Emerson Fisher 4194HA User manual

www.Fisher.com

Fisher™4194HA, HB, and HC Differential Pressure

Indicating Controllers

Contents

1. Introduction

Scope of Manual 3.............................

Description 4.................................

Specifications 4...............................

Educational Services 4.........................

2. Installation, Mounting, and Connections

Controller Mounting Orientation 8...............

Pipestand Mounting 8.........................

Pressure Connections 8........................

Process Pressure Connections 10................

Supply Pressure 10............................

Vent Connection 11...........................

Remote Set Point (suffix letter M) Connection 11...

External Feedback Connection

(4194HB Controllers only) 11.................

3. 4194HA Proportional‐Only Controllers

Adjustments for 4194HA Controllers 12...........

Manual Set Point Adjustment 13.............

Remote Set Point (suffix letter M)

Adjustment 14..........................

Proportional Band Adjustment (PB ADJ) 14.....

Changing Controller Action 15...............

Switching The Auto/Manual Station

(suffix letter E) 15.........................

Prestartup Checks for 4194HA Controllers 15......

Startup for 4194HA Controllers 16...............

Calibration for 4194HA Controllers 17............

General Calibration Instructions 17...........

Process Indicator Zero‐and‐Span

Calibration 17..........................

Remote Set Point (suffix letter M)

Zero‐and‐Span Adjustment 18.............

Flapper Alignment 19......................

Principle of Operation for 4194HA Controllers 20...

Overall Operation 20.......................

Remote Set Point Option

(suffix letter M) 21.......................

Auto/Manual Station Option

(suffix letter E) 21.......................

4. 4194HB Proportional‐Plus‐Reset

Controllers and 4194HC

Proportional‐Plus‐Reset‐Plus‐Rate

Controllers

Adjustments for 4194HB and HC Controllers 22....

Manual Set Point Adjustment 22.............

Remote Set Point (suffix letter M)

Adjustment 22..........................

Proportional Band Adjustment (PB ADJ) 22.....

Changing Controller Action 22...............

Reset (suffix letter B) Adjustment 23..........

Rate (suffix letter C) Adjustment 23...........

Anti‐Reset Windup (suffix letter F)

Adjustment 23..........................

Switching the Auto/Manual Station

(suffix letter E) 23.......................

Prestartup Checks for 4194HB and

HC Controllers 23...........................

Startup for 4194HB and HC Controllers 24.........

Calibration for 4194HB and HC Controllers 25......

General Calibration Instructions 25...........

Process Indicator Zero‐and‐Span

Calibration 26..........................

Remote Set Point (suffix letter M)

Zero‐and‐Span Calibration 27.............

Flapper Alignment 27......................

Anti‐Reset Windup Valve

(suffix letter F) Calibration 30..............

Principle of Operation for 4194HB and

HC Controllers 31...........................

Overall Operation 31.......................

Anti‐Reset Windup Option (suffix letter F) 34...

Remote Set Point Option (suffix letter M) 34...

Auto/Manual Station Option (suffix letter E) 34.

External Feedback Option 35................

5. Maintenance

Inspection and Maintenance 37..................

Troubleshooting 37............................

Changing Controller Action 41..................

Replacing the Differential Pressure Unit 42........

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Replacing Controller Parts 43....................

Replacing the Process Differential

Pressure Scale 44........................

Replacing the Relay 44.....................

Replacing the Case and Cover 45.............

Replacing the Gauges 46....................

Replacing the Links 46......................

Link 1 47................................

Link 2 48................................

Link 3 49................................

Link 4 50................................

Replacing the Supply, Proportional, Reset,

Reset Valve, and Relief Tubing

Assemblies 51........................

Replacing the Proportional Band Adjustment

Knob, Nozzle Assembly, and Set Point

Beam Assembly 52.....................

Replacing the Flapper Assembly and

Flexure Pivot Assembly 56................

Replacing the Proportional or Reset

Bellows 59.............................

