0 to 1500

150 300 500 1100

300 600 1000 1500

–30 0 0 0

420 840 1300 1950

480 960 1500 2250

2200 3700 6000 7500 11,000 18,000

3000 5000 8000 10,000 15,000 20,000

0 0 0 0 0 0

3900 6000 9600 12,000 18,000 24,000

4500 7000 11,200 14,000 21,000 28,000

2 4 4 7

–1 –1 –1 –1

3 6 6 10

3.3 6.6 6.6 11

0 to 3000 0 to 5000 0 to 8000 0 to 10,000 0 to 15,000 0 to 20,000

STANDARD MATERIAL

316 stainless steel

403 stainless steel

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

Metric units

1 2 2 3.5

0 to 10 0 to 16 0 to 25 0 to 40

7 10 20 20

14 20 40 40

–1 –1 0 0

20 30 60 60

22 33 66 66

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

35 76 160 260

70 100 200 350

0 0 0 0

90 135 270 420

103 155 310 482

0 to 550

420

550

0

670

772

0 to 600 0 to 1000 0 to 1400

520 720 1250

700 1000 1400

0 0 0

830 1250 1700

965 1448 1930

316 stainless steel

403 stainless steel

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 maximum values.

2. Travel stops should be used when the maximum or minimum process pressure will be 5% over or under the calibrated range. For example, a 0 to 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.

Table1-5. Optional Process Connections PSIG INPUT RANGE

BAR INPUT RANGE

Up to 0 to 5000

Up to 0 to 400

Table 1-6. Supply Pressure Data

CONNECTION Size 1/2-inch NPT male or 1/2-inch NPT female

Material Steel or stainless steel

0 to 5000 to 0 to 15,000

0 to 400 to 0 to 100

1/2-inch NPT female

Stainless steel

0 to 5000 to 0 to 20,000

0 to 400 to 0 to 1600

1/2-inch NPT male

Stainless steel

1–4

Output Signal Range Psig g Bar

0 & 20

Normal Operating Supply Pressure(1) 20

Maximum Pressure to Prevent Internal Damage(2) 50

0 & 35

35

50

0 & 1.4

1.4

3.4

0 & 2.4

2.4

3.4

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

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

4195S Series Section 2 Installation The controllers should be mounted with the housing vertical (as shown in figure 2-1) so the vent points down.

Piping Refer to figure 2-5. Supply, output, and vent connections are 1/4–inch NPT. Process pressure connections are 1/4 or 1/2–inch NPT (optional).

SPACER SPOOLS

Actuator Mounting Refer to figure 2-1. Controllers specified for mounting on a control valve actuator will be 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.

CAPSCREWS AND LOCKWASHERS

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.

Panel Mounting

MOUNTING BRACKET

Refer to figure 2-2. Cut a hole in the panel surface using the dimensions shown in Figure 2-2. 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 draw the case snugly and evenly to the panel surface.

W5661 / IL

Figure 2-1. Typical Actuator Mounting

Wall Mounting Refer to figure 2-3. Drill holes in the wall (using the dimensions in figure 2-3) to align with the four holes in the bracket (key 68). If the process 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.

Pipestand Mounting Refer to figure 2-4. 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.

36A9780-A A2757-4 / IL

INCH (mm)

Figure 2-2. Panel Mounting

2–1

4195S Series

36A9761-A A2759-4 / IL

INCH (mm)

Figure 2-3. Wall Mounting

46A9765-A A2998-1/IL

Figure 2-5. Location of 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. To avoid such injury or damage, provide suitable pressure-relieving or pressure-limiting devices if supply pressure or process pressure is capable of exceeding the maximum allowable pressures in tables 1-3 and 1-4.

Process Pressure Process pressure is piped to the connection marked A on the bottom of the case for Bourdon tube controllers and vacuum pressure capsular controllers, or to connection B for positive and compound pressure capsular element controllers. (See figure 2-5).

36A9758-A A2869-1/IL

Figure 2-4. Pipestand Mounting

2–2

When installing process piping, follow accepted practices to ensure accurate transmission of the process pressure to the controller. Install shutoff valves, vents, drains, or seal systems as needed in the process pressure line. If the instrument is located such that the adjacent process pressure line will be approximately horizontal, the line should slope downward to the in-

4195S Series strument for liquid-filled lines and upward toward the instrument for gas-filled lines. This will minimize the possibility of air becoming trapped in the sensor with liquid-filled line or of condensate becoming trapped with gas-filled line. The recommended slope is 1 inch per foot (80 millimeters per meter).

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. Install a needle valve in the process pressure line to dampen pulsations.

tion by installing a remote vent pipe to exhaust the vented gas to a properly ventilated area.

The vent (figure 2-5) 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.

CAUTION When installing a remote vent pipe, take care not to overtighten the pipe in the vent connection. Excessive torque will damage the threads in the connection.

Supply Pressure Vent WARNING If a flammable or hazardous gas is being used as the supply pressure medium and the controller is in an enclosed area, personal injury and property damage could result from fire or explosion of accumulated gas. To avoid such injury or damage, provide adequate ventila-

Supply pressure must be clean, dry air or noncorrosive gas. Use a suitable supply pressure regulator to reduce the supply pressure source to 20 psig (1.4 br) for an output signal range of 0 and 20 psig (0 and 1.4 bar) and to 35 psig (2.4 bar) for an output signal range of 0 and 35 psig (0 and 2.4 bar).

Remote Set Point Pressure (Option M) If the controller has the remote set point option, connect the remote set point pressure to the top of the controller case at the location shown in figure 2-5. Use a clean, dry air or noncorrosive gas.

2–3

4195S Series Section 3 Controller Operation Operating Information 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.

This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustments is 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.

Adjustments Manual Set Point The set point adjustment adjusts the upper or lower switching point, depending on controller action. To adjust the set point, open the controller cover, and move the set point adjustment until the pointer indicates the desired value of pressure on the process pressure scale. Move the adjustment to the right to increase the set point, and to the left to decrease it. Adjusting the set point does not affect the differential gap setting.

Changing Controller Action Controller action can be switched from direct to reverse or vice versa by loosening the screws on the proportional band indicator cover and moving the cover out so the proportional band knob can be rotated to the desired action. The white portion of the adjustment enables direct controller action; the black portion enables reverse controller action.

Auto/Manual Switching (Option E) Refer to figure 4-21 if the controller has the auto/ manual option. Two balance methods are available to equalize the manual output with the controller pressure. 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. The move the automatic/manual switch to MANUAL. Turn the loader knob clockwise to increase the controller output or counter clockwise 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. Turn the switch to AUTOMATIC, and adjust the set point manually or with the remote set point pressure to control the output.

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.

CAUTION Switching the controller between automatic and manual mode without balancing can bump the process.

Remote Set Point (Option M)

Prestartup Checks

CAUTION Do not move the set point manually on controllers with remote set point. Doing so could damage the controller.

If the controller is equipped with 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.

When performing the checks, open loop conditions must exist. Refer to figure 3-1 for location of adjustments.

Note If the controller has the auto/manual option (option E), be sure the controller is in the automatic mode prior to performing prestartup checks.

Proportional Band (Differential Gap)

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.

The proportional band knob adjusts width of the gap between switching points. Rotate the knob until the desired value is opposite the line on the proportional band indicator cover.

2. For controllers with remote set point (option 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.

3–1

4195S Series

C0528-1/IL

Figure 3-1. Location of Controller Parts and Adjustments See Errata Sheet

3. Loosen two screws (key 6), lift off the proportional band cover (key 36), and set the proportional band knob between DIRECT and REVERSE. 4. The process indicator should indicate the process pressure. For example, with the process pressure at 50 percent of the input span, the process pointer should be 50 percent (+/-1 percent) of its span. Slight adjustment of the indicator zero screw may be necessary. See figure 3-1 for zero adjustment and locking screw location.

5. If desired, the accuracy can be verified at other points on the scale. If the indicator appears to be out of calibration, refer to the process zero and span adjustment portion of the calibration procedure.

6. Install the proportional band cover and install two screws (key 6).

Calibration 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.

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.

Startup It is recommended that the controller switching points be set as described in the calibration procedures.

If they are used, slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve.

3–2

Note If the controller has the auto/manual option, be sure the controller is in the automatic mode prior to performing the calibration procedures.

4195S Series

C0528-1/IL

Figure 3-1. Location of Controller Parts and Adjustments (Continued)See Errata Sheet

Process Zero and Span Adjustment Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw.

1. Refer to figure 3-1 for location of adjustments.

2. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

3. Set the proportional band between DIRECT and REVERSE. 4. Adjust the process pressure to the low limit of the input range.

5. Adjust the process pointer to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw.

6. Adjust the process 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.

7. 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.

8. Repeat steps 4 through 6 until the error is eliminated.

9. Install the proportional band indicator cover (key 36), and tighten the two screws (key 6).

Remote Set Point Zero and Span Adjustment (Option M) Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw.

1. Refer to figures 3-1 and 3-2 for location of adjustments.

2. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

3. Set the proportional band between DIRECT and REVERSE. 4. Adjust the process pressure to the low limit of the input range.

5. Adjust the process pointer to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw.

6. Adjust the process 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.

3–3

4195S Series

GUIDE FLEXURE

MOUNTING SCREW LINK A

DRIVE FLEXURE ADJUSTMENT SCREW

PIVOT ASSEMBLY A LINK B

LOWER TRAVEL STOP UPPER TRAVEL STOP

LINEARITY ADJUSTMENT

TIE BAR

MOUNTING SCREW

PIVOT ASSEMBLY B CAPSULES

REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW 36A9751-C B1668-4 / IL

7. 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.

Changing the proportional band adjustment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point.

8. Repeat steps 4 through 7 until the error is eliminated.

Figure 3-3 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller. The following example illustrates how to use figure 3-3.

9. Install the proportional band indicator cover (key 36), and tighten the two screws (key 6).

Setting Switching Points Direct-Acting Controllers The controller output signal will switch from zero pressure to full supply pressure when increasing process pressure passes the upper switching point.

Example: The sensing element has a range of 30 psi.

The lower switching point is to be set at 10 psi and the upper switching point is to be set at 25 psi.

Proceed as follows: Divide the differential gap (the difference between the upper and lower switching points) by the sensing element range. Multiply the result by 100 as shown in the following equation.

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:

Sensing Element Range

Changing the set point adjustment will move both switching points equally in the direction of adjustment.

Locate the 50 percent line on figure 3-3. Move along this line until you intersect the curve. Read the

3–4

Differential Gap

x 100 =

15 psi

x 100 = 50%

30 psi

4195S Series Changing the set point adjustment will move both switching points equally in the direction of adjustment.

Changing the proportional band adjustment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point.

Figure 3-3 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller. The following example illustrates how to use figure 3-3.

A2853–1 / IL

Figure 3-3. Curve for Determining Proportional Band Setting

Example: The sensing element has a range of 30 psi.

The lower switching point is to be set at 10 psi and the upper switching point is to be set at 25 psi.

Proceed as follows:

proportional band setting on the left hand axis. For this example, the setting is approximately 35 percent.

1. Using the curve in figure 3-3, determine the correct proportional band setting for the desired gap (expressed as a percent of the input span) between the switching points.

Divide the differential gap (the difference between the upper and lower switching points) by the sensing element range. Multiply the result by 100 as shown in the following equation.

Differential Gap

x 100 =

15 psi

x 100 = 50%

2. Set the proportional band knob to the desired setting determined in step 1.

Sensing Element Range

3. Adjust the set point to the desired upper switching point.

Locate the 50 percent line on figure 3-3. 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.

4. Increase the process pressure until the controller output signal switches from zero pressure to full supply pressure.

5. Decrease the process 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 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.

Reverse-Acting Controllers The controller output signal will switch from zero pressure to full supply pressure when decreasing process pressure passes the lower switching point.

The controller output signal will not return to zero pressure until increasing process pressure passes the upper switching point. When making adjustments as described in the following steps, keep in mind that:

30 psi

1. Using the curve in figure 3-3, determine the correct proportional band setting for the desired gap (expressed as a percent of the maximum input element span) between the switching points.

2. Set the proportional band knob to the desired setting determined in step 1.

3. Adjust the set point to the desired lower switching point.

4. Decrease the process pressure until the controller output signal switches from zero pressure to full supply pressure.

5. Increase the process 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 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.

3–5

4195S Series SET POINT INDICATOR

POSITIVE FEEDBACK BELLOWS PROPORTIONAL BELLOWS (VENTED)

PROCESS POINTER REMOTE SET POINT CONNECTED HERE

REVERSE ACTION QUANDRANT

PROPORTIONAL BAND ADJUSTMENT FEEDBACK LINK

FEEDBACK MOTION

INPUT ELEMENT CONNECTED HERE

DIRECT ACTION QUADRANT

CONNECTING LINK

FLAPPER PIVOT INPUT MOTION

OUTPUT PRESSURE TO FINAL CONTROL ELEMENT FLAPPER

NOZZLE

SUPPLY PRESSURE

RELAY OUTPUT PRESSURE POSITIVE FEEDBACK PRESSURE

SUPPLY PRESSURE

NOZZLE PRESSURE B1546–2 / IL

Figure 3-4. Schematic of Operation for 4195S Series Controllers

Principle of Operation

adjustment moves both the upper and lower switching points.

Overall Operation

The proportional band knob positions the nozzle on the flapper. Increasing (widening) the proportional band moves the nozzle away from the input connection. When the proportional band adjustment moves the nozzle across the feedback connection, the controller action changes between direct and reverse. On a direct-acting controller, changing the proportional band adjustment will widen or narrow the differential gap between the two switching points. This is accomplished by moving the position of the lower switching point. On a reverse–acting controller, changing the proportional band adjustment will widen or narrow the differential gap between the two switching points by moving the position of the upper switching point.

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). This movement restricts the flow through the nozzle and increases nozzle pressure. When this occurs, relay action increases the output pressure (delivery) of the controller. Output pressure is fed back to the positive feedback bellows. The action of this bellows is a positive feedback action that moves the flapper closer to the nozzle, increasing nozzle pressure, which in turn, increases the relay output. Output pressure to the final control element switches to full supply pressure.

As the process pressure decreases, approaching the lower switching point, the flapper moves away from the nozzle (in a direct-acting controller) reducing nozzle pressure. Through relay action, pressure to the positive feedback bellows is reduced, moving the flapper further away from the nozzle, and further reducing nozzle pressure. Output pressure to the final control element switches to zero.

Remote Set Point (Option M)

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

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

3–6

The capability to adjust the controller set point from a remote location is available with all 4195 Series controllers. This option is designated by the letter M in the type number.

Auto/Manual Option

4195S Series MANUAL LOADER AUTOMATIC POSITION AUTO/MANUAL SWITCH

MANUAL LOADER KNOB

PLASTIC TUBE OUTPUT PRESSURE TO FINAL CONTROL ELEMENT

METAL BALL

MANUAL POSITION

RELAY

AUTO/MANUAL SWITCH

SUPPLY PRESSURE

OUTPUT PRESSURE TO FINAL CONTROL ELEMENT

RELAY OUTPUT PRESSURE SUPPLY PRESSURE MANUAL LOADER OUTPUT PRESSURE 48A5230-A A2999-1 / IL

Figure 3-5. Schematic of Auto/Manual Option

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 output of the controller. When the auto/manual switch is in the AUTO position, the relay output is channeled through

the switch to become the output of the controller.

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. Pressure imbalance forces the ball to one end of the tube where it forms a seal, blocking air flow through the tube.

3–7

4195S Series

3–8

4195S Series Changing Controller Action

Section 4 Maintenance 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.

Select the appropriate maintenance procedure, and perform the numbered steps. Each procedure requires that supply pressure and process pressure be shut off before beginning maintenance.

