Emerson Fisher 4195KA User manual

www.Fisher.com
Fisher™4195KA, KB, KC, and KS Gauge Pressure
Controllers
Contents
1. Introduction
Scope of Manual 4.............................
Description 4.................................
Specifications 4...............................
Educational Services 4.........................
2. Installation
Controller Mounting Orientation 9...............
Pipestand Mounting 10........................
Panel Mounting 10............................
Wall Mounting 11.............................
Actuator Mounting 11.........................
Pressure Connections 12.......................
Process Pressure Connection 12..............
Supply Pressure Connection 12..............
Remote Set Point (suffix letter M)
Pressure Connection 13..................
External Feedback Pressure Connection
(4195KB Controllers Only) 13.............
Vent 14......................................
3. 4195KA Proportional‐Only Controllers
Adjustments for 4195KA Controllers 15...........
Manual Set Point Adjustment 15.............
Remote Set Point (suffix letter M)
Adjustment 16..........................
Proportional Band Adjustment (PB ADJ) 16.....
Changing Controller Action 16...............
Switching The Auto/Manual Station
(suffix letter E) 17.......................
Prestartup Checks for 4195KA Controllers 17......
Startup for 4195KA Controllers 18...............
Calibration of 4195KA Controllers 18.............
General Calibration Instructions 19...........
Process Indicator Zero and Span Calibration 19.
Remote Set Point (suffix letter M)
Zero and Span Calibration 21..............
Flapper Alignment 22......................
Principle of Operation for 4195KA Controllers 23...
Overall Operation 23.......................
Remote Set Point (suffix letter M)
Operation 24...........................
Auto/Manual Station (suffix letter E)
Operation 24...........................
4. 4195KB Proportional‐Plus‐Reset
Controllers and 4195KC
Proportional‐Plus‐Reset‐Plus‐Rate Controllers
Adjustments for 4195KB and KC Controllers 25.....
Manual Set Point Adjustment 25.............
Remote Set Point (suffix letter M)
Adjustment 26..........................
Proportional Band Adjustment (PB ADJ) 26.....
Changing Controller Action 26...............
Reset Adjustment 27.......................
Rate Adjustment 27........................
Anti‐Reset Windup (suffix letter F)
Adjustment 27..........................
Switching the Auto/Manual Station
(suffix letter E) 27.......................
Prestartup Checks for 4195KB and KC
Controllers 28..............................
Startup for 4195KB and KC Controllers 28.........
Calibration of 4195KB and KC Controllers 30.......
General Calibration Instructions 30...........
Process Indicator Zero and Span
Calibration 30..........................
Remote Set Point (suffix letter M)
Zero and Span Calibration 32..............
Flapper Alignment 33......................
Anti‐Reset Windup (suffix letter F)
Differential Relief Valve Calibration 35......
Principle of Operation for 4195KB and KC
Controllers 36..............................
Overall Operation 36.......................
Anti‐Reset Windup (suffix letter F)
Operation 39...........................
Remote Set Point (suffix letter M)
Operation 39...........................
Auto/Manual Station (suffix letter E)
Operation 40...........................
External Feedback Operation 41..............
5. 4195KS Differential Gap Controllers
Operating Information 42......................
Adjustments for 4195KS Differential Gap
Controllers 43..............................
Manual Set Point 43........................
Remote Set Point (Option M) 43.............
Proportional Band (Differential Gap) 43.......
Changing Controller Action 43...............
Instruction Manual
D200160X012
4195K Controllers
July 2018