Replacing the Reset Restriction Valve

(4194HB Controllers) 61..................

Replacing the Rate/Reset Valve Assembly

(4194HC Controllers) 61.................

Replacing the Differential Relief Valve

Assembly (suffix letter F) 62...............

Replacing the Relief Valve Tubing

Assembly (suffix letter F) 62...............

Calibration After Controller Maintenance 63.......

Process Indicator Zero‐and‐Span

Calibration 63..........................

Flapper Alignment 64......................

4194HA Proportional‐Only Controllers 65.....

4194HB Proportional‐Plus‐Reset and

4194HC Proportional‐Plus‐Reset‐

Plus‐Rate Controllers 65..................

Anti‐Reset Windup Valve (suffix letter F)

Calibration 67..........................

Remote Set Point (suffix letter M)

Maintenance 68............................

Remote Set Point Assembly

Replacement 69........................

Replacing Remote Set Point Parts 69..........

Pivot Assembly A (Key 114) 69..............

Pivot Assembly B (Key 115) 70..............

Drive Flexure 71..........................

Remote Set Point Tubing 71................

Link A 71................................

Link B 72................................

Pressure Control Block for Remote

Set Point 72............................

Remote Set Point Maintenance Calibration 72.....

Remote Set Point Precalibration Procedures 72.

Setting Remote Set Point Travel Stops 73......

Aligning Remote Set Point Linkage 73.........

Remote Set Point Zero‐and‐Span

Adjustment 73..........................

Remote Set Point Linearity Adjustment 74.....

Replacing Auto/Manual Station

(suffix letter E) Parts 75......................

Disassembly of the Auto/Manual Station 75....

Assembly of the Auto/Manual Station 75......

Replacing the Auto/Manual Station Switch

Body Assembly, Lever O‐Ring, Switch

Body O‐Ring, and the Tubing Assembly 76..

Replacing the Auto/Manual Station Switch

Range Spring, Diaphragm Assembly,

Ball Seat, Tubing, and Ball 77.............

Replacing the Auto/Manual Station Loader

Valve Plug and Valve Plug Spring 78........

6. Parts

Parts Kits 79..................................

Parts Ordering 79.............................

Abbreviations Used In Parts List 79...............

Controller Parts 80............................

Process and Set Point Indicator Assembly 87.......

Remote Set Point Assembly 88..................

Indicator Assembly 89.........................

Auto/Manual Station (suffix letter E) 89...........

Controller Mounting Parts 92....................

Fittings 92................................

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Section 11‐1‐

Introduction

Scope of Manual

This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for

the 4194HA, HB, and HC (high static pressure) differential pressure indicating controllers.

Portions of this manual apply only to specific 4194HA, HB, and HC controller configurations. These configurations are

indicated by letter suffixes in the type number that correspond to the mode and option designated in table 1‐2.

The specific controller type number (with letter suffixes) is located on the nameplate (figure 1‐1). Refer to table 1‐2 for

the definition of each 4194H controller type number.

Figure 1‐1. Fisher 4194H Differential Pressure Controller

W5907

W5908

NAMEPLATE

Do not install, operate, or maintain a 4194HA, HB, or HC controller without being fully trained and qualified in valve,

actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is

important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and

warnings. If you have any questions about these instructions, contact your Emerson sales office or Local Business

Partner before proceeding.

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Description

The controllers described in this manual provide differential control with options as shown in table 1‐2.

D 4194HA controllers: Proportional‐only control

D 4194HB controllers: Proportional‐plus‐reset control

D 4194HC controllers: Proportional‐plus‐reset‐plus‐rate control

4194HA, HB, or HC controllers show process differential pressure and set point on an easy‐to‐read process scale. The

controller output is a pneumatic signal that operates a final control element.

Specifications

Specifications for 4194HA, HB, and HC controllers are listed in table 1‐1.