The replacing controller parts portion of this section describes part replacement common to both the Bourdon tube controllers and the capsular element controllers. Other portions of this section describe part replacement, link replacement, and maintenance calibration specifically for a Bourdon tube controller, capsular element controller, and the remote set point option. When maintenance procedures, including maintenance calibration and flapper alignment have been completed, refer to the appropriate prestartup procedure.

Note Unless otherwise noted, key numbers refer to figure 4-17. Figures 3-1 and 3-2 show the location of adjustments and major components. For maintenance on the indictor assembly, refer to figure 4-23.

The following steps describe changing controller action from direct (increasing process pressure produces increasing output pressure) to reverse (increasing process pressure produces decreasing output pressure or vice versa.

1. Loosen two screws (key 6) in the proportional band indicator cover (key 36). The screws need not be removed.

2. Lift the proportional band indicator cover as shown in figure 4-2.

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).

Replacing Common Controller Parts Process Pressure Scale

CAUTION Take care not to bend the process indicator or the set point adjustment while performing the following procedure.

1. Refer to figure 4-3. Adjust the set point adjustment manually or with the remote set point pressure to 50 percent of scale.

2. Remove four screws (key 37).

WARNING The following maintenance procedures require taking the controller out of service. To avoid personal injury and property damage caused by uncontrolled process pressure, provide some temporary means of control for the process before taking the controller out of service.

Troubleshooting As an aid to troubleshooting, table 4-1 lists some common operating faults, their probable cause, and suggests procedures for correcting the fault.

3. Slide the process scale (key 61) so that the top of the slot touches the set point adjustment. Deflect the lower portion of the slot, and carefully slide the scale upward and off, clearing the set point indicator as shown in figure 4-3.

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. This procedure is described in the zero and span adjustment portion of the calibration procedures.

4–1

4195S Series 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 Common Controller Parts Procedures describe replacement of parts that are common to both the Bourdon tube controller and the capsular element controller. Where specified in the text, perform flapper alignment procedures.

Bourdon Tube Controllers

Capsular Element Controllers

Procedures describe replacement of parts in Bourdon tube controllers. The procedures may be performed separately, but must be followed by maintenance calibration for this section and, where specified, by flapper alignment procedures.

Procedures describe replacement of parts in capsular element controllers. The procedures may be performed separately, but must be followed by maintenance calibration for this section and, where specified, by flapper alignment procedures.

Flapper Alignment Procedures align the flapper for both direct and reverse controller action.

Remote Set Point (Option M) Procedures describe replacement of parts in the remote set point assembly. The procedures may be performed separately, but must be followed by maintenance calibration.

Auto/Manual (Option E) Procedures describe disassembly and assembly of the auto/manual station.

Controller Operation A description of prestartup, startup, and calibration procedures to return the controller to service.

Figure 4-1. Maintenance Guide

4–2

4195S Series Table 4-1. Troubleshooting Chart Fault 1. Output does not snap when process pointer and set point i di indicator are aligned. li d

Possible Cause 1.1 Flapper out of alignment 1.2 Process pointer not calibrated correctly

1.1 Align flapper as necessary 1.2 Adjust as necessary 1.3 Provide correct supply pressure

1.4 Leak in nozzle or feedback tubing

1.4 Using a soap solution, check for leaks

1.4 Repair or replace defective parts

1.5 Leak in relay O–rings

1.5 Using a soap solution, check for leaks

1.5 Repair or replace defective O-rings

2.1 Output pressure gauge not functioning

2.1 Check output with external gauge

2.1 Replace gauge if necessary

2.2 Supply pressure incorrect 2.3 Leak in positive feedback tubing

2.3 Using soap solution, check for leaks

2.2 Repair or replace pressure regulator if necessary 2.3 Replace defective parts as necessary

2.4 Leak in nozzle tubing assembly

2.4 Using soap solution, check for leaks

2.4 Replace defective parts as necessary

2.5 Inspect element or linkage for damaged parts

2.5 Repair or replace damaged parts

2.6 Manually cap the nozzle output by pushing the flapper toward the nozzle. Output should go to supply pressure.

2.7 Refer to the flapper alignment or to the setting switching points procedure ---

2.6 If output does not change as described, remove relay. Replace O-rings if necessary. Replace relay if necessary.

2.7 Make alignments and adjustments as necessary 2.8 Refer to the maintenance procedures for link adjustment 3.1 Align flapper as necessary 3.2 Adjust switching as necessary 3.3 Replace faulty parts 3.4 Replace links as necessary 3.5 Replace the relay. If the output still does not go to zero, replace the nozzle pivot assembly

2.5 Sensing element or linkage failure 2.6 Relay malfunction 2.7 Switching point has not been reached 2.8 Link 4 not adjusted correctly

3. Controller output will not snap to zero pressure

Correction

1.3 Check supply pressure

1.3 No supply pressure

2. Controller output will not snap to full output pressure

Check 1.1 Refer to flapper alignment procedures 1.2 Refer to the process zero and span adjustment procedures

3.1 Flapper out of alignment 3.2 Switching point has not been reached 3.3 Sensing element or linkage failure 3.4 links 2, 3, and 4 defective 3.5 Relay malfunction or clogged nozzle

Relay 1. Loosen the two captive screws that hold the relay (key 50) in place.

2. Tip the relay slightly toward the case to clear the output pressure gauge and lift out the relay.

3. Make sure the replacement relay has three O-ring assemblies as shown in figure 4-4. The fourth port is for exhaust and does not require an O-ring.

2.2 Check with an external source

3.1 Refer to the flapper alignment procedure 3.2 Refer to the setting switching points procedure 3.3 Inspect sensing element and linkage for damaged parts. Using soap solution, check for leaks 3.4 Inspect links for loose screws and improper connections. Ensure links are not rubbing or catching on other parts.

3.5 Manually push the flapper away from the nozzle. The output should go to zero.

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.

4. Install the replacement relay, making sure the tabs on the relay (see figure 4-4), aligns with the tab on the frame.

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.

5. Tighten the two screws that hold the relay in place.

2. Remove the controller from its mounting (see installation section) to a maintenance area.

4–3

4195S Series CLEAN-OUT WIRE

EXHAUST PORT (NO O-RING USED)

O-RINGS

RELAY TAB W3439 / IL

Figure 4-2 Changing Controller Action

RELAY MOUNTING SCREWS

W3441*

Figure 4-4. Relay Construction See Errata Sheet

5. Slide the controller frame down to assure an O-ring seal at the pressure connections. Hold the frame in place.

6. Install and tighten the nine mounting screws.

7. Remove the blow-out plug (key 72) from the original case, and install in the replacement case.

8. Mount the controller as described in the Installation section.

9. Connect the supply, output, and process pressure piping to the controller.

W3440 / IL

Gauges

CAUTION Before performing this procedure, be sure the replacement gauges are the correct range so that they are not damaged by overpressure.

1. Unscrew the output pressure gauge (key 46) or the supply pressure gauge (key 47) from the frame (key 3).

W3492 / IL

Figure 4-3. Changing the Scale

2. Before installing the replacement gauge, coat the threads on the gauge with a suitable sealant.

3. Screw the replacement gauge into the frame.

Pressure Control Block 3. Remove the nine screws (key 38) from the case and cover assembly (key 1) and lift out the controller assembly.

4. Install the controller assembly in the replacement case.

4–4

1. Carefully remove the process pressure piping from the controller after bleeding away process pressure.

2. Loosen the nut on that portion of the tubing that connects the pressure sensing element to the pressure control block (key 57).

4195S Series 3. Remove the two cap screws (key 58) that hold the pressure control block to the frame (key 3), and lift out the pressure control block.

4. Install the O-ring (key 7) on the replacement pressure control block.

5. Install the replacement pressure control block to the frame with two screws (key 58).

6. Tighten the net that was loosened in step 2.

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 pivot assembly (key 17) to the frame, and remove the pivot assembly. Refer to figure 4-16.

5. Disconnect the nut that holds the relay nozzle tubing (key 18) into to the frame (key 3) (Refer to figure 4-17).

7. Apply the process pressure equal to the maximum value on the process scale, and check for leaks.

6. While holding the proportional band knob, remove the screw and washer (keys 19 and 20) that hold the relay nozzle tubing assembly (key 18) to the frame.

8. Connect the process pressure piping to the controller.

7. Remove the proportional band knob nozzle pivot and the set point beam assembly from controller.

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).

2. Install the replacement tubing assemblies.

3. Apply the correct supply pressure, and check for leaks.

4. Install the frame in the case.

5. Install and tighten the nine self-tapping screws (key 38) into the frame.

6. Mount the controller as described in the installation procedure.

7. Connect supply, output, and process pressure piping to controller.

Proportional Band Knob, Nozzle Pivot, and Set Point Beam Assembly 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 two screws (key 6) and lift off the proportional band indicator cover (key 36) (figure 4-2).

2. Disconnect link number 3 from the set point beam assembly (key 23). Refer to figure 4-13 for location of the link.

8. Remove the relay nozzle tubing assembly (key 18) from the set point beam assembly (key 23).

9. Remove the E-ring (key 27) from the nozzle assembly (key 21).

10. Remove the nozzle assembly (key 21) from the bottom of the set point beam assembly (key 23).

11. Remove the retaining clip (key 26).

12. Remove the proportional band knob (key 25) from the set point beam assembly (key 23).

13. Inspect the nozzle pivot O-ring (key 24).

14. Inspect the nozzle assembly (key 21), and replace if necessary. Inspect the nozzle orifice, and clean it if necessary.

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. While holding the nozzle tubing (key 21) against the set point beam assembly (key 23), depress the retaining clip (key 26), and install the E-ring (key 27) into the E-ring groove on the nozzle tubing assembly (key 18).

19. Inspect the O-ring on the relay nozzle tubing assembly (key 18) and, replace it if necessary. Apply a suitable lubricant 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 4-6.

22. Position the proportional band knob, nozzle pivot, and the set point beam assembly on the frame. Install

4–5

4195S Series TAB

CAP (WITH O-RING INSIDE)

E-RING

NOZZLE TUBING ASSEMBLY

RETAINING CLIP

O-RING PROPORTIONAL BAND ADJUSTMENT

SET POINT BEAM ASSEMBLY

SET POINT PIVOT ASSEMBLY

W3452-1*/IL

SET POINT BEAM SHOE

NOZZLE

FLAPPER

RETAINING CLIP E-RING

POSITIVE FEEDBACK TUBING ASSEMBLY

CAP

PROPORTIONAL BAND ADJUSTMENT KNOB

SET POINT BIAS SPRING SHOE ADJUSTMENT SCREWS SET POINT BEAM ASSEMBLY SET POINT BEAM SHOE W3852*/IL

LINK 3

RELAY NOZZLE TUBING ASSEMBLY

Figure 4-5. Proportional Band Adjustment and Set Point Beam Details

the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 4–7.

23. Insert the screw and washer (keys 19 and 20) into the relay nozzle tubing assembly (key 18). Refer to figure 4-18.

24. Install the screw (key 19) through the frame (key3) and into the relay nozzle tubing assembly (key 18).

4–6

Tighten the screw and make sure the nozzle remains centered on the flapper with the set point beam assembly snugly against the relay nozzle tubing assembly.

25. Insert the pivot of the set point pivot assembly (key 17) in the hole in the set point beam assembly (key 23).

26. Install the washer (key 20) on the screw (key 19).

4195S Series TAB

HOLE

FLAPPER

W3761 / IL

Figure 4-6. Proportional Band Adjustment Knob Setting

27. Install the screw and washer (keys 19 and 20) through the frame (key 3) into the set point pivot assembly (key 23). Do not tighten.

28. First, slide the beam assembly snugly toward the relay tubing assembly; then, slide the set point pivot assembly (key 17) toward the set point beam until the cone lightly contacts the set point beam, and tighten the screw. The proportional band knob should fall freely when the controller is in the upright position. If it does not, reposition the set point pivot assembly (key 17) until the proportional band knob falls freely.

29. Tighten the nut on the relay nozzle tubing assembly (key 18), apply supply full pressure, and check for leaks. Disconnect supply pressure.

30. Install the set point beam bias spring (key 28) into the frame bore and onto the spring seat on the set point beam assembly (see figure 4-5).

31. Attach link number 3 to the set point assembly (key 23). See figure 4-5.

32. If the position of the set point beam shoe (key 29), shown in figure 4-5 was changed relative to the position of the set point beam assembly (key 23) during this procedure, go to step 33. If the position of the set point beam shoe was not changed, go to step 53.

33. Connect supply pressure and regulated process pressure to the controller. Also, provide a means of measuring controller output pressure.

NOZZLE

W3449 / IL

Figure 4-7. Nozzle-Flapper Positioning

34. Perform the flapper alignment procedures. Then, proceed as directed by the following note.

Note For direct-acting controllers, go to step 35. For reverse-acting controllers, go to step 44.

35. For direct acting controllers, adjust the proportional band knob to 5 percent direct acting. Adjust the set point adjustment or 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). Personal injury or equipment damage may result from overpressure.

36. Slowly increase the process 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.

37. If the output pressure snaps to supply pressure below 2 percent of set point, adjust flapper leveling screw number 3 clockwise (see figure 3-1 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.

4–7

4195S Series 38. Repeat steps 36 and 37 until the output pressure snaps within 2 percent. If the tolerance cannot be obtained with the flapper leveling screw, go to step 41.

39. Adjust the set point adjustment or remote set point pressure to 95 percent of the process scale range.

40. If the output pressure is not 0 psig, decrease the process pressure until the output pressure snaps to zero.

Then slowly increase the process pressure until the output snaps to supply pressure. The output should snap to supply pressure within 2 percent of set point.

41. If the output pressure snaps to supply pressure within 2 percent of set point, go to step 53. If the output pressure does not snap to supply pressure within 2 percent of set point, go to step 42.

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.

WARNING In step 49, do not exceed the operating limits of the controller (refer to table 1-3). Personal injury or equipment damage may result from overpressure.

49. Increase the process pressure until the output pressure snaps to zero. Then, slowly decrease the process pressure until the output pressure snaps to supply pressure. The output should snap to supply pressure within 2 percent of set point.

50. If the output pressure snaps to supply pressure within 2 percent of set point, go to step 53. If the output pressure does not snap to supply pressure within 2 percent, go to step 51.

51. 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 pressure snaps to supply pressure above 2 percent of set point adjust the set point beam shoe slightly away from the center of the nozzle pivot.

52. Repeat steps 44 through 51 until the output pressure snaps to supply pressure within 2 percent of set point at 5 and 95 percent of the process scale range; then go to step 53.

43. Repeat steps 35 through 42 until the output pressure snaps to supply pressure within 2 percent of set point at 5 and 95 percent on the process scale range; then go to step 53.

53. 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.

44. For reverse acting controllers, adjust the proportional band knob to 5 percent reverse action. Adjust the set point adjustment or remote set point pressure to 5 percent of the process scale range.

55. Refer to the flapper alignment procedures.

45. Carefully adjust the process pressure to 100 percent of the process scale range. Then, slowly decrease the process pressure until the output pressure snaps to supply pressure. The output should snap to supply pressure within 2 percent of set point.

46. If the output pressure snaps to supply pressure below 2 percent of set point, adjust flapper leveling screw number 1 counterclockwise (see figure 3-1 for location of screw). If the output pressure snaps to supply pressure above 2 percent of set point, adjust flapper leveling screw number 1 clockwise.

47. Repeat steps 44 through 46 until the output pressure snaps to supply pressure within 2 percent of set point. If the tolerance cannot be obtained with the flapper leveling screw, go to step 51.

48. Adjust the set point adjustment or remote set point pressure to 95 percent to the process scale range.

4–8

54. Install and tighten the nine mounting screws that hold the controller assembly in place.

Flapper Flexure Pivot Assembly 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 two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Disconnect link number 3 from the set point beam assembly (key 23). Refer to figure 4-13 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. Remove the set point pivot assembly (key 17).