Instruction Manual
D200160X012
4195K Controllers
July 2018
2
Contents (continued)
Auto/Manual Switching (Option E) 44.........
Prestartup Checks 44..........................
Startup 44...................................
Calibration 45................................
Process Zero and Span Adjustment 45........
Remote Set Point Zero and Span
(Option M) 45..........................
Setting Switching Points 46.................
Direct‐Acting Controllers 46.................
Reverse‐Acting Controllers 48...............
Principle of Operation 48.......................
Overall Operation 48.......................
Remote Set Point (Option M) 50.............
Auto/Manual Option 50.....................
6. Maintenance
Inspection and Maintenance 51..................
Troubleshooting 51............................
Replacing Common Controller Parts 55...........
Replacing the Process Pressure Scale 55.......
Replacing the Relay 56.....................
Replacing the Case and Cover 56.............
Replacing the Gauges 57....................
Replacing the Supply Gauge, Proportional,
Reset, Reset Valve and Positive Tubing
Feedback Assemblies 58..................
Replacing the Proportional Band Adjustment
Knob, Nozzle Assembly, and Set Point
Beam Assembly 58......................
Replacing the Flapper Assembly and
Flapper Flexure Pivot Assembly 63.........
Replacing the Proportional or Reset
Bellows 68.............................
Replacing the Reset Restriction Valve
(4195KB Controllers) 70..................
Replacing the Rate/Reset Valve Assembly
(4195KC Controllers) 71..................
Replacing the Anti‐Reset Windup
(suffix letter F) Differential Relief Valve 72...
Replacing the Anti‐Reset Windup
(suffix letter F) Relief Valve Tubing
Assembly 72............................
Bourdon Tube Controller Maintenance
and Calibration 73..........................
Replacing the Bourdon Tube 73..............
Replacing Bourdon Tube Controller Links 74...
Replacing Link 1 74......................
Replacing Link 2 75......................
Replacing Link 3 76......................
Replacing Link 4 77......................
Bourdon Tube Travel Stop Installation
and Adjustment 78......................
Bourdon Tube Controller Calibration:
Zero and Span Adjustment 79.............
Capsular Element Controller Maintenance
and Calibration 82..........................
Replacing the Capsular Element
Assembly 82..........................
Replacing Capsular Element Parts 83........
Replacing the Long Pivot Assembly 83......
Replacing the Short Pivot Assembly 84......
Replacing the Process Drive Flexure 84......
Replacing the Process Tubing 85...........
Replacing Capsular Element
Controller Links 85....................
Replacing Link 1 86......................
Replacing Link 2 86......................
Replacing Link 3 87......................
Replacing Link 4 87......................
Replacing Link 5 88......................
Capsular Element Controller
Maintenance Calibration 88...............
Precalibration Procedure 89...............
Aligning the Drive Bracket Assembly 89.....
Setting the Travel Stops 89................
Aligning the Linkage 90...................
Capsular Element Controller
Zero and Span Adjustment 91.............
Remote Set Point (suffix letter M)
Maintenance 92............................
Replacing the Remote Set Point
Assembly 92............................
Replacing Remote Set Point
Assembly Parts 94.....................
Replacing Pivot Assembly A (key 114) 94....
Replacing Pivot Assembly B (key 115) 95....
Replacing the Drive Flexure 95.............
Replacing the Remote Set Point Tubing 96...
Replacing Link A 96......................
Replacing Link B 96......................
Remote Set Point (suffix letter M)
Maintenance Calibration 96..................
Precalibration Procedure 96.................
Aligning the Flexures 97....................
Setting the Travel Stops 97..................
Aligning the Linkage 98.....................
Remote Set Point Zero and Span
Adjustment 98..........................
Remote Set Point Linearity Adjustment 99.....
Auto/Manual Station (suffix letter E)
Maintenance 100...........................
Replacing the Auto/Manual Station 100.......
Replacing the Switch Body Assembly,
Lever O‐Ring, Switch Body O‐Ring,
and Tubing Assembly 101................
Replacing the Loader Range Spring,
Diaphragm Assembly, Ball Seat,
Tubing, and Ball 102.....................
Replacing the Loader Valve Plug and
Valve Plug Spring 103....................

