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
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4194HA, HB, HC Controllers
July 2018
2
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................................

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D200156X012
4194HA, HB, HC Controllers
July 2018
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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.

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July 2018
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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: [phone] or 1-800-338-8158
E-mail: [email protected]
emerson.com/fishervalvetraining

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D200156X012
4194HA, HB, HC Controllers
July 2018
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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-

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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
4194HA
4194HAE
4194HAM
4194HAME
X
X
X
X
X
X
X
X
4194HB
4194HB
4194HBE
4194HBF
4194HBFE
4194HBM
4194HBME
4194HBFM
4194HBFME
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
4194HC
4194HC
4194HCE
4194HCF
4194HCFE
4194HCM
4194HCME
4194HCFM
4194HCFME
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1. Reverse‐acting constructions are designated by an R added to the type number.

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July 2018
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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.

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4194HA, HB, HC Controllers
July 2018
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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.

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July 2018
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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
1
1
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
1
1
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

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4194HA, HB, HC Controllers
July 2018
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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.
2
1
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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July 2018
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Supply pressure medium must be clean, dry, and noncorrosive and meet the requirements of ISA Standard 7.0.01 or
ISO 8573-1. 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 supply medium should be minimized.
Use a suitable supply pressure regulator to reduce the supply pressure source to 1.4 bar (20 psig) for an output signal
range of 0.2 to 1.0 bar (3 to 15 psig) and to 2.4 bar (35 psig) for an output signal range of 0.4 to 2.0 bar (6 to 30 psig).
Vent Connection
WARNING
Personal injury or property damage could result from fire or explosion of accumulated gas, or from contact with hazardous
gas, if a flammable or hazardous gas is used as the supply pressure medium. Because the controller case and cover
assembly do not form a gas‐tight seal when the assembly is enclosed, a remote vent line, adequate ventilation, and
necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas. However, a remote
vent pipe alone cannot be relied upon to remove all flammable or hazardous gas. Vent line piping should comply with local
and regional codes and should be as short as possible with adequate inside diameter and few bends to reduce case pressure
buildup.
CAUTION
When installing a remote vent pipe, take care not to over‐tighten the pipe fitting in the vent connection. Excessive torque
will damage the threads in the connection.
If a remote vent is required, the vent line must be as short possible with a minimum number of bends and elbows. Vent
line piping should have a minimum inside diameter of 19 mm (3/4 inches) for runs up to 6.1 m (20 feet) and a
minimum inside diameter of 25 mm (1 inch) for runs from 6.1 to 30.5 m (20 to 100 feet).
If a remote vent is not required, the vent opening (figure 2‐2) 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.
Remote Set Point (suffix letter M) Connection
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 2‐2. If pressure is supplied to the remote set point connection with a regulator, a
small bleed orifice should be placed between the regulator and remote set point connection to prevent pressure
variations due to regulator lock‐up.
External Feedback Connections (4194HB Controllers Only)
When a secondary controller in an override application has this option, reset windup is minimized in the secondary
controller. Connect the external feedback connection of the secondary controller to the output of the
customer‐supplied high or low select relay. See figure 2‐2.

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D200156X012
4194HA, HB, HC Controllers
July 2018
12
Section 3 3‐3‐
4194HA Proportional‐Only Controllers
Adjustments for 4194HA Controllers
Note
Some of the following procedures require adjusting the proportional band knob between DIRECT and REVERSE. If this is done, it
will be necessary to set the proportional band knob to 400 (direct or reverse action) before replacing the proportional band
indicator cover.
This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustments
is shown in figure 3‐1. To better understand the adjustments and overall operation of the controller, refer to the
principle of operation and the schematic diagrams (figures 3‐3, 4‐2, and 4‐3). Unless otherwise noted, refer to figure
6‐1 for key number locations.