4195S Series FLAPPER LEVELING SCREW NUMBER 2

INPUT FEEDBACK BEAM ASSEMBLY (KEY 11)

FOUR SCREWS (KEY 10)

FLEXURE PIVOT ASSEMBLY

INPUT FEEDBACK BEAM ASSEMBLY

FLEXURE PIVOT ASSEMBLY SCREW W3450*/IL

Figure 4-8. Leveling Screw Alignment

W3450*/IL

Figure 4-9. Exploded View of Flexure Pivot Assembly

6. Disconnect the nut that secures the relay nozzle tubing (key 18) into the frame (key 3).

7. While holding the proportional band knob, remove the screw and washer (keys 19 and 20) that hold the relay nozzle tubing assembly (key 18) to the frame.

8. Remove the proportional band knob nozzle pivot and set point beam assembly from controller.

9. Disconnect link number 2 from the input feedback beam assembly (key 11) shown in figure 4-8. Refer to figure 4-13 for location of the link.

10. Disconnect link number 4 from the bellows bracket (key 31). Refer to figure 4-13 for location of the link.

11. Remove the screw (key 12) with washer (key 13) from the flexure pivot assembly (key 9). See figure 4-8 for screw location.

12. Remove the input feedback assembly as shown in figure 4-9.

13. Remove the four screws (key 10),shown in figure 4-10 that hold the flexure pivot assembly to the frame.

14. Remove the flexure pivot assembly (key 9).

15. Install the replacement flexure pivot assembly with the four screws (key 10). Do not tighten the screws.

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. Install the screw (key 12) with the washer (key 13) through the input feedback beam assembly (key 11) into the flexure pivot assembly (key 9). Do not tighten the screw.

19. Align flapper leveling screw number 2 (see figure 3-1 for screw location) with the centerline of the oblong hole in the frame as shown in figure 4-8. Tighten the screw (key 12). Make sure link 4 does not touch the frame.

20. Disconnect link number 1 from the pivot assembly,and manually position the process pointer to 100 percent of the scale. Refer to figure 4-13 for location of link.

21. Adjust the length of link number 2 by turning the adjustment screw clockwise to increase the length or counterclockwise to decrease the length, so that the pin on the end of the link is approximately one-half of its diameter short of aligning with the hole in the input feedback beam assembly, as shown in figure 4-10.

22. Connect link number 2 to the flapper assembly.

23. Connect link number 1 to the pivot assembly.

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 4-6.

25. Position the proportional band knob nozzle pivot and set point beam assembly on the frame, and install the relay nozzle tubing fitting loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 4-7.

26. insert the washer (key 20) on the screw (key 19).

27. Install the screw (key 19) through the frame (key 3) and into the relay nozzle tubing assembly (key 18).

Tighten the screw. Ensure the nozzle remains centered on the flapper with the set point beam assembly slid snugly towards the relay nozzle tubing assembly.

28. Insert the pivot of the set point pivot assembly (key 17) in the hole in the set point beam.

4–9

4195S Series

W3476/IL

W3451/IL

Figure 4-10. Link 2 Adjustment

29. Install washer (key 20) on screw (key 19).

30. Install the screw (key 19) through the frame (key 3) into the set point pivot assembly (key 23). Do not tighten.

31. Slide the set point pivot assembly (key 17) toward the set point beam until the cone lightly contacts the set point beam, and tighten the screws. The proportional band now should fall freely when the controller is in the upright position. If it does not, reposition the set point pivot assembly (key 17).

32. Tighten the relay nozzle tubing nut (key 18). Apply supply pressure and check for leaks. Disconnect the supply pressure.

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. Apply proper supply pressure to the controller, and check for leaks.

36. Apply process pressure equal to the lower range value.

40. If the position of the set point beam shoe (key 29) relative to the set point beam assembly (key 23) was changed during this procedure, perform steps 32 through 52 in the replacing proportional band knob, nozzle pivot, and set point beam assembly procedure.

Otherwise, perform step 40.

41. 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.

42. Tighten the nine screws that hold the controller assembly in the case.

43. Refer to the flapper alignment procedure.

44. Replace the proportional band cover (key 36), and replace the two screws (key 6).

Positive Feedback Bellows 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. Both bellows need not be removed if only one requires replacement.

37. Adjust the proportional band to 5 percent direct action, and adjust set point to the maximum value on the process scale. Controller output pressure should be 0 psig.

1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

38. With zero pressure in both feedback bellows, loosen the two adjusting screws on link number 4, and connect the link to the bellows bracket assembly, allowing the link to find its free length.

3. Remove the screw (key 34), spring (key 33) and bellows adjustment bracket (key 32) from the bellows bracket (key 31).

39. Tighten two adjusting screws.

4–10

2. Disconnect link 4 (key 65) from the bellows bracket (key 31).

4. Refer to figure 4-11 for locations. Remove two screws (key 35) from the bellows assembly.

4195S Series RESET BELLOWS TWO SCREWS (KEY 35) PROPORTIONAL BELLOWS

BELLOWS BRACKET

LINK 4

FOUR SCREWS (KEY 6) W3448*/IL

Figure 4-11. Cutaway View of Bellows Assembly

5. Remove the four screws (key 6) from the bellows beam (key 49), and remove the bellows bracket.

12. Apply the correct supply pressure, and check for leaks. Remove the supply pressure.

6. Remove the positive feedback tubing assembly (key 45) from the positive feedback bellows.

If the length of link 4 (key 65) was not changed, proceed with step 13.

CAUTION When removing and replacing positive feedback bellows, keep in mind that the bellows has left-hand threads. Overtightening could damage the threads.

7. Unscrew the bellows.

8. Before installing the replacement bellows, coat the threads with a suitable lubricant. Screw in the replacement bellows until it is finger tight against the frame (key 3).

9. Install the four screws (key 6) through the bellows bracket (key 31) into the bellows beam.

10. Install the two screws (key 35) through the bellows bracket (key 31) into the bellows. Install the bellows adjustment bracket (key 32), spring (key 33) and tighten the screw (key 34) until the spring is compressed completely. Make sure the bellows bracket does not rub against the frame. Tighten the two screws (key 35).

11. Replace the positive feedback tubing assembly on the bellows base.

13. If the length of link 4 (key 65) was changed during this procedure, refer to the replacement procedures for the flapper flexure assembly. Perform steps 36 through 38 of the procedures 14. Replace link 4 (key 65) on the bellows bracket. make sure the link does not touch frame. If it does, repeat steps 8 through 12.

15. Refer to the flapper alignment procedures.

16. Remove the supply pressure, the output measurement device, and the regulated process pressure source.

17. Replace the proportional band indication cover (key 36), and tighten the two screws (key 6).

18. To install the frame (key 3) into the case, refer to the replacing case and cover procedure.

Bourdon Tube Controllers 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

4–11

4195S Series to 400 (direct or reverse action) before replacing the proportional band indicator cover.

Replacing Parts Bourdon Tube Note After part replacement, perform the maintenance calibration procedures.

1. Disconnect link 1 from the tip of the Bourdon tube (see figure 4-13).

2. Remove the tubing nut from the pressure control block (key 57).

3. Remove the two self-tapping screws from the base of the Bourdon tube.

W3447/IL

Figure 4-12. Link-Bourdon Tube Alignment See Errata Sheet

4. Lift out the Bourdon tube.

5. Install the replacement Bourdon tube, and replace the two self-tapping screws, but do not tighten these screws.

6. Tighten the nut that was loosened in step 2.

7. Manually position the process indictor at the 50 percent position on the scale. Hold link 1 perpendicular to the process indicator.

8. Move the Bourdon tube until the hole in the tip of the Bourdon tube aligns with the centerline of the link as shown in figure 4-12.

9. Tighten the two screws to secure the Bourdon tube.

10. Apply process pressure to the controller equal to the upper range limit of the bourdon tube, and check for leaks. Remove process pressure.

11. Connect link 1 to Bourdon tube tip.

12. Remove the two screws (key 6) and lift off the proportional ban indicator cover (key 36).

13. Move the set point adjustment to 100 percent of scale. Set the proportional band between DIRECT and REVERSE. 14. The process indicator should be in line with the indicator subassembly. If not, use the five zero adjustment to achieve alignment, as shown in figure 4-14.

15. Apply 50 percent of the process scale reading to the controller. The process indicator should read 50 percent 1 percent on the process scale. If not, loosen the two screws in link 1 (see figure 4-13), and move the indicator to 50 percent. Tighten the two screws.

16. Adjust the proportional band to 400 percent in the desired control action.

4–12

17. Install the proportional band indicator (key 36), and tighten the two screws (key 6).

18. Refer to the process zero and span adjustment procedures.

19. Refer to the maintenance calibration procedure and to the flapper alignment procedure.

Links This section describes the separate replacement of four links in the controller. Figure 4-13 shows the location of each link. To clarify the location of each link, the links are numbered as follows: link number 1 connects the Bourdon tube and the process pointer; link number 2 connects the process pointer and the input feedback beam assembly (key 11); link number 3 connects the set point adjustment and the set point beam assembly (key 23); link number 4 (key 65) connects the input feedback assembly and the bellows bracket (key 31).

Link Number 1 1. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

2. Disconnect the link from the Bourdon tube (see figure 4-13) and from the process pointer assembly. remove the link. Adjust the length of the replacement link to the same length as the link being replaced.

3. Attach the replacement link to the process pointer assembly and Bourdon tube or pivot arm.

4. Move set point adjustment manually or with remote set point pressure to 100 percent of the process scale range, and set the proportional band between DIRECT and REVERSE. 5. The process pointer should be lined up with the pointer subassembly (as shown in figure 4-14). If not,

4195S Series COARSE ZERO ADJUSTMENT LINK 1

LINK 4 ADJUSTMENT LINK 4

W3454/IL

DISCONNECTING LINK 1 FROM BOURDON TUBE

LINK 2

LINK 3 ADJUSTMENT

LINK 2 ADJUSTMENT W3442-1*/IL

LINK 3

BOURDON TUBE CONTROLLERS

LINK 5

LINK 1

LINEARITY ADJUSTMENT SCREW W3753-1*/IL

LINK 4

LINK 2

LINK 4 ADJUSTMENT

LINK 3 ADJUSTMENT

LINK 2 ADJUSTMENT

LINK 3

CAPSULAR ELEMENT CONTROLLERS

Figure 4-13. Link Location See Errata Sheet

adjust the fine zero adjustment to align the process pointer and pointer subassembly.

7. Refer to the maintenance calibration and flapper alignment procedures.

6. With a regulated air supply, adjust process pressure to 50 percent of process scale range. The process pointer should be at the 50 percent 1 percent position on the scale. If not, loosen the screw (coarse zero adjustment shown in figure 4-13) in the link, move the pointer to 50 percent of process scale, and tighten the screw.

Link Number 2 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Disconnect the link from process pointer assembly and from the input feedback beam assembly (key 11).

Remove the link.

4–13

4195S Series

ALIGNED

ZERO ADJUSTMENT LOCKING SCREW

W3443-1 / IL

MISALIGNED

FINE ZERO ADJUSTMENT

W3475-1 / IL

Figure 4-14. Process Pointer Alignment

3. Install the replacement link with the screw head nearest the process pointer as shown in figure 4-13.

Connect the link to the process pointer assembly only.

4. Move set point adjustment manually or with remote set point pressure to 100 percent of the process scale range. Set the proportional band between DIRECT and REVERSE. 5. Disconnect link number 1 from the Bourdon tube and manually position the process pointer to 100 percent on the scale.

6. Adjust the length of link number 2 (by turning the adjusting screw clockwise to increase length, counterclockwise to decrease length) so that the pin on the end of the link is approximately one-half of its diameter short of aligning with the hole in the input feedback beam assembly as shown in figure 4-10. The adjustment provides the proper tension on the link.

7. Connect the link to the input feedback beam assembly.

2. Disconnect link number 3 from set point indicator and the set point beam assembly (key 23).

3. Install the replacement link with the screw head toward set point beam assembly as shown in figure 4-13.

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 4-5.

5. Adjust the proportional band between DIRECT and REVERSE. 6. Adjust the set point adjustment manually or with remote set point pressure to 50 percent of scale. Adjust the screw on the link so that the edge of the proportional band knob is parallel to the case or the set point adjustment as shown in figure 4-15.

7. Refer to the maintenance calibration procedure and to the flapper alignment procedure

Link Number 4

8. Connect link number 1 to the Bourdon tube or pivot arm.

1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

9. Refer to the maintenance calibration and flapper alignment procedures.

2. Disconnect the link from the bellows bracket assembly (key 31) and the input feedback assembly (key 11).

Link Number 3 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

4–14

3. Connect the replacement link to the flapper assembly so that the two adjusting screws on the link are nearest to the feedback bellows bracket and so that

4195S Series 6. Tighten the two adjusting screws on the link.

7. Refer to the maintenance calibration and the flapper alignment procedures.

Maintenance Calibration Note Perform full maintenance calibration (includes all procedures) upon completion of maintenance procedures. Key numbers are referenced in figure 4-17. Adjustments are shown in figure 3-1. After maintenance calibration, perform the flapper alignment procedures if directed to do so. Otherwise, go to the appropriate prestartup instructions.

LINK 3 W3445–1*/IL

Figure 4-15. Link Number 3 Adjustment SCREW HEADS

SET POINT PIVOT ASSEMBLY

Calibration Procedures–100 Percent of Bourdon Tube Range Adjustments are shown in figure 3-1. Provide a means of applying process pressure to the controller.

Note Any adjustment of the indicator span adjustment screw will require readjustment of the indicator 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. Adjust the set point to 50 percent of the process scale.

W3446*/IL

SCREW AND WASHER (KEYS 19 AND 20) 2

SCREW AND WASHER (KEYS 19 AND 20) 1

NOTES: 1 SCREW INSERTED INTO THE SET POINT PIVOT ASSEMBLY. 2 SCREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY.

Figure 4-16.Position of Link Number 4 Adjusting Screws

the screw heads are facing the bottom of the controller as shown in figure 4-16.

4. Adjust the process pressure to 0 percent of the process scale range.

5. Adjust the proportional band to 5 percent direct acting, and move the set point adjustment manually or with remote set point pressure to 100 percent of scale range. Controller output pressure should be 0 psig.

With zero pressure in the feedback bellows, loosen the two adjusting screws on the link. Connect the free end of the link to the bellows bracket assembly, and allow the link to find its free length.

3. Adjust the process pressure to the low limit of the input range.

4. Adjust the process indicator to the lowest limit of the process scale by turning the zero adjustment screw.

5. Adjust the process pressure to the upper limit of the input span. Note whether the pointer 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 of the error.

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

8. Verify indicator accurate at 50 percent of the scale.

Indicator should be within 1 percent of the input range.

If desired, accuracy can be verified at other points on the scale.

9. Refer to the flapper alignment procedure.

4–15

4195S Series Calibration Procedures–Less Than 100 Percent of Bourdon Tube Range

1. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

Adjustments are shown in figure 3-1. Provide a means of applying process pressure to the controller.

2. Set the proportional band between DIRECT and REVERSE.

1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Set the proportional band to 5 percent direct acting, adjust set point to 50 percent of the process scale.

3. Disconnect link 1 from the Bourdon tube as shown in figure 4-13.

4. Adjust process pressure to the midrange of the process scale.

5. Align the process indicator with the pointer subassembly as shown in figure 4-14.

6. Loosen the screws in link 1 (see figure 4-13).

7. Connect link 1 to the Bourdon tube.

8. Manually position the process indicator to the midrange of the scale.

9. Tighten the two screws in link 1.

Note Any adjustment of the indicator span adjustment screw will require readjustment of the indicator zero adjustment screw.