Instruction Manual
D200160X012
4195K Controllers
July 2018
3
Figure 1‐1. Fisher 4195K Gauge Pressure Controllers
NAMEPLATE
W5663‐1 W6831
Contents (continued)
7. Parts
Parts Ordering 105............................
Parts Kits 105.................................
Parts List 105.................................
Abbreviations Used In The Parts List 105.......
Controller Common Parts 106...............
Process and Set Point Indicator
Assembly 114...........................
Indicator Assembly 116.....................
Capsular Element Assembly 117..............
Remote Set Point Assembly
(suffix letter M) 118......................
Auto/Manual Station (suffix letter E) 119.......
Controller Mounting Parts 121...............
Pipestand Mounting 121..................
Pipestand Mounting with Regulator 121.....
Panel Mounting 121......................
Wall Mounting 121.......................
Controller Mounting Parts for Actuator
with Casing‐Mounted Controller 121.....
Controller Mounting Parts for Actuator
with Yoke‐Mounted Controller 121.......
Regulator Mounting Parts 122...............
Regulator Mounting Parts for
Casing‐Mounted Regulator 122..........
Regulator Mounting Parts for
Yoke‐Mounted Regulator (Mounting
Bracket Not Required) 122..............
Regulator Mounting Parts for
Yoke‐Mounted Regulator
(With Mounting Bracket) 122............
Fittings 122...............................

Instruction Manual
D200160X012
4195K Controllers
July 2018
4
Section 1 Introduction
Scope of Manual
This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for
Fisher 4195KA, KB, KC, and KS gauge pressure indicating controllers.
Portions of this manual apply only to specific 4195K 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 shown in figure 1‐1. Refer to
table 1‐2 for the definition of each 4195K type number.
Do not install, operate, or maintain a 4195K 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.
Description
The controllers described in this manual provide gauge pressure control with the options as shown in table 1‐2.
D 4195KA: Proportional‐only control
D 4195KB: Proportional‐plus‐reset control
D 4195KC: Proportional‐plus‐reset‐plus‐rate control
D 4195KS: Differential gap control
These controllers 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.
Specifications
Specifications for 4195KA, KB, KC, and KS controllers are listed in table 1‐1.
Educational Services
For information on available courses for 4195KA, 4195KB, 4195KC, and 4195KS gauge pressure indicating 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

Instruction Manual
D200160X012
4195K Controllers
July 2018
5
Table 1‐1. Specifications
Available Configurations
See table 1‐2
Input Signal (Process Sensor Range)
Lower and Upper Range Limits: See tables 1‐3 and 1‐4
Maximum Allowable Operating Limits: See tables 1‐3
and 1‐4
Output Signal
Proportional‐Only, Proportional‐Plus‐Reset, or
Proportional‐Plus‐Reset‐Plus‐Rate Range: 0.2 to 1.0
bar or 0.4 to 2.0 bar (3 to 15 psig or 6 to 30 psig)
Differential Gap Range: 0 and 1.4 bar (0 and 20 psig)
or 0 and 2.4 bar (0 and 35 psig)
Action: Field‐reversible between direct (increasing
sensed process pressure increases output pressure)
or reverse (increasing sensed process pressure
decreases output pressure).
Process Scale
Standard scale is matched to the range of the sensing
element, with the exception of receiver controllers.
Optional(1) scales are available.
Process Connections
Standard: 1/4 NPT, internal, stainless steel
(all input ranges)
Optional: 1/2 NPT, see table 1‐5
Supply and Output Connections
1/4 NPT, internal
Supply Pressure Requirements(2)
See table 1‐6
Supply Pressure Medium
Air or Natural Gas
Supply medium must be clean, dry, and noncorrosive
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 or 0.4 to 2.0 bar
(3 to 15 psig or 6 to 30 psig)
Controller Adjustments
Proportional Band: 5 to 500% of process input span
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
Differential Gap Controllers: Adjustable from 5 to
100% of process scale range
Set Point: Adjustable from 0 to 100% of the scale span
Controller Performance
Repeatability: 0.4% of output span
Dead Band: Less than 0.4% of process scale span
Typical Frequency Response: 1.5 hertz and 90 degree
phase shift with 3.05 m (10 feet) of 6.4 mm (1/4‐inch)
tubing and 1639 cm3(100 cubic inch) volume
Steady‐State Air Consumption(3)(4)
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)
Operative Ambient Temperature Limits(2)(5)
-40 to 71_C (-40 to 160_F)
Hazardous Area Classification
Complies with the requirements of ATEX Group II
Category 2 Gas and Dust
-continued-