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July 2018
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Figure 3‐1. Location of Controller Parts and Adjustments
DRIVE ARM
LOCKING SCREW
PIVOT BRACKET
DRIVE ARM
CONNECTING LINK 1
ZERO ADJUSTMENT
ZERO ADJUSTMENT
LOCKING SCREW
PROCESS SPAN
ADJUSTMENT
SUPPLY PRESSURE
GAUGE
SEE VIEW A
SET POINT
ADJUSTMENT
PROCESS
INDICATOR
PROPORTIONAL
BAND INDICATOR
COVER
PROPORTIONAL
BAND ADJUSTMENT
KNOB
OUTPUT
PRESSURE
GAUGE
NOTE:
1 ON CONTROLLERS EQUIPPED WITH REMOTE SET POINT
OPTION, THIS IS THE REMOTE SET POINT INDICATOR.
FRONT VIEW
SIDE VIEW OF SET POINT / PROCESS
INDICATOR ASSEMBLY
35A7374‐B
W3688‐1
REMOTE SET POINT
SPAN ADJUSTMENT
SPAN
ADJUSTMENT
SIDE VIEW OF CONTROLLER
SHOWING FLAPPER LEVELING SCREWS
56A9752‐S SHT 1
SCREW 1
SCREW 2
SCREW 3
Manual Set Point Adjustment
To adjust the set point, open the controller cover and move the set point indicator until the desired value on the
process differential pressure scale is below the line on the set point indicator. Move the adjustment to the right to
increase the set point and to the left to decrease it.

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Remote Set Point (suffix letter M) Adjustment
CAUTION
Do not manually move the set point indicator on controllers with remote set point. Moving the set point indicator could
damage the controller.
If the controller is equipped with the remote set point option (figure 3‐2), vary the remote set point pressure to
change the set point. Increase the pressure to increase the set point and decrease the pressure to decrease the set
point.
Figure 3‐2. Parts and Adjustments, Remote Set Point Option
PIVOT
ASSEMBLY A
GUIDE FLEXURE MOUNTING SCREW
LINK A ADJUSTMENT
SCREW
LINK B
LINEARITY
ADJUSTMENT
PIVOT
ASSEMBLY B
MOUNTING
SCREW
TIE BAR
REMOTE SET POINT ZERO ADJUSTMENT SCREW
ZERO ADJUSTMENT LOCKING SCREW
CAPSULES
UPPER TRAVEL
STOP
LOWER TRAVEL
STOP
DRIVE FLEXURE
SIDE VIEW
FRONT VIEW
36A9751‐C
B1668‐4
Proportional Band Adjustment (PB ADJ)
The proportional band adjustment determines the output sensitivity of the controller. The proportional band knob is
marked in percentages of process differential pressure required to drive the controller from zero output to full output.
For example, a typical 4194H unit offers 0.2 to 1.0 bar (3 to 15 psig) output. Furthermore, this controller comes
equipped with a differential pressure unit capable of sensing a process pressure differential ranging from 0 to 1.0 bar

Instruction Manual
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4194HA, HB, HC Controllers
July 2018
15
(0 to 15 psig). Then, at a proportional band setting of 100 percent DIRECT, the controller output goes from 3 to 15
psig as the process pressure differential goes from 0 to 15 psig. If the proportional band setting is subsequently
changed to 50 percent DIRECT, the controller output would change from 3 to 15 psig as the process pressure
differential changed from 0 to 7.5 psig.
Adjusting the proportional band has minimal effect on the set point.
Changing Controller Action
Controller action is switchable from direct to reverse or vice versa by simply 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.
Switching The Auto/Manual Station (suffix letter E)
Note
Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller
cycling.
Refer to figure 6‐5 if the controller has the auto/manual option.
To switch from automatic to manual mode, you must balance the manual output with the controller output.
Two balance methods are available to equalize the manual output with the controller output.
To switch from automatic to manual mode, carefully adjust the loader knob until the metal ball inside the plastic tube
moves into the switching zone. Then move the automatic/manual switch to MANUAL. Turn the loader knob clockwise
to increase the controller output or counterclockwise to decrease it.
To switch from manual to automatic mode, adjust the set point manually or with remote set point pressure to move
the ball into the switching zone. Turn the switch to AUTOMATIC and adjust the set point manually or with 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.
Prestartup Checks for 4194HA Controllers
Refer to figure 3‐1 for location of adjustments and refer to figure 6‐1 for location of key numbers.
When performing the checks, open loop conditions must exist. An open loop exists when the controller output does
not affect the input pressure or other control signal to the controller.
Note
If the controller has the auto/manual option (suffix letter E), be sure the controller is in the automatic mode before performing the
prestartup checks.