Educational Services

For information on available courses for 4194HA, 4194HB, and 4194HC controllers, as well as a variety of other

products, contact:

Emerson Automation Solutions

Educational Services - Registration

Phone: 1-641-754-3771 or 1-800-338-8158

E-mail: [email protected]

emerson.com/fishervalvetraining

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Table 1‐1. Specifications

Available Configurations

See table 1‐2

Input Signal (Differential Pressure Sensing Element

Range)

Differential Pressure Range: See table 1‐3

Maximum Safe Working Pressure: See table 1‐3

Output Signal

Proportional‐Only, Proportional‐Plus‐Reset, or

Proportional‐Plus‐Reset‐Plus‐Rate Range: 0.2 to 1.0

bar (3 to 15 psig) or 0.4 to 2.0 bar (6 to 30 psig)

Action: Field‐reversible between direct(1) (increasing

differential pressure increases output pressure) or

reverse(1) (increasing differential pressure decreases

output pressure)

Process Scale

Standard scale is matched to the range of the

differential pressure sensing element. Linear, square

root, and optional scales(2) available

Process Connections (To Differential Pressure Unit)

Standard: 1/4 NPT internal stainless steel

(all input ranges)

Optional: 1/2 NPT internal stainless steel

Supply And Output Connections

1/4 NPT internal

Supply Pressure Requirements

See table 1‐4

Supply Pressure Medium

Air or Natural Gas

Supply medium must be clean, dry and non-corrosive

Per ISA Standard 7.0.01

A maximum 40 micrometer particle size in the air

system is acceptable. Further filtration down to 5

micrometer particle size is recommended. Lubricant

content is not to exceed 1 ppm weight (w/w) or

volume (v/v) basis. Condensation in the air supply

should be minimized.

Per ISO 8573-1

Maximum particle density size: Class 7

Oil content: Class 3

Pressure Dew Point: Class 3 or at least 10_C less than

the lowest ambient temperature expected

Remote Set Point Pressure Ranges

0.2 to 1.0 bar (3 to 15 psig) or

0.4 to 2.0 bar (6 to 30 psig)

Controller Adjustments

Proportional Band: 5 to 500% of process scale range

Reset: Adjustable from 0.01 to more than 74 minutes

per repeat (from 100 to less than 0.0135 repeats per

minute)

Rate: Adjustable from 0 to 20 minutes

Set Point: Continuously adjustable from 0 to 100% of

the scale range

Controller Performance

Repeatability: 0.4% of output span

Dead Band: Less than 0.2% of process scale range

Steady‐State Air Consumption(3)

Without Auto/Manual Station

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

0.08 m3/hr (2.8 scfh)

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

0.07 m3/hr (2.5 scfh)

With Auto/Manual Station (suffix letter E)

Add 0.01 m3/hr (0.5 scfh)

Operative Ambient Temperature Limits(4)

–40 to 70°C (–40 to 160°F)

-continued-

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Table 1‐1. Specifications (continued)

Hazardous Area Classification

Complies with the requirements of ATEX Group II

Category 2 Gas and Dust

Housing

Designed to NEMA 3 and IEC 529, IP54 specifications

Mounting

Controller is mounted on a pipestand. See figure 2‐1.

Approximate Weight

Controller: 4.5 kg (10 lb) without the differential

pressure unit

Differential Pressure Unit: 21.5 kg (47 lb)

Total Weight (controller and differential pressure

unit): 26 kg (57 lb) (with a Barton 199 Differential

Pressure Unit)

Declaration of SEP

Fisher Controls International LLC declares this

product to be in compliance with Article 4 paragraph

3 of the PED Directive 2014/68/EU. It was designed

and manufactured in accordance with Sound

Engineering Practice (SEP) and cannot bear the CE

marking related to PED compliance.

However, the product may bear the CE marking to

indicate compliance with other applicable EC

Directives.

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 − Process Instrument Terminology.

1. With Barton 199 differential pressure unit. For ranges other than those listed in table 1‐3, contact your Emerson sales office or Local Business Partner.