Instruction Manual
D200160X012
4195K Controllers
July 2018
6
Table 1‐1. Specifications (continued)
Housing
Designed to NEMA 3 (Weatherproof) and IEC 529
IP54 Specifications
Mounting
Controller can be mounted on actuator, panel, wall,
or pipestand.
Approximate Weight
4.5 kg (10 pounds)
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. Consult your Emerson sales office or Local Business Partner for additional information.
2. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded.
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. Without auto/manual station. With auto/manual station add 0.01 m3/hr (0.5 scfh) for either output range.
5. Also use these temperatures for transportation and storage limits.
Table 1‐2. Available Configurations for Fisher 4195KA, 4195KB, 4195KC, and 4195KS Controllers
CONTROLLER TYPE
NUMBER(1)
MODES OPTIONS
Proportional‐
Only
(One‐Mode
Controllers)
Proportional‐
Plus‐Reset
(Two‐Mode
Controllers)
Proportional‐
Plus‐Reset‐
Plus‐Rate
(Three‐Mode
Controllers)
Differential
Gap Controller
Internal
Auto/Manual
Station
E
Anti‐Reset
Windup
F
Remote
Setpoint
M
4195KA
4195KA
4195KAE
4195KAM
4195KAME
X
X
X
X
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
- - -
X
- - -
- - -
- - -
- - -
- - -
- - -
X
X
4195KB
4195KB
4195KBE
4195KBF
4195KBFE
4195KBM
4195KBME
4195KBFM
4195KBFME
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
X
X
X
X
X
X
X
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
- - -
X
- - -
X
- - -
X
- - -
- - -
X
X
- - -
- - -
X
X
- - -
- - -
- - -
- - -
X
X
X
X
4195KC
4195KC
4195KCE
4195KCF
4195KCFE
4195KCM
4195KCME
4195KCFM
4195KCFME
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
X
X
X
X
X
X
X
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
- - -
X
- - -
X
- - -
X
- - -
- - -
X
X
- - -
- - -
X
X
- - -
- - -
- - -
- - -
X
X
X
X
4195KS
4195KS
4195KSE
4195KSM
4195KSME
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
X
X
X
X
- - -
X
- - -
X
- - -
- - -
- - -
- - -
- - -
- - -
X
X
1. Reverse‐acting constructions are designated by the suffix letter R added to the type number.