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1. Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to
the controller. Provide a means of measuring the controller output pressure. Also, provide a means of applying
process differential pressure to the differential pressure unit.
2. For a controller with remote set point (suffix letter M), connect regulated pressure of 0.2 to 1.0 bar (3 to 15 psig)
or 0.4 to 2.0 bar (6 to 30 psig) to the remote set point connection at the top of the controller case.
3. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36).
4. Set the proportional band between DIRECT and REVERSE.
5. Adjust the process differential pressure until the controller indicates 50 percent of the input range. The process
indicator should point out the process differential pressure within ±1 percent of the input span.
6. If the process indicator is out of calibration, refer to the process indicator zero‐and‐span adjustment procedures in
the Calibration section. Also, check the accuracy of the process indicator at other points on the scale.
7. For controllers with manual set point, move the set point indicator to 50 percent of the scale range. For controllers
with remote set point (suffix letter M), adjust the remote set point pressure until the set point moves to 50 percent
of the scale range.
8. The output of the controller should be:
D 0.62 ±0.007 bar (9 ±0.1 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output
D 1.2 ±0.01 bar (18 ±0.2 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output
9. Adjust the proportional band to 20 percent DIRECT. The output of the controller should remain essentially the
same.
D 0.62 ±0.017 bar (9 ±0.25 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output
D 1.2 ±0.03 bar (18 ±0.5 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output
10. Adjust the proportional band to 20 percent REVERSE. The output of the controller should remain essentially the
same.
D 0.62 ±0.017 bar (9 ±0.25 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output
D 1.2 ±0.03 bar (18 ±0.5 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output
11. If the controller output is out of tolerance in steps 8, 9, or 10, the flapper needs to be aligned. Refer to the flapper
alignment procedure.
12. If the controller output is within tolerance, replace the proportional band cover and go to the startup procedure.
Startup for 4194HA Controllers
Perform the prestartup checks and, if necessary, calibrate the controller prior to this procedure.
Note
When performing the startup procedure, keep in mind the initial settings are guidelines. They will vary depending on the actual
process being controlled.
1. Be sure the supply pressure regulator is delivering the proper supply pressure to the controller.
2. For controllers with:
D manual set point:
Move the set point indicator to the desired set point.

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D remote set point:
a. See figure 2‐2 for the location of the remote set point connection. Connect an adjustable pressure source to
the remote set point connection.
b. Adjust the pressure source until the set point indicator reaches the desired set point. Remember: Increasing
the remote set point pressure increases the set point of direct‐acting controllers.
3. Set the proportional band adjustment to 100 percent for fast processes. For slow processes, calculate the
proportional band percentage from the equation below:
Proportional
Band
Adjustment
+200 AllowableOvershoot
PressureSpan
For example:
200 2Psig
30Psig ^13%
4. Create a load upset by momentarily changing the set point. Check for system cycling. If the system does not cycle,
lower the proportional band setting (thus raising the gain) and disturb the system again by changing the set point.
Continue this procedure until the system cycles. At this point, double the proportional band setting (proportional
band setting X 2).
Calibration for 4194HA Controllers
WARNING
To avoid personal injury or property damage resulting from the sudden release of pressure, do not exceed the operating
limits given in this manual.
General Calibration Instructions
Note
If the controller has the auto/manual option, be sure the controller is in the automatic mode before performing calibration.
If the prestartup checks revealed faulty controller operation, perform the calibration described in this section. These
instructions are valid for either shop or field calibration, provided open process loop conditions exist. Unless otherwise
noted, key numbers are found in figure 6‐1.
Process Indicator Zero‐and‐Span Calibration
Before starting this procedure:
D Provide a regulated process differential pressure to the differential pressure unit.
D Provide a regulated supply pressure to the controller. Do not exceed the normal operating pressure in table 1‐4.
Note
Any change in process indicator span will require readjustment of the process indicator zero adjustment screw.