2. Consult your Emerson sales office or Local Business Partner for additional information.

3. Normal m3/hr: normal cubic meters per hour (0°C and 1.01325 bar absolute). Scfh: standard cubic feet per hour (60°F and 14.7 psia).

4. Also for transportation and storage limits.

Table 1‐2. Available Configurations

CONTROLLER(1)

MODES OPTIONS

Proportional‐Only Proportional‐Plus‐

Reset

Proportional‐Plus‐

Reset‐Plus‐Rate

Anti‐Reset

Windup

Remote Set

Point

Internal Auto/

Manual Station

4194HA

4194HAE

4194HAM

4194HAME

4194HB

4194HBE

4194HBF

4194HBFE

4194HBM

4194HBME

4194HBFM

4194HBFME

4194HC

4194HCE

4194HCF

4194HCFE

4194HCM

4194HCME

4194HCFM

4194HCFME

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

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Table 1‐3. Process Sensor (Barton 199) Range and Pressure Ratings

DIFFERENTIAL PRESSURE RANGE(1) SAFE WORKING PRESSURE(2) HOUSING

MATERIAL

Bar Psig

Psig (bar)

0 to 15 (0 to 1)

0 to 30 (0 to 2)

0 to 40 (0 to 2.8)

0 to 50 (0 to 3.4)

0 to 60 (0 to 4)

0 to 75 (0 to 5)

68.9 1000 Stainless steel

0 to 15 (0 to 1)

0 to 30 (0 to 2)

0 to 40 (0 to 2.8)

0 to 50 (0 to 3.4)

0 to 60 (0 to 4)

0 to 75 (0 to 5)

172 2500 Steel

0 to 15 (0 to 1)

0 to 30 (0 to 2)

0 to 40 (0 to 2.8)

0 to 50 (0 to 3.4)

0 to 60 (0 to 4)

0 to 75 (0 to 5)

414 6000 Steel

Inches w.c. (mbar)

0 to 20 (0 to 50)

0 to 25 (0 to 62)

0 to 50 (0 to 124)

0 to 75 (0 to 186)

0 to 100 (0 to 248)

68.9 1000 Stainless steel

0 to 20 (0 to 50)

0 to 25 (0 to 62)

0 to 50 (0 to 124)

0 to 75 (0 to 186)

0 to 100 (0 to 248)

172 2500 Steel

0 to 20 (0 to 50)

0 to 25 (0 to 62)

0 to 50 (0 to 124)

0 to 75 (0 to 186)

0 to 100 (0 to 248)

414 6000 Steel

1. Differential pressure ranges are in English units of measurement; metric equivalents are shown here for reference only. Consult your Emerson sales office or Local Business Partner for special

differential pressure ranges.

2. The Barton 199 differential pressure unit may be pressured to this value without permanent zero shift or structural damage to controller components.

Table 1‐4. Supply Pressure Requirements

Output Signal Range Normal Operating Supply Pressure (1) Maximum Pressure to Prevent

Internal Damage(2)

Bar 0.2 to 1.0 1.4 2.8

0.4 to 2.0 2.4 2.8

Psig 3 to 15 20 40

6 to 30 35 40

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

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

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Section 2 2‐2‐

Installation, Mounting,and Connections

WARNING

To avoid personal injury or property damage resulting from the sudden release of pressure:

D Always wear protective clothing, gloves, and eyewear when performing any installation operations.

D Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and

preventive measures are not taken. Preventive measures may include, but are not limited to, one or more of the

following: Remote venting of the unit, re‐evaluating the hazardous area classification, ensuring adequate ventilation,

and the removal of any ignition sources. For information on remote venting of this controller, refer to page 11.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

D If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section of this

instruction manual.

Controller Mounting Orientation

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

Pipestand Mounting

A 4194H controller mounts on a pipestand. Install with the vent opening facing down. Secure the mounting coupling

to the pipestand by three set screws as shown in figure 2‐1.