Instruction Manual
D200160X012
4195K Controllers
July 2018
7
Table 1‐3. Process Sensor (Capsular Element) Pressure Ratings
CAPSULE
MATERIAL
CAPSULAR
STANDARD RANGES
SPAN(1) OPERATING RANGE OPERATING
LIMIT(2)
Min Max Min Max
N09902
Metric units
Positive pressure
0 to 150 mbar
0 to 400 mbar
0 to 0.6 bar
0.2 to 1 bar
0 to 1 bar
100 mbar
350 mbar
0.35 bar
0.4 bar
0.5 bar
160 mbar
700 mbar
0.7 bar
0.8 bar
1 bar
-350 mbar
-1 bar
-1 bar
-1 bar
-1 bar
350 mbar
1 bar
1 bar
1.4 bar
1.4 bar
510 mbar
1.5 bar
1.5 bar
2 bar
2 bar
0 to 1.4 bar
0 to 1.6 bar
0.4 to 2 bar
0 to 2 bar
0.7 bar
1 bar
0.8 bar
1 bar
1.4 bar
2 bar
1.6 bar
2 bar
-1 bar
-1 bar
-1 bar
-1 bar
1.7 bar
2.4 bar
2 bar
2.4 bar
2.5 bar
3.5 bar
3 bar
3.5 bar
Vacuum
-150 to 0 mbar
-340 to 0 mbar
-400 to 0 mbar
-0.6 to 0 bar
-1 to 0 bar
85 mbar
170 mbar
350 mbar
0.35 bar
0.5 bar
170 mbar
340 mbar
700 mbar
0.7 bar
1 bar
-350 mbar
-480 mbar
-1 bar
-1 bar
-1 bar
350 mbar
480 mbar
1 bar
1 bar
1.4 bar
510 mbar
724 mbar
1.5 bar
1.5 bar
2 bar
Compound
-50 to 100 mbar
-175 to 175 mbar
-150 to 250 mbar
-0.2 to 0.4 bar
100 mbar
175 mbar
350 mbar
0.35 bar
160 mbar
350 mbar
700 mbar
0.7 bar
-350 mbar
-480 mbar
-1 bar
-1 bar
350 mbar
480 mbar
1 bar
1 bar
510 mbar
724 mbar
1.5 bar
1.5 bar
-0.4 to 0.6 bar
-0.6 to 0.8 bar
-1 to 0.6 bar
-1 to 1 bar
0.5 bar
0.7 bar
1 bar
1 bar
1 bar
1.4 bar
2 bar
2 bar
-1 bar
-1 bar
-1 bar
-1 bar
1.4 bar
1.7 bar
2.4 bar
2.4 bar
2 bar
2.5 bar
3.5 bar
3.5 bar
U.S. units
Positive pressure
0 to 60 inch wc
0 to 5 psig
0 to 10 psig
3 to 15 psig
0 to 15 psig
40 inch wc
2.5 psig
5 psig
6 psig
7.5 psig
60 inch wc
5 psig
10 psig
12 psig
15 psig
-10 inch Hg
-14 inch Hg
-30 inch Hg
-30 inch Hg
-30 inch Hg
5 psig
7 psig
15 psig
20 psig
20 psig
7.5 psig
10.5 psig
22.5 psig
30 psig
30 psig
0 to 20 psig
6 to 30 psig
0 to 30 psig
10 psig
12 psig
15 psig
20 psig
24 psig
30 psig
-30 inch Hg
-30 inch Hg
-30 inch Hg
25 psig
30 psig
35 psig
37.5 psig
45 psig
52.5 psig
Vacuum
-5 to 0 inch Hg
-10 to 0 inch Hg
-20 to 0 inch Hg
-30 to 0 inch Hg
2.5 inch Hg
5 inch Hg
10 inch Hg
15 inch Hg
5 inch Hg
10 inch Hg
20 inch Hg
30 inch Hg
-10 inch Hg
-14 inch Hg
-30 inch Hg
-30 inch Hg
5 psig
7 psig
15 psig
20 psig
7.5 psig
10.5 psig
22.5 psig
30 psig
Compound
-30 to 30 inch wc
-5 inch Hg to 2.5 psig
-10 inch Hg to 5 psig
40 inch wc
2.5 psig
5 psig
60 inch wc
5 psig
10 psig
-10 inch Hg
-14 inch Hg
-30 inch Hg
5 psig
7 psig
15 psig
7.5 psig
10.5 psig
22.5 psig
-15 inch Hg to 7.5 psig
-20 inch Hg to 10 psig
-30 inch Hg to 15 psig
7.5 psig
10 psig
15 psig
15 psig
20 psig
30 psig
-30 inch Hg
-30 inch Hg
-30 inch Hg
20 psig
25 psig
35 psig
30 psig
37.5 psig
52.5 psig
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 350 mbar (0 to 5 psig) sensing element is used and the
minimum span of 1.75 mbar (2.5 psig) is set, the process indication can be calibrated to a range of -340 mbar to -203 mbar (-10 inch Hg to -6 inch Hg), 0 to 172 mbar (0 to 2.5 psig),
172 to 345 mbar (2.5 to 5 psig), 305 to 480 mbar (4.5 to 7 psig), 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.