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Refer to figure 3‐1 for location of adjustments.
1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and REVERSE.
3. The process indicator should be aligned with the indicator subassembly as shown in figure 5‐6. If not, loosen the
zero adjustment locking screw and adjust the fine zero adjustment to align the process indicator and indicator
subassembly. See figure 6‐4.
4. Adjust the process differential pressure until the controller indicates 50 percent of the input range.
5. The process indicator should point to 50 percent of the process scale range. If not, loosen the drive arm locking
screw (key 331, figure 6‐2) that holds the drive arm (key 322) to the shaft extension (key 321) and readjust the drive
arm on the shaft until the process indicator points to 50 percent of the process scale range. Tighten the drive arm
locking screw.
6. Adjust the process differential pressure to the lower limit of the input span. Note the position of the process
indicator.
7. If necessary, adjust the process indicator to the lowest limit of the input scale by loosening the zero adjustment
locking screw and turning the zero adjustment screw.
8. Adjust the process differential pressure to the upper limit of the input span. Note whether the process indication is
above or below the upper limit of the process scale.
9. Adjust the span screw as follows: Clockwise to increase span for a low indication or counterclockwise to decrease
span for a high indication. Adjust the span screw to correct one‐half the error.
10. Repeat steps 6 through 9 until the error is eliminated.
11. Adjust the process differential pressure to 50 percent of the input range. The process indicator should point to the
mid‐scale value within ±1 percent of the input span. If the process indicator does not point to the proper value,
select the appropriate instructions, below:
D If the process indicator error at mid‐range is greater than ±1 percent but not greater than ±2 percent, turn the
zero adjustment screw to bring the process indicator within ±1 percent at mid‐range. Then, check the process
indicator accuracy at the lower and upper scale limits, to verify it is within ±1 percent of the input span.
After adjusting the process indicator to ±1 percent at the low, mid‐range, and upper scale limits, proceed with
step 12.
D If the process indicator error at mid‐range is greater than ±2 percent, loosen the two screws in the drive arm (key
322, figure 6‐2) and lengthen or shorten the drive arm approximately 6.3 mm (1/4‐inch). Then, repeat steps 6
through 11.
After adjusting the process indicator to ±1 percent at the low, mid‐range, and upper scale limits, proceed with
step 12.
12. Perform the flapper alignment procedure. Install the proportional band indicator cover (key 36) and tighten the two
screws (key 6).
Remote Set Point (suffix letter M) Zero‐and‐Span Adjustment
Refer to figure 3‐1 for location of adjustments. Refer to figures 6‐1 and 6‐2 for key number locations.
Note
Any adjustment of the set point span adjustment screw will require readjustment of the set point zero adjustment screw. Refer to
figure 3‐1.