Pressure Connections

WARNING

To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any system

component, including the differential pressure unit, where service conditions could exceed the limits given in this manual.

Use pressure‐relieving devices as required by government or accepted industry codes and good engineering practices.

CAUTION

Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed

by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.

Refer to figures 2‐1, 2‐2, and 2‐3 for the location of all input and output connections for the controller and differential

pressure unit. Also, refer to the differential pressure unit instruction manual for specific information about

connections and piping.

Supply, output, vent, and remote set point connections are 1/4 NPT. Use 1/4 or 3/8‐inch pipe or tubing for supply,

output, vent, and remote set point piping.

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Process pressure connections are 1/4 or 1/2 NPT (optional). When installing process piping to the differential pressure

unit attached to the controller, follow accepted engineering, installation, and safety practices to insure the safe and

accurate transmission of the process differential pressure to the differential pressure unit. Install shutoff valves, vents,

drains, or seal systems as required by accepted practices.

NOTE:

1 LOW PRESSURE CONNECTION ON A BARTON 199

DIFFERENTIAL PRESSURE UNIT.

Figure 2‐1. Right Side View of Controller

SET SCREW

(3 REQ'D)

W3635-1

BARTON 199

DIFFERENTIAL

PRESSURE UNIT

1/2 NPT

PRESSURE CONNECTION

1/4 NPT PRESSURE

CONNECTION

PIPESTAND MOUNTING

BRACKET

PIPESTAND

NOTE:

1 HIGH PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT.

Figure 2‐2. Connections

1/4 NPT REMOTE SET

POINT CONNECTION

REMOTE SET POINT

CONNECTION

1/2 NPT

1/4 NPT

FRONT VIEW

LEFT SIDE VIEW

TOP VIEW

18A5903‐B

A3000-1

1/4 NPT

OPTIONAL EXTERNAL

FEEDBACK CONNECTION

SUPPLY PRESSURE

CONTROLLER

OUTPUT PRESSURE

1/4 NPT VENT

1/4 NPT

2 HOLES

BOTTOM VIEW

Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

Process Pressure Connections

Process pressures are piped to the connections on the ends of the differential pressure unit (figure 2‐3). Refer to the

differential pressure unit instruction manual for the high and low pressure connections.

Figure 2‐3. Simplified Control Loop Diagram

W5910

SUPPLY

PRESSURE OUTPUT

SIGNAL

LOW PRESSURE

PIPING

LOW

PRESSURE

CONNECTIONS

HIGH PRESSURE

CONNECTIONS

HIGH PRESSURE PIPING

ORIFICE PLATE

NOTE:

1 TO ALLOW A REAR VIEW OF THE CONTROLLER/DIFFERENTIAL PRESSURE UNIT,

THE SCHEMATIC SHOWS PROCESS FLOW FROM RIGHT TO LEFT.

2 SEE FIGURE 2‐1 FOR LOW PRESSURE CONNECTIONS.

When installing process piping, follow accepted practices to ensure accurate transmission of the process pressures to

the differential pressure unit. Install a three‐valve bypass, shutoff valves, vents, drains, or seal systems as needed in the

process pressure lines.

If the instrument is located such that the adjacent process pressure lines will be approximately horizontal, the lines

should slope downward to the instrument for liquid‐filled lines and upward toward the instrument for gas‐filled lines.

This will reduce the chance of air becoming trapped in the sensor with liquid‐filled lines or of condensate becoming

trapped with gas‐filled lines. The recommended slope is 83 millimeters per meter (1 inch per foot).

Supply Pressure

WARNING

Severe personal injury or property damage may occur if the instrument supply medium is not clean, dry air or oil‐free,

noncorrosive gas. While use and regular maintenance of a filter that removes particles larger than 40 micrometer in

diameter will suffice in most applications, check with an Emerson Automation Solutions field office and industry

instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or method of air

filtration or filter maintenance.

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