Instruction Manual
D200160X012
4195K Controllers
July 2018
8
Table 1‐4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials
BOURDON TUBES SPAN(1) OPERATING RANGE(2) OPERATING
LIMITS(4)
STANDARD
MATERIAL
Minimum Maximum Minimum Maximum(3)
Bar
Metric units
0 to 1.6
0 to 2.5
0 to 4
0 to 6
1
2
2
3.5
2
4
4
7
-1
-1
-1
-1
3
6
6
10
3.3
6.6
6.6
11
S31600 (316 SST)
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 160
0 to 300
55
76
160
250
70
100
200
350
0
0
0
0
90
135
270
420
103
155
310
482
Psig Psig Psig Inch Hg Psig Psig STANDARD
MATERIAL
U.S. units
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
S31600 (316 SST)
0 to 300
0 to 600
0 to 1000
0 to 1500
150
300
750
1100
300
600
1000
1500
-30
0
0
0
420
840
1300
1950
480
960
1500
2250
0 to 3000
0 to 5000
2200
3700
3000
5000
0
0
3900
6000
4500
7000
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 2 bar (0 to 30 psig) sensing element is used and the
minimum span of 1 bar (15 psig) is set, the process indication can be calibrated to a range of -1 to 0 bar (-30 inch Hg to 0 psig), 0 to 1 bar (0 to 15 psig), 1 to 2 bar (15 to 30 psig), 2 to 3 bar (27
to 42 psig) 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 2 bar (0 to 30 psig) sensing element is
calibrated for 0.7 to 2 bar (10 to 30 psig), the desired range. The minimum expected pressure is 0 psig and the maximum expected pressure is 2.8 bar (40 psig). Travel stops must be used to
prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5% of the 1.4 bar (20 psig) span which is ±70 mbar (±1 psig).
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.
Table 1‐5. Optional Process Connections
INPUT RANGE CONNECTION
Bar Psig Size Material
Up to
0 to 400
Up to
0 to 5000
J1/2 NPT external
or J1/2 NPT
internal
JSteel or
Jstainless
steel
0 to 400 to
0 to 600
0 to 5000 to
0 to 10,000 1/2 NPT internal Stainless steel
0 to 400 to
0 to 600
0 to 5000 to
0 to 10,000 1/2 NPT external Stainless steel
Table 1‐6. Supply Pressure Data
Output Range Signal Normal Operating
Supply Pressure (1)
Maximum
Pressure Limit (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 may be impaired.
2. If this pressure is exceeded, damage to the controller may result.

Instruction Manual
D200160X012
4195K Controllers
July 2018
9
Section 2 Installation
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 14.
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.
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.
Controller Mounting Orientation
Mount the controller with the housing vertical, as shown in figure 2‐1, so the vent points down.
MOUNTING PLATE
FISHER 657 ACTUATOR
4195K
CONTROLLER
67CFR
FILTER
REGULATOR
W8462-1
Figure 2‐1. Typical Actuator Mounting

Instruction Manual
D200160X012
4195K Controllers
July 2018
10
Pipestand Mounting
Refer to figure 2‐2. 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.
Figure 2‐2. Pipestand Mounting
49A3196‐A
A6732
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
HEX NUT
(KEY 364)
LOCKWASHER
(KEY 363)
PIPE CLAMP
(KEY 69)
LOCKWASHER
(KEY 363)
HEX NUT
(KEY 364)
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 362)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
REGULATOR
HEX HEAD
CAP SCREW
(KEY 362)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
PIPE CLAMP
(KEY 69)
VERTICAL PIPE
HORIZONTAL PIPE
Panel Mounting
Using the dimensions shown in figure 2‐3, cut a hole in the panel surface. 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 seat the case snugly and evenly against the panel surface.

Instruction Manual
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4195K Controllers
July 2018
11
Figure 2‐3. Panel Mounting HEX HEAD
CAP SCREW
(KEY 66)
LOCK
WASHER
(KEY 67)
ROUND
HEAD
MACHINE
SCREW
(KEY 70)
BRACKET
(KEY 68)
TOP VIEW
36A9760‐A
A6733
84
(3.29)
63
(2.49)
306
(12.06)
14
(0.56 R)
236
(9.31)
mm
(INCH)
13
(0.50)
62
(2.43)
REAR VIEW
DIMENSIONS OF
PANEL CUTOUT
Wall Mounting
Using the dimensions in figure 2‐4, drill holes in the wall to align with the four holes in the bracket (key 68). If the
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.
Figure 2‐4. Wall Mounting
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
BRACKET
(KEY 68)
TOP VIEW
36A9761‐B
A6734
161
(6.35)
260
(10.25)
152
(6.00)
62
(2.43)
13
(0.50)
13
(0.50)
REAR VIEW mm
(INCH)
Actuator Mounting
Refer to figure 2‐1. A controller specified for mounting on a control valve actuator is 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.
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.