3. Apply process pressure to the controller equal to 105 percent of the process pressure range.

4. Install the upper travel stop (key 74) with the screw (key 75). Do not tighten the screw.

5. Slide the upper travel stop until it touches the Bourdon tube.

6. Tighten the screw.

7. Decrease process pressure to 100 percent of the process pressure range.

8. The Bourdon tube should not touch the upper travel stop. If it does, repeat steps 2 through 6.

9. If the process pressure will never be less than the lower limit of the process scale, proceed with steps 10 through 12. If the process pressure may be less than the lower limit of the process scale, perform steps 13 through 17.

10. Adjust the process pressure to the lower limit of the process scale.

11. Install the lower travel stop (key 73) with screw (key 76). Do not tighten the screw.

12. Adjust the lower travel stop so it does not interfere with the bourdon tube travel at the lower range limit.

Tighten the screw.

10. Adjust process pressure to upper range limit. Note whether the indicator is above or below the upper limit of the process scale.

13. Subtract 5 percent of the process range form the lower limit of the process range. Adjust the process pressure to this value.

11. Adjust the span screw as follows: clockwise to increase span for a low indication; counterclockwise to decrease span for a high indication.

14. Slide the lower travel stop until it touches the Bourdon tube.

12. Adjust the process pressure to the lower range limit.

16. Increase the process pressure to the lower limit of the process range.

13. Adjust the process indicator to the lower limit of the process scale.

17. The Bourdon tube should not touch the lower travel stop. If it does, repeat steps 13 through 16.

14. Repeat steps 10 through13 until error is eliminated.

18. Install the proportional band indicator (key 36), and tighten the two screws (key 6).

15. Refer to the flapper alignment procedure for correct flapper alignment.

Capsular Element Controllers

Travel Stop Installation and Adjustment

Note The process indicator should be calibrated prior to installing or adjusting travel stops. Refer to the process zero and span adjustment procedures.

4–16

15. Tighten the screw.

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.

4195S Series Replacing Parts

3. Set the linearity adjustment screw to approximately the same location as the old assembly.

Note

After part replacement, perform the maintenance calibration procedures.

Refer to figures 4-18 or 4-19 for key number location.

Refer to figures 3-1 and 4-13 for parts location.

4. Insert the replacement pivot assembly on the mounting plate, and attach it with the two mounting screws.

5. Attach links 1 and 5 (keys 88 and 90) in the same hole position as noted in step 3.

6. Refer to the maintenance calibration procedure.

Long Pivot Assembly

Process Drive Flexure

1. Remove process pressure.

1. Set the process pressure to 75 percent of input span.

2. Remove the tie bar (key 97).

3. Disconnect Link 5 (key 88) from the lever arm on the pivot assembly (key 79). Note which hole the link is connected to.

2. Remove tie bar (key 97) by removing two screws from the capsular assembly.

4. Using a wrench, disconnect the drive flexure (key 79) from the adjustment arm of the pivot assembly.

Take care not to bend or kink the drive flexure.

3. Remove the screws and washers (keys 12 and 13) to disconnect the drive flexure (key 79) from the drive bracket assembly (key 84) and from the adjustment arm of the pivot assembly (key 78). Remove the drive flexure.

5. Remove the two screws (key 102) attaching the pivot assembly to the mounting plate (key 77).

4. Connect the replacement drive flexure in place, making sure it is straight and horizontal.

6. Loosen the screw on the adjustment arm of the replacement pivot clevis assembly, and adjust the arm to the same length as the arm on the pivot assembly being replaced.

5. Before tightening the screws (key 12) and mounting the flexure, set the pivot in the center of the bushing end play.

7. Attach the new pivot assembly to the mounting plate with the two mounting screws.

8. Loosely connect the drive flexure to the pivot adjustment arm on the new pivot assembly.

9. Apply 75 percent of the input pressure range to the capsule. The drive flexure should be straight and horizontal. Before tightening the drive flexure mounting screws, set the pivot in the middle of the bushing end play. Tighten the flexure to hold the pivot in that position. If necessary, adjust the length of the adjustable pivot arm as needed until the flexure is straight. Take care not to kink or twist the flexure when tightening the screws.

10. Connect the left-hand end of link 5 (key 88) to the pivot lever arm in the position prior to removal in the hole noted in step 3.

6. Tighten the drive flexure to hold the pivot in position. Take care not to kink or twist the flexure when tightening the screws.

7. Refer to the maintenance calibration procedure.

Process Tubing 1. Remove the input pressure to the controller.

2. Using two open-end wrenches, disconnect the pressure tubing (keys 91 or 92) at the pedestal assembly (key 81) and at the bottom of the controller case.

3. Remove the tubing (keys 91 or 92) from the pressure element.

4. Install the replacement tubing, and tighten all connections. Check for leaks.

5. Refer to the maintenance calibration procedures.

11. Replace the tie bar (key 97).

Capsular Element Assembly

12. Refer to the maintenance calibration procedure.

1. Remove the process pressure from the controller.

Short Pivot Assembly

2. Disconnect link 1 (key 90) from the pointer. Note the hole location in the pivot and pointer assembly.

1. Remove the process pressure from the controller.

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. Disconnect the process pressure connection (key 93) from the pedestal assembly (key 81). Use two 5/16-inch hex wrenches.

4. Remove the four mounting screws (key 127) that attach the capsular element to the process/set point indicating assembly.

4–17

4195S Series CAUTION In the following step, do not lift out the capsular element by holding the capsular element or linkages. These parts are easily damaged.

5. Lift out the capsular element assembly by holding the plate (key 77) travel stop (key 83) or pedestal (key 81).

7. With a regulated air supply, adjust process pressure to 50 percent of capsular element range. The process pointer should be at the 50 percent position on the scale. If not loosen the screw (coarse zero adjustment shown in figure 4-13) in the link, and move the pointer to 50 percent of process scale, and tighten the screw.

8. Refer to the maintenance calibration procedure and to the flapper alignment procedure.

Link Number 2

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 connection.

9. Apply process pressure to the controller, and check for leaks.

10. Refer to the maintenance calibration procedure.

Links This section describes the separate replacement of five links in the controller. To clarify the location of each link, the links are numbered as follows: link number 1 connects short pivot assembly and the process pointer; link number 2 connects the process pointer and the flapper assembly (key 11); link number 3 connects the set point adjustment and the set point beam assembly (key 23); link number 4 (key 65) connects the input feedback beam assembly and the bellows bracket assembly (key 31); link number 5 (key 88, figure 4-18 or 4-19) connects the short pivot assembly and the long pivot assembly. Figure 4-13 shows the location of each link.

Link Number 1 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Disconnect the link from the pivot arm (see figure 4-13) and from the process pointer assembly. Remove the link.

3. Attach the replacement link to the process pointer assembly and pivot arm.

4. Remove the two screws (key 6) and lift off the proportional ban indicator cover (key 36).

5. Move the set point adjustment to 100 percent of the scale, and set the proportional band between DIRECT and REVERSE. 6. The process pointer should be lined up with the pointer subassembly as shown in figure 4-14. If not, adjust the fine zero adjustment to align the process pointer and pointer subassembly.

4–18

CAUTION 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. Disconnect the link from the process pointer assembly and from the flapper assembly (key 11). Remove the link.

3. Install the replacement link with the screw head nearest the process pointer as shown in figure 4-13.

Connect the link to the process pointer only.

4. Move the set point adjustment to 100 percent of scale. Set the proportional band between DIRECT and REVERSE. 5. Disconnect link number 1 from the pivot are, and manually position the process pointer to 100 percent of the scale.

6. Adjust the length of link number 2 (by turning the adjusting screw clockwise to increase the length, counterclockwise to decrease the length) so that the pin on the end of the link is approximately one-half of its diameter short of aligning with the hole in the input feedback beam assembly as shown in figure 4-10. The adjustment provides the proper tension on the link.

7. Connect the link to the input feedback beam assembly.

8. Connect link number 1 to the pivot arm.

9. Refer to the flapper alignment procedure for correct flapper alignment.

10. Refer to the maintenance calibration procedure.

Link Number 3 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Disconnect link number 3 from the set point adjustment assembly and the set point beam assembly (key 23).

4195S Series 3. Install the replacement link with the screw head toward the set point beam assembly as shown in figure 4-15.

4. Check that the set point beam bias spring (key 28) is correctly located in the frame bore and the spring seat on the set point beam assembly as shown in figure 4-5.

5. Adjust the proportional band between DIRECT and REVERSE. 6. Manually move the set point adjustment to 50 percent of scale. Adjust the screw on the link so that the edge of the proportional band knob is parallel to the set point adjustment as shown in figure 3-1.

7. Refer to the maintenance calibration procedure and to the flapper alignment procedure.

Link Number 4 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36).

2. Disconnect the link from the bellows bracket assembly (key 31) and the input feedback assembly (key 11).

3. Connect the replacement link to the input feedback assembly so that the two adjusting screws on the link are nearest to the bellows bracket and so that the screw heads are facing the bottom of the controller as shown in figure16.

Maintenance Calibration Note Perform full maintenance calibration (includes all procedures) upon completion of maintenance procedures. If only zero and span or linearity adjustments are required, use only those procedures.

Key numbers are referenced in figures 4-18 and 4-19. Adjustments are shown in figure 3-1. After maintenance calibration, perform the flapper alignment procedures if directed to do so. Otherwise, go to the appropriate prestartup instructions.

Precalibration Procedures 1. Set the proportional band adjustment to 5 percent direct acting. Adjust the set point manually or with remote set point pressure to 100 percent of the process scale range.

2. Remove the tie bar (key 97).

Aligning the Drive Bracket Assembly 1. Loosen the set screw in the hex nut (key 86) of the drive bracket assembly (key 84) 2. Loosen the screw (key 98) that holds the guide flexure to the tab on the mounting plate.

4. Adjust the process pressure to 0 percent of the process scale range.

3. Adjust the input pressure to 75 percent of full pressure span.

5. Adjust the proportional band to 5 percent direct action, and move the set point adjustment to 100 percent. Output pressure should be 0 psig.

4. Slide the drive bracket assembly (key 84) along the diaphragm capsule extension (key 82) until the guide flexure is aligned with the center of pivot A (key 78).

6. With zero pressure in the feedback bellows, loosen the two adjusting screws on the link. Connect the free end of the link to the bellows bracket assembly, and allow the link to find its free length.

5. Tighten the set screw in the hex nut to fasten the drive bracket assembly in that position.

7. Tighten the two adjusting screws on the link.

1. Loosen the set screw in the travel stop nut (key 86).

8. Refer to the maintenance calibration procedure and to the flapper alignment procedure.

Link Number 5 1. Refer to figure 4-18 or 4-19 for key number locations.

2. Note the location of the connection holes, and disconnect both ends of link 5 (key 88) from the lever arms of the two pivot assemblies.

3. Loosen the adjustment screw on the replacement link, and adjust the length to match the original link.

Tighten the adjustment screw.

4. Attach the replacement link to the two lever arms in the same holes noted in step 2.

5. Refer to the maintenance calibration procedure.

Setting Travel Stops

Note Make sure the loose travel stop nut does not bind up on the diaphragm capsule extension when pressurizing the capsules. Damage to the capsules may result.

2. Full span stop–Adjust pressure input 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.

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4195S Series Slide the travel stop nut (key 86), along the diaphragm capsule extension (key 82) until it is approximately1/64-inch (0.4 mm) away from the travel stop. Tighten the set screw to lock the travel stop nut in that position.

the set screw to lock the travel stop nut in that position.

Adjusting Linkage

6. Make certain that the process pointer and pointer subassembly are aligned (see figure 4-14).

1. Adjust the process pressure to 75 percent of the input span. The drive flexure (key 79) should be straight and horizontal. If it is not, proceed as follows: a. Loosen the screw on the pivot adjustment arm on the long pivot assembly (key 78) and the two screws mounting the drive flexure. b. If necessary adjust the length of the pivot adjustment arm so that the drive flexure is straight and parallel to the centerline of the capsules. c. Tighten the screw to set the length of the adjustment arm in that position. Before retightening the screws, set the pivot in the middle of the bushing end play. d. Tighten down the drive flexure to hold the pivot in that position.

2. Full span stop–Adjust the pressure input 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 unit it is just touching the end of the capsule stack.

Tighten the travel stop mounting screws to lock it into that position.

For positive or compound pressure, two capsules: Loosen the set screw in the travel stop nut (key 86) adjacent to the capsule stack. Slide the nut along the diaphragm capsule extension (key 82) until it just touches the travel stop (key 83). Tighten the set screw to lock the nut in position.

For vacuum pressure: Loosen the set screw in the travel stop nut (key 86) on the end of the diaphragm capsule extension (key 82).

The nut is located in the opposite side of the travel stop from the capsule. Slide the nut along the diaphragm capsule extension until it just touches the travel stop (key 83). Tighten the set screw to lock the nut in position.

3. Zero stop–Adjust pressure input to 0 percent of the full span.

Slide the travel stop nut (key 86), along the diaphragm capsule extension (key 82) until it is approximately 1/64-in. (0.4 mm) away from the travel stop. Tighten

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4. Tighten the guide flexure to the mounting plate.

5. Set the linearity adjustment screw on the short pivot assembly in the middle of its slot.

7. The short (bottom) arm on the short pivot assembly (key 89) should be parallel with the process pointer and the pointer subassembly. Change the length of link 1 (key 90) to the middle of its adjustment to accomplish this.

8. Turn the span adjustment screw on the bottom of the process pointer counterclockwise as far as it will go. The span adjustment bracket will be in its highest position.

9. Adjust the process pressure input to 50 percent of full input span. Adjust the length of link 5 (key 88) so that the pivot level arms are as close to parallel as possible.

10. To complete maintenance calibration, the zero and span adjustments must be set. Refer to the following procedure. If linearity adjustments must also be made, refer to that procedure.

11. Replace the tie bar (key 97) after the controller is calibrated.

12. Refer to the flapper alignment procedure.

Zero and Span Adjustment 1. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36).

2. Set the proportional band between DIRECT and REVERSE. 3. Apply 0 percent of the process pressure input span.

4. Loosen the screw on link 5 (key 88), and adjust the length so that the process pointer points to scale zero.

Tighten the screw.

5. Make fine zero adjustments by loosening the zero adjustment locking screw on the process pointer and turning the zero adjustment screw. Tighten the locking screw.

6. Apply 100 percent of the process pressure input span.

7. To increase the span, proceed as follows (adjust span to correct one-half the error): a. Turn the span adjustment screw clockwise. 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 4-5 for link location.

4195S Series c. Make fine adjustments with the span adjustment screw.

8. To decrease the span, proceed as follows (adjust span to correct one-half the error.): a. Turn the span adjustment screw counterclockwise. b. to decrease the span further than the adjustment will allow, move both ends of link 5 (key 88) up one set of holes. Refer to figure 4-5 for link location. c. Make fine adjustments with the span adjustment screw.

9. Repeat the adjustments until zero and span indications are within 1 percent of input span.

10. Check the pointer position at 50 percent of full process pressure input span. If the error is greater than 1 percent of input span, perform the linearity adjustment procedures.

11. Set the proportional band adjustment to 400 percent in the desired control action.

12. Install the proportional band indicator cover (key 36), and tighten the two screws (key 6).

Linearity Adjustment Adjust the linearity by turning the linearity adjustment screw in the curved slot on the lever arm of the short pivot assembly (key 89). Adjusting the linearity affects the zero and span. Refer to the preceding procedures for those adjustments.

1. Adjust the process pressure to 50 percent of input span. The process pointer should indicate the 50 percent mark on the scale.

2. If the pointer indicates high, turn the linearity screw counterclockwise in the slot. If the pointer indicates low turn the linearity screw clockwise in the slot.

3. Check the zero and span as described in the adjusting zero and span procedure. Make any necessary adjustments.

4. Repeat steps 1 through 3 until zero, span, and linearity indications are within 1 percent of input span.

Flapper Alignment Leveling screws numbers and adjustments are shown in figure 3-1. Provide a means of applying process pressure and supply pressure to the controller and a means of measuring output pressure. After flapper alignment, go to the appropriate prestartup procedures.