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1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and REVERSE.
3. Adjust the set point pressure to the low limit of the set point input range. Note the position of the set point
indicator. Loosen the set point zero adjustment locking screw and adjust the zero adjustment screw (figure 3‐1)
until the set point indicator aligns with the lowest scale limit.
When the set point indicator is properly aligned with the low scale limit, tighten the zero adjustment locking screw.
4. Adjust the set point pressure to the upper limit of the input span. Note whether the indication is above or below the
upper limit of the process scale.
5. 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.
6. Repeat steps 3 through 5 until the error is eliminated.
7. Adjust the remote set point pressure to 50 percent of the remote set point range.
8. Make sure the remote set point indicator is within ±1 percent of the mid‐scale mark and, if so, proceed to step 10. If
the set point indicator is not within ±1 percent but is within ±2 percent of the mid‐scale mark then proceed with
step 9. If the set point indicator is not within ±2 percent, proceed to the remote set point calibration in Section 5.
9. Loosen the zero adjustment locking screw and adjust the zero screw to correct for one‐half the error. Tighten the
locking screw.
10. Adjust the remote set point pressure to the lower and upper range limits and make sure the set point indicator is
within ±1 percent.
11. Install the proportional band indicator cover and tighten the two screws.
12. If necessary, proceed to the process indicator zero‐and‐span calibration procedure in this section. Otherwise,
proceed to the flapper alignment procedure in this section.
Flapper Alignment
Note
Perform the process indicator zero‐and‐span calibration procedure and, if necessary, the remote set point calibration procedure
before the flapper alignment.
Flapper leveling screw numbers and adjustments are shown in figure 3‐1.
Provide a means of applying supply pressure to the controller. Also, provide an accurate means of measuring output
pressure.
Apply process differential pressure to the differential pressure unit. Refer to figures 2‐1 and 2‐2 for the differential
pressure unit connections.
1. For a controller with manual set point, move the set point indicator to 50 percent of the scale range. For a controller
with remote set point (suffix letter M), adjust the remote set point pressure until the set point indicator is at 50
percent of the scale range.
2. Apply differential pressure equal to 50 percent of the input range.
Note
If a pressure source is not available to pressure the input element (differential pressure unit) to 50 percent of range, an alternate
method is to disconnect link 1 at the drive arm and tape the process indicator at 50 percent of the input range. Note the hole from
which link 1 was removed for proper replacement.

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July 2018
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This method should only be used if pressure is not available to drive the differential pressure unit to 50 percent.
3. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36). Adjust the
proportional band adjustment between DIRECT and REVERSE.
4. The controller output should be 0.62 ±0.007 bar (9 ±0.1 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or 1.2 ±0.01
bar (18 ±0.2 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output. If not, adjust flapper leveling screw number 2.
5. Adjust the proportional adjustment to 20 percent DIRECT (direct acting).
6. The controller output should be 0.62 ±0.02 bar (9 ±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not, adjust flapper
leveling screw number 3.
7. Adjust the proportional band adjustment to 20 percent REVERSE (reverse acting).
8. The controller output should be 0.62 ±0.02 bar (9 ±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not, adjust flapper
leveling screw number 1.
9. Repeat steps 5 through 8 until the output of the controller remains in tolerance without further leveling screw
adjustments.
10. If link 1 was disconnected, remove the tape and reconnect link 1 to the drive arm.
11. Set the proportional band adjustment to 400 percent in the desired controller action. Replace the proportional
band indicator cover (key 36) and install the machine screws (key 6).
Principle of Operation for 4194HA Controllers
Overall Operation
Refer to the schematic diagram in figure 3‐3.
Figure 3‐3. Schematic for Fisher 4194HA Controller
SET POINT
INDICATOR
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
BEAM
FLAPPER
NOZZLE
PROPORTIONAL
BELLOWS
RESET BELLOWS (VENTED)
PROPORTIONAL
BAND ADJUSTMENT
SUPPLY
PRESSURE
RELAY
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
REVERSE ACTION
QUADRANT
FLAPPER
PIVOT
FEEDBACK
LINK
FEEDBACK
MOTION
DIRECT ACTION
QUADRANT
INPUT MOTION
FLAPPER DETAIL
SUPPLY PRESSURE
OUTPUT PRESSURE
NOZZLE PRESSURE
46A9764‐C
B1907