Instruction Manual
D200160X012
4195K Controllers
July 2018
12
Pressure Connections
WARNING
To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any system
component 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 figure 2‐5 for pressure connection locations. Supply, output, remote set point, external feedback, and vent
connections are 1/4 NPT, internal. Process pressure connections are 1/4 or 1/2 NPT (optional). Use 1/4‐inch or 3/8‐inch
pipe or tubing for supply, output, remote set point, and external feedback connections.
Process Pressure Connection
The connection marked A on the bottom of the case is the process input for all Bourdon tube controllers and those
capsular element controllers used in vacuum pressure applications. The connection marked B is the process input for
capsular element controllers used in positive pressure and compound pressure applications. See figure 2‐5 for the
location of the A and B connections.
When installing process piping, follow accepted practices to ensure accurate transmission of the process pressure to
the controller. Install a three‐valve bypass, shutoff valves, vents, drains, or seal systems as needed in the process
pressure lines. If necessary, install a needle valve in a process pressure sensing line to dampen pulsations.
If the instrument is located such that the adjacent process pressure lines are approximately horizontal, the lines should
slope downward to the instrument for liquid‐filled lines and upward toward the instrument for gas‐filled lines. This
reduces the possibility of air becoming trapped in the sensor with liquid‐filled lines or of condensation becoming
trapped in gas‐filled lines. The recommended slope is 83 millimeters per m (1 inch per foot).
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.
Supply Pressure Connection
WARNING
Severe personal injury or property damage may occur if the instrument air supply is not clean, dry and oil‐free, or
noncorrosive gas. While use and regular maintenance of a filter that removes particles larger than 40 micrometers 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.

Instruction Manual
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4195K Controllers
July 2018
13
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 the normal operating supply pressure
shown in table 1‐6. Connect supply pressure to the SUPPLY connection on the bottom of the case, shown in figure 2‐5.
Remote Set Point (suffix letter M) Pressure Connection
If the controller has remote set point (suffix letter M), connect the remote set point pressure to the top of the
controller case at the location shown in figure 2‐5. Use clean, dry air or noncorrosive gas. Use a 0.2 to 1.0 bar (3 to 15
psig) remote set point pressure range for a 0.2 to 1.0 bar (3 to 15 psig) controller output signal range or a 0.4 to 2.0
bar (6 to 30 psig) remote set point pressure range for a 0.4 to 2.0 bar (6 to 30 psig) controller output signal range. 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 Pressure Connection (4195KB 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 figures 2‐5 and 4‐9).
Figure 2‐5. Connection Locations
260
(10.25)
102
(4.00)
130
(5.13)
51
(2.00)
330
(13.00)
3.44
(87)
10.04
(255)
5/16
UNC‐28
3 HOLES
(MOUNTING)
1/4‐18 NPT CONTROLLER
OUTPUT CONNECTION
1/4‐18 NPT
SUPPLY PRESSURE
CONNECTION
1/4 NPT
REMOTE SET POINT CONNECTION
147
(5.80)
66
(2.56)
31
(1.22)
1/4 NPT 4 HOLES
1/4‐18
NPT VENT
CONNECTION
mm
(INCH)
FRONT VIEW REAR VIEW
BOTTOM VIEW TOP VIEW
NOTES:
1 1/4‐18 NPT PROCESS CONNECTION (MARKED A) FOR ALL BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR
ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.
2 1/4‐18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND PRESSURE APPLICATIONS.
3 FOR THE EXTERNAL FEEDBACK CONNECTIONS (4195KB CONTROLLERS ONLY), EITHER THE A OR B CONNECTION IS USED, DEPENDING ON THE
LOCATION OF THE PROCESS CONNECTION.
46A9765‐A
A2892‐4

Instruction Manual
D200160X012
4195K Controllers
July 2018
14
Vent
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 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 as 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 meters (20 feet) and
a minimum inside diameter of 25 mm (1 inch) for runs from 6.1 to 30.5 meters (20 to 100 feet).
The vent must be protected against the entrance of any foreign material that could plug it; or if a remote vent is not
required, the vent opening in the case 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.