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 (option M), adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range.

2. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

3. Adjust the proportional band adjustment to 5 percent direct acting.

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 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. If the output snaps to supply pressure below 2 percent of set point, adjust flapper leveling screw number 3 clockwise. If the output snaps above 2 percent of set point, adjust flapper leveling screw number 3 counterclockwise.

6. Repeat steps 4 and 5 until the output pressure snaps within 2 percent of set point.

7. Adjust the proportional band adjustment between DIRECT and REVERSE. 8. if the output pressure snaps to supply pressure, depress the flapper with a screwdriver so the output pressure snaps to zero pressure. Slowly release the flapper. If the output snaps to supply pressure, adjust flapper leveling screw number 2 clockwise until the output does not snap to supply pressure. Then, adjust screw number 2 counterclockwise 1/8 of a turn at a time until the output snaps to supply pressure.

9. Repeat step 8 to recheck the adjustment of flapper leveling screw number 2.

10. Adjust the proportional band adjustment to 5 percent reverse acting.

11. Carefully adjust the process pressure to 100 percent of the process scale range. Then, slowly decrease the process 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. If the output snaps to supply above 2 percent of set point, adjust flapper leveling screw number 1 clockwise.

13. Repeats steps 11 and 12 until the output pressure snaps within 2 percent of set point.

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4195S Series 14. Repeat steps 3 through 13 to recheck adjustments. Continue to adjust flapper leveling screws 1, 2, and 3 as necessary until no flapper adjustments are required.

15. Replace the proportional band indicator cover (key 36), and tighten the two screws (key 6).

screws. Adjust the length of the pivot arm if necessary until the flexure is straight.

12. Decrease the remote set point pressure to 0 psig.

13. Connect the end of link A (key 116) in figure 4-20 to the pivot lever arm in the same position it was in before.

14. Replace the tie bar (key 106).

Remote Set Point (Option M)

15. Refer to the maintenance calibration procedure.

Replacing Parts

Pivot Assembly B (Key 115) Note

After part replacement, perform the maintenance calibration procedures Figure 3-2 shows the location of the parts. Key numbers refer to figure 4-20.

Pivot Assembly A (Key 114) 1. Decrease the remote set point pressure to 0 psig.

2. Remove the tie bar (key 106).

3. Note where the link is connected. Disconnect link A (key 116) 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 (keys 122), the washer (key 123) and the nut (key 124) that attach the guide flexure to the top of the pivot assembly.

6. Remove the pivot screw snap ring washer (keys 109 and 112) and the mounting screw (key 102) attaching the pivot assembly to the mounting plate. Lift out the pivot assembly.

7. Loosen the screw (key 118) on the adjustment arm of the replacement pivot assembly, and set the arm to the same length as the arm on the pivot assembly being replaced. Tighten the screw.

8. To replace the pivot assembly, first put the spring washer on the screw. Then, install the screw through the pivot assembly into the mounting plate.

9. Connect the guide flexure to the top of the new pivot assembly with the screw (key 122), the washer, and the nut as it was before.

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

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1. Refer to figure 4-20 for the key-numbered assembly.

2. Decrease the remote set point pressure to 0 psig.

3. Note the holes where links are connected. Disconnect the links (keys 116 and 126) from the arms of pivot assembly (key 115).

4. Remove the two screws (key 102) that attach the pivot assembly to the mounting plate (key 111). Remove the pivot assembly.

5. Loosen the linearity adjustment screw on the replacement pivot assembly and set it in the same position as the adjustment on the original pivot assembly.

Tighten the screw.

6. Set the replacement pivot assembly on the mounting plate, and attach it with the two machine screws.

7. Attach the links (keys 116 and 126) to the arms of the new pivot assembly in step 3.

8. Refer to the maintenance calibration procedure.

Drive Flexure 1. Disconnect the drive 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 the remote set point pressure to 50 percent of the remote set point input range.

3. Connect the new flexure making sure it stays straight and horizontal. Before tightening the drive flexure, set pivot A 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.

4. Decrease the remote set point pressure to 0 psig.

5. Perform the maintenance calibration procedure Tubing 1. Decrease the remote set point pressure to 0 psig.

2. Using two open-end flat head wrenches, 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.

4195S Series 3. Remove the tubing.

4. Install the replacement tubing, and reconnect the two pressure connections.

5. Apply full remote set point pressure, and check for leaks.

Remote Set Point Capsular Element Assembly Note Remove the supply pressure gauge before attempting to remove the capsular element assembly.

1. Decrease the remote set point pressure to 0 psig.

2. Remove the pressure connection (key 93) at the pedestal assembly (key 105). Use two open end wrenches.

3. Disconnect link B (key 126) from the pivot hole on set point indicator assembly.

4. Remove the three mounting screws that attach the capsular element assembly to the process/set point indicator assembly. See figure 3-2 for location of screws.

CAUTION In the following step, do not lift out the capsular element assembly by holding the capsule or the linkages. These parts are easily damaged.

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. Replace the supply pressure gauge.

10. Refer to the maintenance calibration procedure.

Link A 1. Note the holes where link A (key 116) is connected (see figure 4-20). Disconnect both ends of the link from the lever arms on the two pivots.

2. Loosen the screw in the replacement link, and adjust the length to match the link being replaced. Tighten the screw. Refer to figure 4-20 for correct orientation of the link.

3. Attach the replacement link to the two lever arms in the same position as the original link.

4. Check the zero setting, and adjust if necessary as described in the zero and span adjustment procedures.

Link B 1. Note the holes where link B (key 126) is connected (see figure 4-20). 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 4-20 for correct orientation of the link.

4. Refer to the maintenance calibration procedure.

Maintenance Calibration Note Perform full maintenance calibration (includes all procedures) upon completion of maintenance. If only zero, span, and linearity adjustments are required, use only those procedures. After maintenance calibration, go to the appropriate prestartup instructions.

Refer to figure 3-2 for parts location. Key numbers refer to figure 4-20.

Precalibration Procedure 1. Set the proportional band adjustment between DIRECT and REVERSE. 2. Remove the tie bar (key 106).

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. Set pivot A in the middle of the bushing end play. e. Tighten the screws that hold the drive flexure in place.

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4195S Series 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 screw on the flexure.

Setting the Travel Stops 1. Loosen the set screw (key 87) in the travel stop nut (key 86).

Note Make sure the loose travel stop nut does not bind up on the diaphragm capsule extension when pressurizing the capsules. Damage to the capsules may result.

2. Full span stop—Adjust the remote set point pressure to 5 percent greater than full span pressure.

Loosen the screw 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 the remote set point pressure to 0 percent of full span.

Slide the travel stop nut (key 86), along the diaphragm capsule extension (key 134) until it is approximately 1/64–in. (0.4 mm) away from the travel stop nut (key 83). Tighten the set screw to lock the travel stop nut in that position.

Aligning the Linkage 1. Adjust the remote set point pressure to 50 percent of full span.

2. Loosen the screw on link a (key 116), and adjust the length so that the set point pointer points to scale zero. Tighten the screw.

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 4-18 for location of the screws.

4. Apply 100 percent of the remote set pressure input span.

5. To increase the span, proceed as follows (adjust span to correct one-half the error): a. Turn the span adjustment screw clockwise. b. To increase the span further than the adjustment screw allows, move both ends of link A to the right. Refer to figure 3-2 for link location. c. Make fine adjustments with the remote set point span adjustment screw.

6. To decrease the span, proceed as follows (adjust span to correct one-half the error: a. Turn the span adjustment screw counterclockwise. b. To decrease the span further than the adjustment screw allows, move both ends of link A to the right. Refer to figure 3-2 for link location. c. Make fine adjustments with the remote set point span adjustment screw.

7. Repeat the adjustments until the zero and span indications are within 1 percent of input span.

2. Set the linearity adjustment screw in the center of the slot on the lever arm of pivot clevis assembly B (key 115).

8. Check the pointer position at 50 percent of full pressure input span. If the error is greater than 1 percent of input span, perform the linearity adjustment procedures.

3. Set the length of link B (key 126) in the middle of its adjustment.

Linearity Adjustment

4. Set the length of link A (key 116) so that the lever arms of pivots A and B are parallel and that link A is perpendicular to them.

Adjust the linearity by rotating the linearity adjustment screw in the curved slot on the lever arm of pivot B (key 115). Adjusting the linearity affects the zero and span adjustment.

5. To complete maintenance calibration, the zero and span adjustments must be set. Refer to the zero and span adjustment procedures. If linearity adjustments must also be made, refer to the linearity adjustment procedure.

6. Replace the tie bar (key 106).

7. Refer to the flapper alignment procedure.

Zero and Span Adjustment 1. Decrease the remote set point pressure to 0 psig.

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1. Adjust the remote set point pressure to 50 percent of the input span. The set point indicator should indicate the 50 percent mark on the scale.

2. If the pointer indicates high, loosen the linearity screw, and rotate it counterclockwise in the slot. If the pointer indicates low, rotate the linearity screw clockwise in the slot.

3. Check the zero and span as described in the zero and span adjustment procedures. make any necessary adjustments.

4195S Series 4. Repeat steps 1 through 3 until zero, span, and linearity indications are within 1 percent of input span.

Auto/Manual (Option E) Note Each of the following procedures requires that the controller be removed from the case. Refer to the replacing case and cover procedures.

CAUTION In the next step, take care to tighten the two screws (keys 314 and 315) evenly.

Uneven tightening could damage the tubing assembly.

3. Position the auto/manual station as far down on the frame and toward the scale as possible. Carefully tighten the two screws (keys 314 and 315) so that the auto/manual station contacts the three pads on the tubing assembly.

4. Carefully tighten the remaining screws and nuts.

Replacing 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).

5. Apply air pressure to the controller, and check for leaks.

6. To install the frame (key 3) into the case, refer to the replacing case and cover procedure.

7. Refer to the flapper alignment procedure.

Replacing the Switch Body Assembly, Lever O-Ring, Switch Body O-Ring, and the Tubing Assembly

Disassembly

Disassembly

1. Refer to figures 4-21 and 4-22 for key number location.

Refer to figure 4-22 for key number location.

2. Loosen the screw (key 316) that holds the auto/ manual station (key 273) to the controller frame.

3. Loosen the two screws (keys 314 and 315) that hold the auto/manual station to the auto/manual tubing assembly (key 138).

4. Remove the auto/manual station from the controller frame.

5. Remove the switch manifold O-rings (key 312).

6. Carefully loosen the nut on the relay nozzle tubing assembly (key 18) where it connects to the auto/ manual tubing assembly (key 138). Loosen three screws (keys 34 and 131) and remove the tubing assembly and frame gaskets (keys 4 and 5).

7. Inspect the gaskets (keys 4 and 5) and O-rings (key 312) for wear. Replace if necessary.

1. Remove the auto/manual station from the controller as described in steps 1 through 4 of the Replacing the Auto/Manual Station procedure.

2. Loosen the two screws (key 288) and remove the lever cover plate (key 305).

CAUTION The lever spring (key 302) is under preload. Take care not to lose any parts during disassembly.

3. Using a 1/16-inch (1.5 mm) punch, push the groove pin (key 303) out toward the surface of the lever cover plate.

4. Remove the switch lever (key 304), lever spring (key 302), and lever spring seat (key 301).

5. Remove the tubing assembly (key 309).

Assembly 1. Install the gaskets and tubing assembly to the frame. Start, but do not tighten, the three screws (keys 34 and 131) and the nut on the relay nozzle tubing assembly (key 18).

2. Install the three O-rings (key 312), and secure the auto/manual station to the controller frame with the screw (key 316) and to the tubing assembly (key 138) with the two screws (keys 314 and 315). Do not tighten any screws.

CAUTION The switch body springs (key 295) are under preload. Take care not to lose any parts when separating the switch body assembly from the loader assembly.

6. Slowly loosen the two screws (key 290), and separate the switch body assembly (key 291) from the loader assembly (key 282).

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4195S Series 7. Remove the O-rings (keys 292, 293, and 294), switch body springs (key 295), and balls (key 296).

9. Drive in the groove pin (key 303) to hold the switch lever.

8. Loosen two screws (key 308), and remove the closing plate (key 307) and the closing plate gasket (key 306).

10. Replace the lever cover plate (key 305) and attach with two screws (key 288).

9. Pull the clip (key 300) from its engagement with the lever assembly shaft (key 297).

10. Pull the lever assembly from the switch body assembly (key 291) and rocker (key 299).

11. Remove the O-ring (key 298).

11. Perform the assembly portion of the replacing the auto/manual station procedure.

Replacing the Loader Range Spring, Diaphragm Assembly, Ball Seat, Tubing, and Ball

12. Inspect the O-rings and gaskets for damage or wear; replace if necessary.

Disassembly

Assembly

2. Remove the auto/manual station from the controller as described in steps 1 through 4 of the replacing the auto/manual station procedure.

1. Insert the lever assembly (key 297) into the switch body assembly (key 291) and hold the rocker (key 299) with the flats on the lever assembly shaft.

1. Refer to figure 4-22 for key number locations.

3. Remove the tubing assembly (key 309).

2. Insert the clip (key 300) in the groove of the lever assembly shaft to hold the lever assembly (key 297) in the switch body assembly (key 291).

Note After assembly in step 3, be sure the side of the closing plate marked OUT is visible.

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 assembly (key 291).

Note In the following step, the ends of the springs must be in the counterbored spring seats before compression.

5. Compress the switch body springs with the loader assembly (key 282), and bolt the switch body assembly (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. 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.

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WARNING To avoid personal injury caused by preload from the range spring (key 283), turn the loader knob (key 287) counterclockwise (opposite to the arrow) to relieve pressure on the spring.

4. Loosen the four screws (key 289), and separate the upper loader assembly (key 282) and the lower loader assembly (key 274).

5. Remove the loader range spring (key 283), range spring cup (key 284), and diaphragm assembly (key 281).

6. Remove the tube (key 278), ball seats (key 280) and ball (key 279).

Assembly 1. Turn the loader knob (key 287) counterclockwise to back the spring adjustment screw (key 285) all the way out to eliminate loading the range spring.

2. Position the range spring cup (key 284), range spring (key 283), and the diaphragm assembly (key 281) on the upper loader assembly (key 282).

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).

4195S Series 4. Bolt the loader assembly halves together using the four screws (key 289).

Replacing the Loader Valve Plug and Valve Plug Spring 1. Refer to figure 4-22 for key number location.

CAUTION Be sure that the supply and exhaust seats of the loader are correctly aligned.

Misalignment will impair loader performance.

2. Loosen the spring seat screw (key 275).

3. Remove the valve plug spring (key 276) and the valve plug (key 277).

4. Inspect the parts and replace as necessary.

5. Install the valve plug spring and valve plug.

6. Tighten the spring seat screw.

5. Attach the tubing assembly (key 309).

7. Temporarily apply supply pressure and process pressure and check for leaks.

6. Perform the Assembly portion of the replacing the auto/manual station procedure.

8. To install the frame (key 3) into the case, refer to the replacing case and cover procedure.

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4195S Series

APPLY LUB/ SEALANT 49A0770-A / DOC

Figure 4-17. Controller Assembly Drawing See Errata Sheet

4–28

4195S Series

56A9752-D Sht 4 / DOC

56A9752-D Sht 1 / DOC

49A070-A Sht 2 / DOC

56A9752-D Sht 2 / DOC

APPLY LUB/ SEALANT

Figure 4–17. Controller Assembly Drawing (Continued)

4–29

4195S Series

36A6966–C / DOC

58A0708–C / DOC

Figure 4-18. Capsular Element Assembly (Positive and Compound Pressure)

4–30

4195S Series

36A6987-C / DOC

58A0710-C / DOC

Figure 4-19. Capsular Element Assembly (Vacuum Pressure)

4–31

4195S Series LINK A

LINK B

36A6988-C B1760/IL

Figure 4-20. Remote Set Point Assembly Drawing

4–32

4195S Series

56A9752-D 49A0770-A C0640/IL

Figure 4-21. Auto/Manual Station Parts

4–33

4195S Series

48A2905-A Sht 1/DOC

48A2905-A Sht 2 / DOC

Figure 4-22. Auto/Manual Station Assembly Drawing

4–34

4195S Series

35A7374-B B1764 / IL

Figure 4-23. Process and Set Point Indicator Assembly (Manual Set Point) See Errata Sheet

4–35

4195S Series

46A7000-B / DOC

Figure 4-23. Process and Set Point Indicator Assembly (Manual Set Point) (Continued) See Errata Sheet

4–36

4195S Series 21 23

Section 5 Parts List Parts Ordering Whenever corresponding with the Fisher Controls sales office or representative 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.

Key

Description

Part Number

General Controller Parts and Bourdon Tubes (figure 4-17) Note For part numbers pertaining to the capsular input element, refer to the capsular element assembly parts list.

1

2 3 4

Case and cover ass’y For bourdon tube & vacuum pressure capsular element w/o remote set 36A6966 X012 w/remote set 36A6966 X032 For positive & compound pressure capsular element w/o remote set 36A6966 X052 w/remote set 36A6966 X062 Nameplate, aluminum 16A6970 X012 Frame, aluminum 56A7001 X012 Frame gasket, 18A0749 X012

5 6 7* 8*

Gasket, neoprene Machine screw, pl steel (6 req’d) O–Ring, nitrile (specify quantity req’d) O-Ring, nitrile (3 req’d)

18A0742 X012 1A5061 28992 1C3762 06992 16A6903 X012

9 10 11 12

Flexure pivot ass’y, sapphire/SST Machine screw, pl steel (4 req’d) Input/Feedback beam Assembly, zn pl steel Machine Screw, stainless steel

16A6917 X012 14A7797 X022 26A6926 X012 1U6213 32982

13 14 16

Plain Washer, stainless steel Flapper, cr pl aluminum Machine Screw, stainless steel (3 req’d)

17A0958 X012 16A6929 X012 19A0672 X012

17 18 19 20

Set Point Pivot Assembly, stainless steel Relay Nozzle Tubing Assembly, stainless steel Machine Screw, pl steel (2 req’d) Plain Washer, pl brass (2 req’d)

16A6914 X012 18A0765 X012 1C8990 28982 1H3397 18992

Nozzle Assembly, stainless steel Set Point Beam Assembly, aluminum/stainless steel

16A6939 X012

24* 25 26 27 28 29 30 31 32

O–ring, nitrile (2 req’d) Proportional Band Knob, polycarbonate Retaining clip, stainless steel 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, pl steel

1E2226 06992 36A6911 X012 16A6913 X012 1V5929 X0012 16A6909 X012 16A6910 X012 13A2201 X012 26A6932 X012 16A6933 X012

33 34 35 36

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

16A6934 X012 1B9925 X0012 16A6935 X022

37 38 39

40

41 45

46 47 48

49

50

*Recommended spare parts 1. See remote set assembly parts list for available replacement parts.

2. Trademark of International Nickel Co.

51 52* 53 56

Self-Tapping Screw, steel (4 req’d) Self–Sel-Tapping Screw, pl steel (9 req’d) Supply Gauge Tubing Assembly Copper/brass Stainless steel/ brass Proportional Tubing Assembly Copper/brass Stainless steel/brass Plug, Stainless steel Positive Feedback Tubing Assembly Copper/brass Stainless steel/brass Output Gauge Supply Gauge Bellows ass’y (2 req’d) Brass/aluminum Stainless steel/aluminum Bellows Beam, aluminum 3 to 15 psig (0.2 to 1.0 bar) 6 to 30 psig (0.4 to 2.0 bar) Relay Assembly 3 to 15 psig (0.2 to 1.0 bar) 6 to 30 psig (0.4 to 2.0 bar) Relief Valve Cover Plate, aluminum O–ring, nitrile Machine screw, pl steel (2 req’d) Process/Set Point Indicator Assembly Bourdon Tubes Capsular Element Assembly

26A6904 X012

36A6936 X012 16A6938 X012 16A6959 X022 16A6952 X012 16A6952 X022 28A0766 X012 28A0766 X022 1P2796 X0012 18A0769 X012 18A0769 X022 See following table See following table

16A6953 X012 16A6953 X022 16A6957 X012 16A6958 X012

BV5997 X00A2 BV5997 X00B2 2V5973 08012 1C8538 06992 1U8842 X0012 See following tables See following table See Key 113 in Capsular Element Assembly Section

5–1

4195S Series Key 46 Output Gauge Key 47 Supply Gauge RANGE 0 to 30 psig 0 to 60 psig 0 to 30 psig/0 to 2 bar 0 to 30 psig/0 to 200 kPA 0 to 60 psig/0 to 4 bar 0 to 60 psig/0 to 400 kPA 0 to 200 kPA 0 to 400 kPA 0 to 2 kg/cm2 0 to 2 kg/cm2 0 to 2 bar 0 to 4 bar

OUTPUT

SUPPLY

Brass

SST

Brass

SST

16A6983 X012 16A6983 X032 16A6983 X332 16A6983 X372 16A6983 X352 16A6983 X392 16A6983 X052 16A6983 X072 16A6983 X092 16A6983 X112 16A6983 X132 16A6983 X152

16A6983 X172 16A6983 X192 --------16A6983 X212 16A6983 X232 16A6983 X252 16A6983 X272 16A6983 X292 16A6983 X312

16A6983 X022 16A6983 X042 16A6983 X342 16A6983 X382 16A6983 X362 16A6983 X402 16A6983 X062 16A6983 X082 16A6983 X102 16A6983 X122 16A6983 X142 16A6983 X162

16A6983 X182 16A6983 X202 --------16A6983 X222 16A6983 X222 16A6983 X262 16A6983 X282 16A6983 X302 16A6983 X322

Key 56 Process/Set Point Indicator Assembly, Bourdon Tube w/o Remote Set PSIG RANGE

BAR RANGE

PART NUMBER

With 316 Stainless Steel Bourdon Tube 0 to 30 0 to 60 0 to 100 0 to 200

0 to 1.6 or 0 to 2 0 to 4 or 0 to 2.5 0 to 6 0 to 10

48A7000 X192 48A7000 X202 48A7000 X212 48A7000 X222

0 to 300 0 to 600 0 to 1000 0 to 1500

0 to 16 0 to 40 or 0 to 25 0 to 60 0 to 100

48A7000 X232 48A7000 X242 48A7000 X252 48A7000 X262

0 to 3000 0 to 5000 0 to 8000

0 to 160 0 to 250 or 0 to 300 0 to 550 With 403 Stainless Steel Bourdon Tube

48A7000 X272 48A7000 X282 48A7000 X292

0 to 10000 0 to 15000 0 to 20000

0 to 600 0 to 1000 0 to 1400

48A7000 X302 48A7000 X312 48A7000 X322

Key 56 Process/Set Point Indicator Assembly, Bourdon Tube w/Remote Set PSIG RANGE

BAR RANGE

PART NUMBER

With 316 Stainless Steel Bourdon Tube

5–2

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

0 to 1.6 or 0 to 2 0 to 4 or 0 to 2.5 0 to 6 0 to 10

38A1734 X012 38A1734 X022 38A1734 X032 38A1734 X042

0 to 300 0 to 600 0 to 1000 0 to 1500

0 to 16 0 to 40 or 0 to 25 0 to 60 0 to 100

38A1734 X052 38A1734 X062 38A1734 X072 38A1734 X082

0 to 3000 0 to 5000 0 to 8000

0 to 160 0 to 250 or 0 to 300 0 to 550 With 403 Stainless Steel Bourdon Tube

38A1734 X092 38A1734 X102 38A1734 X112

0 to 10000 0 to 15000 0 to 20000

0 to 600 0 to 1000 0 to 1400

38A1734 X122 38A1734 X132 38A1734 X142

3.

4.

5.

6.

7.

Use to mount Remote Set assembly to Process/Set Point Indicator assembly.

Use to mount Capsular Element assemble to the Process/Set Point Indicator assembly.

Trademark of Fiske Bros. Refining Co. Trademark of Armite Laboratories.

Trademark of Tretolite Dive. of Petrolite Corp.

4195S Series Key 56 Process and Set Point Indicator Assembly, Capsular Element w/o Remote Set PRESSURE RANGE

Positive

Vacuum

Compound

MATERIAL Stainless Steel

Ni–Span C

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 3 to 15 psig

36A6986 X012 36A6986 X022 36A6986 X032 36A6986 X042

36A6986 X082 36A6986 X092 36A6986 X102 36A6986 X112

0 to 15 psig 0 to 20 psig 6 to 30 psig 0 to 30 psig

36A6986 X292 36A6986 X052 36A6986 X062 36A6986 X072

36A6986 X302 36A6986 X122 36A6986 X132 36A6986 X142

36A6987 X012 36A6987 X022 36A6987 X032 36A6987 X042

36A6987 X052 36A6987 X062 36A6987 X072 36A6987 X082

36A6986 X012 36A6986 X022 36A6986 X032 36A6986 X292 36A6986 X052 36A6986 X072

36A6986 X082 36A6986 X092 36A6986 X102 36A6986 X302 36A6986 X122 36A6986 X142

–5 to 0 Inch Hg –10 to 0 Inch Hg –20 to 0 Inch Hg –30 to 0 Inch Hg –30 to 30 in. Hg –5 in. Hg to 2.5 psig –10 in. Hg to 5 psig –15 in. Hg to 7.5 psig –20 in. Hg to 10 psig –30 in. Hg to 15 psig

Key 56 Process and Set Point Indicator Assembly, Capsular Element w/Remote Set PRESSURE RANGE

Positive

Vacuum

Compound

MATERIAL Stainless Steel

Ni–Span C

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 3 to 15 psig

36A6986 X152 36A6986 X162 36A6986 X172 36A6986 X182

36A6986 X222 36A6986 X232 36A6986 X242 36A6986 X252

0 to 15 psig 0 to 20 psig 6 to 30 psig 0 to 30 psig

36A6986 X312 36A6986 X192 36A6986 X202 36A6986 X212

36A6986 X322 36A6986 X262 36A6986 X272 36A6986 X282

36A6987 X092 36A6987 X102 36A6987 X112 36A6987 X122

36A6987 X132 36A6987 X142 36A6987 X152 36A6987 X162

36A6986 X152 36A6986 X162 36A6986 X172 36A6986 X312 36A6986 X192 36A6986 X212

36A6986 X222 36A6986 X232 36A6986 X242 36A6986 X322 36A6986 X262 36A6986 X282

–5 to 0 Inch Hg –10 to 0 Inch Hg –20 to 0 Inch Hg –30 to 0 Inch Hg –30 to 30 in. Hg –5 in. Hg to 2.5 psig –10 in. Hg to 5 psig –15 in. Hg to 7.5 psig –20 in. Hg to 10 psig –30 in. Hg to 15 psig

5–3

4195S Series Key 113 Capsular Element Assembly(1) PRESSURE RANGE

Positive

Vacuum

Compound

MATERIAL Stainless Steel

Ni–Span C

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 3 to 15 psig

58A0708 X012 58A0708 X022 58A0708 X032 58A0708 X042

58A0708 X082 58A0708 X092 58A0708 X102 58A0708 X112

0 to 15 psig 0 to 20 psig 6 to 30 psig 0 to 30 psig

58A0708 X162 58A0708 X052 58A0708 X062 58A0708 X072

58A0708 X152 58A0708 X122 58A0708 X132 58A0708 X142

58A0710 X012 58A0710 X022 58A0710 X032 58A0710 X042

58A0710 X052 58A0710 X062 58A0710 X072 58A0710 X082

58A0708 X012 58A0708 X022 58A0708 X032 58A0708 X292 58A0708 X052 58A0708 X072

58A0708 X082 58A0708 X092 58A0708 X102 58A0708 X302 58A0708 X122 58A0708 X142

–5 to 0 Inch Hg –10 to 0 Inch Hg –20 to 0 Inch Hg –30 to 0 Inch Hg –30 to 30 in. Hg –5 in. Hg to 2.5 psig –10 in. Hg to 5 psig –15 in. Hg to 7.5 psig –20 in. Hg to 10 psig –30 in. Hg to 15 psig

1. for information on scale compatibility consult your Fisher sales office or sales representative. Capsular Element assembly may be ordered as part of the Process/Set Point indicator assembly (key 56) or ordered separately. See Capsular Element assembly parts list for available replacement parts.

Key 57 58 59

60

61

Description Part Number Pressure Control Block, 316 stainless steel (1 req’d w/o remote set; 2 req’d w/remote set) 26A6962 X012 Cap screw, pl steel (2 req’d w/o remote set; 4 req’d w/remote set 1A3525 24052 Hex Reducing Nipple (used only when specified) up to 0-5000 psig (0-345 bar) Steel 16A6992 X012 Stainless steel 16A6992 X022 0-5000 psig (0-345 bar) to 0-20000 psig (0-1379 bar) Stainless steel 16A6996 X012 Reducing Adaptor (use only when specified) Up to 0-5000 psig (0-345 bar) Steel 16A6993 X012 Stainless steel 16A6993 X022 0-5000 psig (0-345 bar) to 0-15000 psig (0-1034 bar) Stainless steel 16A6997 X012 Process scale, aluminum See following table

63 64 65

Remote set assembly(1) (for 4195SM, and SME only) Remote set pt ass’y (suffix letter M) Ni–Span C(2) 3 to 15 psig (0.2 to 1.0 bar) 36A6988 X032 6 to 30 psig (0.4 to 2.0 bar) 36A6988 X042 Stainless steel 3 to 15 psig (0.2 to 1.0 bar) 36A6988 X012 6 to 30 psig (0.4 to 2.0 bar) 36A6988 X022 Machine screw, stainless steel (2 req’d) 590611 60X12 Machine screw, pl steel 1J8415 28982 Feedback Link Assembly 16A7036 X012

71 72

Machine screw, pl steel (4 req’d) Blowout plug, silicone

62

Key

5–4

Part Number Note

Key numbers 73 through 76 are only for use with a 4195S with Bourdon Tube element. Use only when specified.

73 74 75 76 120 127 131 135

136 138

140 310 311 317 318

1P4743 28982 2V7660 05312

Description

338

Upper Travel Stop, zn pl steel Lower Travel Stop, zn pl steel Machine Screw, pl steel Machine Screw, stainless steel Machine Screw,(3) pl steel (2 req’d) (for 4195SM and SME only) Machine Screw,(4) pl steel (4 req’d) Machine Screw, pl steel (2 req’d) Frame Manifold, Aluminum (for 4195S and SM only)

26A9768 X012 26A9771 X012 1H2676 28982 1V4130 38982 1J8415 28982 1J8415 28982 1A6531 28982 28A0756 X012

Rate/Reset Manifold, Aluminum) 28A0747 X012 Manual/Automatic Tubing Assembly (for 4195SE and SME only) Aluminum/brass 38A2859 X012 Aluminum/stainless steel 38A2859 X022 Machine Screw(3), steel (for 4195SM and SME only) 16A7007 X012 Lubriplate Mag-1 lubricant,(5) 14 oz (0.396 kg) can (not furnished with controller) 1M1100 X0012 Led-Plate No. 250 Sealant(6) 5 lb (2.27 kg) can (not furnished with controller) 1M5240 06992 Molykote No. 33 Grease Lubricant,(7) 5.3 oz (0.150 kg) tube (not furnished with controller) 1M5964 X0012 Dow Corning 111 Lubricant(7) 5.3 oz (0.150 kg) tube (not furnished with controller) 1M5282 06992 Machine Screw, stainless steel (2 req’d) 14A3118 X012

*Recommended spare parts

4195S Series Key 61 Process Scale, Positive Pressure Scale Range

Psig Scales

Bar Scales

kPa Scales

Key 61 Process Scale, Vacuum and Compound Pressure Part Number

0 to 60 inch wc 0 to 5 0 to 10 3 to 15 0 to 15 0 to 20 6 to 30 0 to 30 0 to 60 0 to 100 0 to 200 0 to 300 0 to 600 0 to 1000 0 to 1500 0 to 3000 0 to 5000 0 to 8000 0 to 10,000

1R0003 X0202 1R0003 X0212 1R0003 X0222 1R0003 X0172 1R0003 X0232 1R0003 X0242 1R0003 X0182 1R0003 X0032 1R0003 X0042 1R0003 X0052 1R0003 X0062 1R0003 X0072 1R0003 X0082 1R0003 X0092 1R0003 X0102 1R0003 X0112 1R0003 X0122 1R0003 X0132 1R0003 X0142

0 to 150 mbar 0 to 160 mbar 0 to 400 mbar 0 to 0.6 0 to 1 0.2 to 1 0 to 1.4 0 to 1.6 0 to 2 0.4 to 2 0 to 2.5 0 to 4 0 to 6 0 to 10 0 to 16 0 to 25 0 to 40 0 to 60 0 to 100 0 to 160 0 to 250 0 to 300 0 to 600 0 to 200 0 to 400 0 to 700 0 to 1400 0 to 2000 0 to 4000 0 to 7000 0 to 10,000 0 to 20,000 0 to 35,000

1R0003 X1562 1R0003 X0412 1R0003 X0422 1R0003 X0402 1R0003 X0432 1R0003 X1602 1R0003 X1612 1R0003 X0442 1R0003 X1652 1R0003 X1622 1R0003 X0452 1R0003 X0462 1R0003 X0472 1R0003 X0482 1R0003 X0492 1R0003 X0572 1R0003 X0502 1R0003 X0512 1R0003 X0522 1R0003 X0532 1R0003 X0542 1R0003 X1802 1R0003 X0552 1R0003 X0922 1R0003 X0932 1R0003 X0942 1R0003 X0702 1R0003 X0952 1R0003 X0962 1R0003 X0972 1R0003 X0712 1R0003 X0982 1R0003 X0992

0 to 55,000 0 to 70,000 0 to 100000 0 to 140000

1R0003 X1002 1R0003 X1012 1R0003 X1022 1R0003 X1032

SCALE RANGE

PART NUMBER

Vacuum Pressure Inches Hg Scales

Bar Scales

5 to 0 10 to 0 20 to 0 30 to 0 150 to 0 mbar 160 to 0 mbar 400 to 0 mbar 0.6 to 0 1 to 0

1R0003 X0322 1R0003 X0332 1R0003 X0342 1R0003 X0192 1R0003 X1632 1R0003 X0582 1R0003 X0592 1R0003 X0602 1R0003 X0612

Compound Pressure Psig Scales

Bar Scales

30 inches wc vac. to 30 inches wc 5 inches Hg vac. to 2.5 psig 10 inches Hg vac. to 5 psig 15 inches Hg vac. to 7.5 psig 20 inches Hg vac. to 10 psig 30 inches Hg vac. to 15 psig –50 to +100 mbar –60 to +100 mbar –150 to +250 mbar –0.2 to +0.4 –0.4 to +0.6 –0.6 to +0.8 –1 to +0.6 –1 to +1

1R0003 X0252 1R0003 X0352 1R0003 X0362 1R0003 X0262 1R0003 X0372 1R0003 X0272 1R0003 X1572 1R0003 X0622 1R0003 X0632 1R0003 X0642 1R0003 X0652 1R0003 X1582 1R0003 X0662 1R0003 X1592

5–5

4195S Series Key 113 Capsular Element Assembly(1) MATERIAL

PRESSURE RANGE

Positive

Vacuum

Compound

Stainless Steel

Ni–Span C

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 3 to 15 psig

58A0708 X012 58A0708 X022 58A0708 X032 58A0708 X042

58A0708 X082 58A0708 X092 58A0708 X102 58A0708 X112

0 to 15 psig 0 to 20 psig 6 to 30 psig 0 to 30 psig

58A0708 X162 58A0708 X052 58A0708 X062 58A0708 X072

58A0508 X152 58A0708 X122 58A0708 X132 58A0708 X142

–5 to 0 inch Hg –10 to 0 inch Hg –20 to 0 inch Hg –30 to 0 inch Hg

58A0710 X012 58A0710 X022 58A0710 X032 58A0710 X042

58A0710 X052 58A0710 X062 58A0710 X072 58A0710 X082

–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

58A0708 X012 58A0708 X242 58A0708 X252 58A0708 X162 58A0708 X052 58A0708 X072

58A0708 X082 58A0708 X092 58A0708 X102 58A0708 X152 58A0708 X122 58A0708 X142

1. For information on scale compatibility, consult your Fisher sales office or sales representative. Capsular Element Assembly may be ordered as part of the Process/Setpoint Indicator Assembly (key 56) or ordered separately. See Capsular Element Assembly section for available replacement parts.

Bourdon Tubes(1) Psig Range

Bar Range

Material

Part Number

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

0 to 1.6 or 0 to 2 0 to 4 or 0 to 2.5 0 to 6 0 to 10

36A7016 X192 36A7016 X202 36A7016 X212 36A7016 X222

0 to 300 0 to 600 0 to 1000 0 to 1500

0 to 16 0 to 40 0 to 60 0 to 100

36A7016 X232 36A7016 X242 36A7016 X252 36A7016 X262

0 to 3000 0 to 5000 0 to 8000

0 to 160 0 to 250 or 0 to 300 0 to 550

0 to 10000 0 to 15000 0 to 20000

0 to 600 0 to 1000 0 to 1400

316 stainless steel

36A7016 X272 36A7016 X282 36A7016 X292

403 stainless steel

36A7016 X302 36A7016 X312 36A7016 X322

1. Part numbers for psig Bourdon Tubes and bar Bourdon Tubes are the same. For information on scale compatibility consult your Fisher sales office or sales representative. Bourdon Tubes may be ordered as part of the Process/Set Point Indicator assembly (key 56) or ordered separately.

Key

Description

Part Number

Capsular Element Assembly (figures 4-18 and 4-19) 12 13 56 78

Machine Screw, stainless steel (2 req’d) Plain washer, stainless steel (2 req’d) Process/Set Point Indicator Assembly Pivot Clevis assembly, plastic/stainless steel

79 80

Drive Flexure, stainless steel 16A9794 X012 Diaphragm Capsule Assembly (for 4195SM SME only) (not shown) Ni-Span-C 3 to 15 psig (0.2 to 1.0 bar) 26A9776 X012 6 to 30 psig (0.4 to 2.0 bar) 26A9778 X012 Stainless steel 3 to 15 psig (0.2 to 1.0 bar) 28A2848 X012 6 to 30 psig (0.4 to 2.0 bar) 28A2850 X012 Connecting Link Assembly. aluminum/bronze/ brass 18A0655 X012 Pivot Clevis Assembly

88 89

5–6

1U6213 32982 610003 10X12 See following table 26A9784 X012

Key 89

90 91 97 102 113

Description Part Number Pivot Clevis Assembly (Cont’d) Use w/Ni-Span-C capsular material 16A9791 X012 Use w/stainless steel capsular material 18A0693 X012 Connecting Link Assembly, aluminum/bronze/ brass 18A0679 X012 Process tubing ass’y, S30400 (304 SST) (positive and compound capsule only) 28A0682 X012 Tie Bar, zn pl steel 26A9803 X012 Machine Screw, pl steel (4 req’d) 1H2675 28992 Capsular Element Assembly See following table

Remote Set Point Assembly (figure 4-20) 12 13 79 102

Machine Screw, stainless steel (2 req’d) Plain Washer, stainless steel (3 req’d) Drive Flexure, stainless steel Machine Screw, pl steel (4 req’d)

1U6213 32982 610003 10X12 16A9794 X012 1H2675 28992

109 112 114

Pivot Screw, aluminum Spring Washer, pl steel Pivot Clevis Assembly, plastic/stainless steel

18A1738 X022 17A2700 X012 18A0658 X012

4195S Series Key 80 Capsular Element Assembly, Travel Stop (key 86) and Diaphragm Assembly Extension CAPSULAR ELEMENT MATERIAL Ni-Span-C RANGE

Capsular Element (key 80) Part Number

Number of Travel Stops (key 86) Required

Stainless Steel Diaphragm Assembly Extension Required

Capsular Element (key 80) Part Number

Number of Travel Stops (key 86) Required

Diaphragm Assembly Extension Required

Positive and Compound Element

U. S. units

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 0 to 15 psig and 3 to 15 psig 0 to 20 psig 6 to 30 psig 0 to 30 psig

26A9773 X012 26A9774 X012 26A9775 X012 26A9776 X032 26A9777 X012 26A9778 X022 26A9779 X012

1 1 2 2 2 2 1

key 82 key 82 key 130 key 130 key 130 key 130 key 82

28A2845 X012 28A2846 X012 28A2847 X012 28A2848 X022 28A2849 X012 28A2850 X022 28A2851 X012

2 2 2 2 2 2 1

key 130 key 130 key 130 key 130 key 130 key 130 key 82

Metric units

0 to 150 mbar 0 to 400 mbar 0 to 0.6 bar 0 to 1 bar and 0.2 to 1 bar 0 to 1.4 bar 0 to 1.6 bar and 0 to 2 bar 0.4 to 2 bar

26A9773 X012 26A9775 X012 26A9775 X012 26A9776 X032 26A9777 X012 26A9779 X012 26A9778 X022

1 2 2 2 2 1 2

key 82 key 130 key 130 key 130 key 130 key 82 key 130

28A2845 X012 28A2847 X012 28A2847 X012 28A2848 X022 28A2849 X012 28A2851 X012 28A2850 X022

2 2 2 2 2 1 2

key 130 key 130 key 130 key 130 key 130 key 82 key 130

U. S. units

–5 to 0 inch Hg –10 to 0 inch Hg –20 to 0 inch Hg –30 to 0 inch Hg

26A9773 X012 26A9774 X012 26A9775 X012 26A9776 X032

2 2 2 2

key 132 key 132 key 133 key 133

28A2845 X012 28A2846 X012 28A2847 X012 28A2848 X022

2 2 2 2

key 133 key 133 key 133 key 133

Metric units

–150 to 0 mbar –400 to 0 mbar and 0.6 to 0 bar –1 to 0 bar

26A9773 X012 26A9775 X012 26A9776 X032

2 2 2

key 132 key 133 key 133

28A2845 X012 28A2847 X012 28A2848 X022

2 2 2

key 133 key 133 key 133

Vacuum Element

Key 115

116 125

126

Description Pivot Clevis Assembly, plastic/stainless steel Use w/Ni-Span-C capsular material Use w/stainless steel capsular material Connecting Link Assembly, aluminum/bronze/ brass Spacer, aluminum) brass Connecting link ass’y, aluminum/bronze/brass

Part Number 16A9808 X012 18A0694 X012 18A0666 X012 18A0702 X012 18A0676 X012 18A0676 X012

Internal Auto/Manual Station (figures 4–21 and 4–22) 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290

Auto/Manual Station Lower Loader Assembly, aluminum Spring Seat Screw, pl steel Valve Plug Spring, zn pl steel Valve Plug, stainless steel Tube, plastic Ball, stainless steel Ball Seat, nitrile (2 req’d) Diaphragm Assembly, rubber/aluminum Upper Loader Assembly, aluminum/plastic Range Spring, stainless steel Range Spring Cup, stainless steel Spring Adjustment Screw, zn pl steel Retaining Ring, pl steel Loader knob, plastic Machine Screw, pl steel (2 req’d) Machine Screw, pl steel (4 req’d) Machine Screw, pl steel (2 req’d)

*Recommended spare parts

48A2905 X012 18A2892 X012 18A2876 X012 18A2877 X012 18A2878 X012 18A2880 X012 18A2902 X012 18A2881 X012 18A2884 X012 18A2893 X012 18A2885 X012 18A2869 X012 18A2886 X012 18A2903 X012 18A2891 X012 1C2082 28982 1C8969 28982 1A3279 28982

Key

Description

291 292* 296 298 299 300 301 302 303 304 305 306* 307 308 309 310

312*

Switch Body Assembly, aluminum/nitrile 28A2890 X012 O–ring, Nitrile 1U2398 X0032 Ball, stainless steel (2 req’d) 1J1550 X0012 O–ring, Nitrile 1E2226 X0032 Rocker, aluminum 18A2871 X012 Clip, stainless steel 18A2872 X012 Lever Spring Seat, stainless steel 18A2870 X012 Lever Spring, zn pl steel 18A2895 X012 Groove Pin, stainless steel 16A6380 X012 Switch Lever, polycarbonate/stainless steel 38A2897 X012 Switch Lever Cover Plate, aluminum/chromate 18A2873 X012 Closing Plate Gasket, neoprene 18A2898 X012 Closing Plate, stainless steel 18A2875 X012 Machine Screw, pl steel (2 req’d) 18A2899 X022 Tubing Assembly, stainless steel 28A2863 X012 Lubriplate Mag–1 Lubricant, 14 oz (0.396 kg) can (not furnished with the Internal Auto/Manual Station assembly) 1M1100X0012 Led–Plate No. 250 Sealant, 5 lb (2.27 kg) can (not furnished with 1M5240 06992 the Internal Auto/Manual station assembly) O-ring, nitrile (3 req’d) 1P8453 X0022

313 314 315 316

Auto/Manual Scale, polycarbonate Machine Screw, stainless steel Machine Screw, pl steel Machine Screw, pl steel

311

Part Number

38A2901 X012 1C1015 35042 1B9925 28992 1U8841 28982

Mounting Parts Pipestand Mounting 66 67 68 69

Cap Screw, pl steel (3 req’d) Lock Washer, pl steel (7 req’d) Bracket, pl steel Clamp, pl steel (2 req’d)

1A3526 24052 1C2257 28982 36A9755 X012 1P4270 28982

5–7

4195S Series Key

Description

Part Number

Panel Mounting 66 67 68 70

Cap Screw, pl steel (3 req’d) Lock Washer, pl steel (3 req’d) Bracket, pl steel Machine Screw, pl steel (4 req’d)

1A3526 24052 1C2257 28982 36A6990 X012 16A9763 X012

Key

Description

Part Number

Mounting Bracket, steel Type 1061 All others

36A6991 X012 36A9754 X012

Spacer Spool, steel (2 req’d) Cap Screw, pl steel (2 req’d)

1J8307 24092 1A3525 24052

Wall Mounting 66 67 68

Cap Screw, pl steel (3 req’d) Lock Washer, pl steel (3 req’d) Bracket, pl steel

1A3526 24052 1C2257 28982 36A6990 X012

Actuator Casing Mounting Spacer Spool, steel (3 req’d) Cap Screw, pl steel (3 req’d) Lockwasher, pl steel (5 req’d) Mounting Bracket, pl steel Cap Screw, pl steel (2 req’d) Mounting Bracket, pl steel Cap Screw, pl steel (2 req’d) Hex Nut, pl steel (2 req’d)

1C5590 24092 1B7624 24052 1C2257 28982 36A9754 X012 1A3526 24052 1F4012 25072 1A5828 24052 1E9440 24112

Actuator Yoke Mounting Spacer Spool, steel (3 req’d) Cap Screw, pl steel (3 req’d) Lockwasher, pl steel (5 req’d)

5–8

1C5590 24092 1B7624 24052 1C2257 28982

Note Specify quantity of fittings and length of tubing required

Tubing For 1/4-in. O.D., copper For 3/8-in. O.D., copper

05000 91701W 05002 01701W

Fittings For 1/4–inch tubing Connector, brass Elbow, brass For 3/8–inch tubing Connector, brass Elbow, brass

*Recommended spare parts

1A6368 14012 1A3971 18992 1B8856 18992 1B8846 18992

4195S Series October 1990

Errata Sheet for 4195S SERIES GAUGE PRESSURE CONTROLLERS Form 5583, June 1983 Instruction Manual This errata sheet provides part numbers for the new style Bourdon tubes (see tables for key 56 in the Parts List section of this errata sheet). It also provides revised figure and part information to support other design changes in the controller and controller subassemblies.

1. On page 1-1, change the title from 4195S Series Gauge Pressure Controllers to 4195KS Series Gauge Pressure Controllers. The type number (4195S Series) has changed to (4195KS Series) reflecting the change from the old style bourdon tube to the new style shown in figure 4-17 of this errata sheet.

2. On page 3-2, cross out the Bourdon tube in the controller drawing shown in figure 3-1. Write a note near the figure that reads: “See Figure 4-17. Bourdon Tube Assembly in the errata sheet.” Figure 4-17 in this errata sheet shows the revised Bourdon tube.

3. On page 3-3, cross out the bourdon tube in the controller drawing (SIDE VIEW OF SET POINT/PROCESS INDICATOR ASSEMBLY) shown in figure 3-1 (continued). Write a note near the figure that reads: “See Figure 4-17. Bourdon Tube Assembly in the errata sheet.”

4. On page 4-4, cross out the photo of the relay shown in the figure 4-4. Write a not near the photo that reads: “See figure 4-4 in the errata sheet.”

5. On page 4-12, cross out the photo in figure 4-12.

The photo is obsolete. Also on page 4-13, figure 4-13, cross out link 1 connection photos (DISCONNECTING LINK 1 FROM BOURDON TUBE). Write a note near the photo that reads: “See figure 4-17 in the errata sheet.” Figure 4-17 shows the design change in the bourdon tube and linkage.

6. On Page 4-12, 4-13, and 4-14, cross out the Bourdon Tube (replacement) procedure and write a note near the procedures that reads: “See replacing Bourdon tube procedure in the errata sheet. Refer to the Bourdon Tube Replacement Procedure below.

7. On page 4-29, In the upper left hand drawing of the controller assembly, cross out the Bourdon tube. In the upper right hand view (CONTROLLERS WITH REMOTE SET POINT OPTION), cross out the Bourdon tube in the view. In the lower center view (BOURDON TUBE TRAVEL STOPS), cross out the Bourdon tube.

Write a note near the view that reads “See Figure 4-17. Bourdon Tube Assembly in the errata sheet.”

8. On page 4-36, cross out the drawing in figure 4-23.

Write a note near the drawing that reads: “See Figure 4-23. Indicator Assembly in the errata sheet.”

9. On page 4-37/4-38, cross out the drawing shown in figure 4-23, (Continued). Write a note near the drawing that reads: “See Figure 4-23. Process Set Point Indicator Assembly (Continued) in the errata sheet.“ 10. On page 5-1, for keys 46 and 47, cross out the notes “See following table,” and write the following note: “For keys 46 and 47, see the table in the errata sheet.”

11. For key 50, change the part number BV5997 X00A2 to 32B0257 X0A2, and change BV5997 X00B2 to 32B0257 X0B2. If replacing the relay assembly (key 50) or individual parts, refer to the Parts List section provided in this errata sheet.

12. For key 56, cross out the notes: “See following tables and See following table.” Write a note near key 56 that reads: “See tables in the errata sheet.”

13. On page 5-2, at the end of the left column, add keys 101 and 383 to the parts list by writing the following: (Key) 101

383

(Description) Indicator Assembly; see Figure 4-23. Indicator Assem bly and the Parts list section in the errata sheet Bourdon tube; see Figure 4-23. Process/Set Point Indicator Assembly and the table for Key 383 in the errata sheet

14. On page 5-3, in Key 61 Process Scale Positive Pressure table, in the Psig Scales section cross out 0 to 15000 and 0 to 20000 scales. In the Bar Scales section, cross out 0 to 1000 and 0 to 1400 scales.

Also, in the kPa Scales section cross out 0 to 10000 and 0 to 140000 scales. These scale ranges are no longer available.

15. On page 5-4, cross out the table for Key 56 Process/Set Point Indicator Assembly, Capsular Element w/o Remote Set, near the table write a note that reads: “For Key 56, see table in the errata sheet.”

Also, cross out the table for key 56 Process/Set Point indicator Assembly, Capsular Element W/Remote Set. It is also provided in the errata sheet.

Fisher Controls International, Inc. 1990; All Rights Reserved

5–9

4195S Series 56

Bourdon Tube Replacement Procedure

Process/set point indicator assembly See following tables

Note

Note

When procedure is complete, refer to the maintenance calibration procedures in the instruction manual.

The part numbers in Key 56 tables are for the complete process/set point indicator assembly with a process sensing element. Individual parts are listed in the Process/Set Point Indicator Assembly Individual parts in this errata sheet.

Key number locations are shown in figure 4-23, Process/Set Point Indicator Assembly (Continued) in this errata sheet.

1. Disconnect link 1 from the Bourdon tube (see figure 4-17 in this errata sheet).

2. Loosen the tubing nut from the Bourdon tube to allow for the Bourdon tube removal.

3. Remove the self-tapping screws from the base of the Bourdon tube.

101

4. Lift out the Bourdon tube.

Indicator Assembly

5. Install the replacement Bourdon tube, and replace the self-tapping screws and tighten.

Note

6. With the process input pressure at 0 psig (0 bar0 adjust the length of link 1 by loosening the two screws and positioning the process pointer at 0 percent on the scale.

The part numbers listed here for key 101 are for the complete indicator assembly without a sensing element. Individual assembly parts are listed in the Indicator Assembly subsection of this parts list. Key number locations are shown in figure 4-23 in this errata sheet.

7. Apply process pressure to the controller equal to the upper range limit on the Bourdon tube, and check for leaks. Remove the process pressure.

8. Connect link1 to the Bourdon tube.

9. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).

10. Move the set point adjustment to 100 percent of the scale range. Set the proportional band between DIRECT and REVERSE. 11. Perform the controller calibration procedure, and if necessary, the appropriate remote set point calibration procedure in section 3.

12. Install the proportional band indicator cover (key 36), and tighten the two screws (key 6).

(End of Bourdon tube replacement procedure)

Parts List Controller General Parts Key

Description

46 47 50

Output Gauge See following table Output Gauge See following table Relay Assembly (see figure 4-4 in this errata sheet) 3 to 15 psig (0.2 to 1.0 bar) 32B0257 X0A2 1 6 to 30 psig (0.4 to 2.0 bar) 32B0257 X0B2 1 (see Relay Assembly Individual Parts list below)

5–10

Part Number

Qty

383

Without remote set point With remote set point Bourdon tube

39A1126 X012 39A1126 X042 see following table

1 1

Relay Assembly Individual Parts (figure 4-4) Key 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

19 20

Description Part Number Qty Relay Base, aluminum 42B0245 X012 1 Exhaust block, aluminum 2U9002 08012 1 3U9019 08012 1 Relay cap, aluminum Output block assembly, aluminum 1U9006 000A2 1 1V5579 02032 1 Gasket, nitrile 1U9016 35032 1 Inner Valve, S30300 (303 SST) Diaphragm ass’y, nitrile/aluminum/SST 1U9018 000A2 1 Diaphragm, nitrile 1V5578 02032 1 Nozzle and adaptor assembly 3 to 15 (0.2 to 1.0 bar), aluminum/sapphire 12B0250 X012 1 6 to 30 (0.4 to 2.0 bar), aluminum/sapphire 12B0251 X012 1 Relay mounting screw, SST 1U9012 28982 2 1P4204 37022 1 Spring, SST Spring, steel plated 19A8907 X012 1 O-ring, nitrile 17A6891 X012 1 O-ring, nitrile 1D1346 06992 1 O-ring, nitrile 1D6875 06992 2 Machine screw, SST 1A8176 X0012 4 Core and wire assembly, SST 3 to 15 psig (0.2 to 1.0 bar) 1V5992 X0012 1 6 to 30 psig (0.4 to 2.0 bar) 1V5992 X0022 1 O-ring, nitrile 1D1347 06992 1 Lubricant, Dow Corning Compound 111,(1) 5.3 oz (0.1 kg) tube (not furnished with controller) 1M5282 06992 1

4195S Series Indicator Assembly Individual Parts (figure 4-23) Key 61 353 367 368 370 371 372 374 375

378 380 381 384 376 377 378 382

Description Process Scale, aluminum

Part Number Qty See general controller part list in the instruction manual Machine screw, SST 16A7044 X022 4 Support bracket 16A7013 X012 1 Link assembly 16A7039 X012 1 Set point pointer and bracket assembly, aluminum/SST/brass 26A9750 X012 1 Pivot pin, S30200 SST 16A7027 X012 2 Washer SST 1V7657 X0012 4 Pointer and bracket assembly, aluminum/steel 26A7059 X012 1 Set point indicating assembly With remote set point 31B2241 X012 1 Without remote set point 26A7045 X012 1 Screw, SST 16A9772 X022 2 Machine screw, SST 1H2674 X0012 1 Process tubing assembly 12B4951 X012 1 Self tapping screw 16A9772 X022 2 Dial bracket, carbon steel/zinc plated 36A7050 X012 1 Dial bracket, Steel 36A7051 X012 1 Screw, SST 16A9772 X022 4 Link assembly, bimetal 22B0469 X012 1

Process and Set Point Indicator Assembly Capsular Element continued) Key 101

For use w/remote set pt 39A1126 X022 Capsular element ass’y See Key 113 table Machine screw, fill hd, S18800 (18–8 SST) Required to mount the capsular element ass’y to the indicator ass’y 1J8415 X0012

113 127

Assembly

Description Indicator ass’y For use w/o remote set pt

4-23,

Part Number

Qty

39A1126 X012

1

Key 101

Description Part Number Qty Indicator ass’y For use w/o remote set pt 39A1126 X012 1 For use w/remote set pt 39A1126 X022 1 Screw, self-tapping, S30400 (304 SST) 18A8870 X012 1 Machine screw, pan hd, S18800 (18–8 SST) 1H2674 X0012 1 Process tubing ass’y, SST 12B4951 X012 1 Link ass’y, steel/SST 22B0469 X012 1 Bourdon tube See Key 383 table in this errata sheet Screw, self–tapping, pl steel 16A9772 X022 1

379 380 381 382 383 384

Key 46/47 Pressure Gauge(1) GAUGE MATERIAL

RANGE

Brass

SST

Dual Scale Gauge 0 to 30 psig/ 0 to 2 kg/cm2

11B8577 X042

11B8583 X032

0 to 60 psig/ 0 to 4 kg/cm2

11B8577 X052

–––

0 to 30 psig/ 0 to 200 kPa/ 0 to 2 bar 0 to 60 psig/ 0 to 400 kPa/ 0 to 4 bar

11B8577 X012

11B8583 X012

11B8577 X022

11B8583 X022

1. One type of pressure gauge is used for both output pressure and supply pressure indication.

Key 56 Process and Set Point Indicator Assembly with Capsular Element Assembly RANGE

ASSEMBLY PART NUMBER

Positive and Compound Compo nd Element

U.S. Units

0 to 60 inch wc 0 to 5 psig 0 to 10 psig 0 to 12 psig 0 to 15 psig 0 to 20 psig 0 to 24 psig 0 to 30 psig

W/O Remote Set Point

W/Remote Set Point

SST

Ni-Span-C

SST

Ni-Span-C

36A6986 X012 36A6986 X022 36A6986 X032 36A6986 X042 36A6986 X292 36A6986 X052 36A6986 X062 36A6986 X072

36A6986 X082 36A6986 X092 36A6986 X102 36A6986 X112 36A6986 X302 36A6986 X122 36A6986 X132 36A6986 X142

36A6986 X152 36A6986 X162 36A6986 X172 36A6986 X182 36A6986 X312 36A6986 X192 36A6986 X202 36A6986 X212

36A6986 X222 36A6986 X232 36A6986 X242 36A6986 X252 36A6986 X322 36A6986 X262 36A6986 X272 36A6986 X282

36A6987 X012 36A6987 X022 36A6987 X032 36A6987 X042

36A6987 X052 36A6987 X062 36A6987 X072 36A6987 X082

36A6987 X092 36A6987 X102 36A6987 X112 36A6987 X122

36A6987 X132 36A6987 X142 36A6987 X152 36A6987 X162

Vacuum Element U.S. Units

–5 to 0 Inch Hg –10 to 0 Inch Hg –20 to 0 Inch Hg –30 to 0 Inch Hg

4

Bourdon Tube Assembly (figure 4-23, continued)

Triple Scale Gauge

(figure

1

5–11

4195S Series Key 56 Process and Set Point Indicator Assembly with Bourdon Tube PSIG RANGE

BAR RANGE

ASSEMBLY PART NUMBER W/O Remote Set Point

W/Remote Set Point

With S31600 (316 SST) Bourdon Tube 0 to 30 0 to 60 0 to 100 0 to 200

0 to 1.6 or 0 to 2 0 to 4 or 0 to 2.5 0 to 6 0 to 10

32B1532 X012 32B1532 X022 32B1532 X032 32B1532 X042

32B1532 X142 32B1532 X152 32B1532 X162 32B1532 X172

0 to 300 0 to 600 0 to 1000 0 to 1500

0 to 16 0 to 40 or 0 to 25 0 to 60 0 to 100

32B1532 X052 32B1532 X062 32B1532 X072 32B1532 X082

32B1532 X182 32B1532 X192 32B1532 X202 32B1532 X212

0 to 3000 0 to 5000

0 to 160 0 to 250 or 0 to 300

32B1532 X092 32B1532 X102

32B1532 X222 32B1532 X232

32B1532 X112 32B1532 X122

32B1532 X242 32B1532 X252

With N09902 Nickel Alloy (Ni–Span C, Alloy 902) Bourdon Tube 0 to 8000 0 to 10,000

0 to 550 0 to 600

Key 383. Bourdon Tubes PSIG RANGE

BAR RANGE

PART NUMBER

With S31600 (316 SST) Bourdon Tube 0 to 30 0 to 60 0 to 100 0 to 200

0 to 1.6 or 0 to 2 0 to 4 or 0 to 2.5 0 to 6 0 to 10

12B4588 X012 12B4588 X022 12B4588 X032 12B4588 X042

0 to 300 0 to 600 0 to 1000 0 to 1500

0 to 16 0 to 40 or 0 to 25 0 to 60 0 to 100

12B4588 X052 12B4588 X062 12B4588 X072 12B4588 X082

0 to 3000 0 to 5000

0 to 160 0 to 250 or 0 to 300

12B4588 X092 12B4588 X102

With N09902 Nickel Alloy (Ni-Span-C, Alloy 902) Bourdon Tube 0 to 8000 0 to 10,000

5–12

0 to 550 0 to 600

12B4588 X112 12B4588 X122

4195S Series

56A9753-K Sht 1 A5680 / DOC

32B0257-A / DOC

Figure 4-4. Relay Assembly

Figure 4-17. Bourdon Tube Assembly

5–13

4195S Series

39A1126-H / DOC

Figure 4-23. Indicator Assembly

36A6966-C / DOC 32B1532-A / DOC

Figure 4-23. Process / Set Point Indication Assembly with Bourdon Tube (Continued)

5–14

Figure 4-23. Process / Set Point Indication Assembly with Bourdon Tube (Continued)

4195S Series

E Fisher Controls International, Inc. 1983; All Rights Reserved 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.

For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 0512 5–15 Printed in U.S.A.

4195S Series

5–16