Instruction Manual
D200160X012
4195K Controllers
July 2018
15
Section 3 4195KA Proportional‐Only Controllers
Adjustments for 4195KA Controllers
This section includes descriptions of adjustments and procedures for prestartup, startup, and calibration. Adjustment
locations are shown in figures 3‐1 and 3‐3. To better understand the adjustments and overall controller operation,
refer to the Principle of Operation section and the schematic diagrams in figures 3‐4 and 3‐5. Unless otherwise noted,
key numbers given in this section are found in figure 7‐1.
Figure 3‐1. Fisher 4195KA Controller Adjustment Locations
METAL BALL
SWITCHING
ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
W3679
AUTO/MANUAL STATION
(SUFFIX LETTER E)
SET POINT
INDICATOR
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE GAUGE
W6832
Manual Set Point Adjustment
Adjust the set point by moving the set point indicator until the line on the set point indicator is over the desired value
on the process pressure scale. Move the indicator to the right to increase the set point and to the left to decrease it.
Adjusting the set point does not affect the proportional band setting.

Instruction Manual
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4195K Controllers
July 2018
16
Remote Set Point (suffix letter M) Adjustment
CAUTION
Do not manually move the set point indicator on controllers with remote set point. Manually moving the set point indicator
could damage the controller.
If the controller is equipped with remote set point (suffix letter M), 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.
Proportional Band Adjustment (PB ADJ)
The proportional band determines the controller output sensitivity. The proportional band adjustment is marked in
percentages of process pressure required to drive the controller from zero output to full output.
To adjust the proportional band, open the controller cover and locate the proportional band adjustment (PB ADJ)
knob. Rotate the knob until the desired value is opposite the line on the proportional band indicator cover.
Changing Controller Action
To change the controller action from direct to reverse or vice versa, loosen the screws on the proportional band
indicator cover. Lift the cover out as shown in figure 3‐2 and rotate the proportional band adjustment to the desired
action. Setting the proportional band to the values in the white portion of the adjustment provides direct controller
action; setting proportional band in the black portion provides reverse controller action.
Figure 3‐2. Changing Controller Action on Fisher 4195KA Controllers
W3439
Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure
D For direct control action—An increasing sensed pressure increases output pressure.
D For reverse control action—An increasing sensed pressure decreases output pressure.
Capsular Element Controllers for Vacuum Pressure
D For direct control action—An increasing sensed vacuum increases output pressure.

Instruction Manual
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4195K Controllers
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D For reverse control action—An increasing sensed vacuum decreases output pressure.
After changing the action, tighten the screws on the proportional band indicator cover.
Switching The Auto/Manual Station (suffix letter E)
Note
Switching the controller between automatic and manual, or manual and automatic mode, without balancing the outputs, can
disturb the process and cause controller cycling.
Refer to figure 3‐1 if the controller has the auto/manual station (suffix letter E). To switch from automatic to manual
mode, or from manual to automatic, you must first 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 to move the ball into the switching zone. Turn the
switch to AUTO and adjust the set point to control the output.
When the auto/manual switch is in AUTO, adjusting the loader knob has no effect on the controller output. When the
auto/manual switch is in MANUAL, changing the set point has no effect on the controller output.
Prestartup Checks for 4195KA Controllers
Refer to figure 3‐1 for adjustment locations and refer to figure 7‐1 for key number locations.
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 station (suffix letter E), be sure the controller is in the automatic mode before performing the
prestartup checks.
1. Provide a means of measuring the controller output pressure by connecting the controller output to a pressure
gauge. Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply
pressure to the controller. Do not exceed the normal operating pressure in table 1‐6.
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 2.1 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. Adjust the set point a minimum of 20 percent of input span above the process pointer.
5. Adjust the proportional band for 5 percent DIRECT.
6. If necessary, connect a pressure source to the process connection and adjust the process pointer to the last mark on
the left side of the scale. If the last scale mark is 0 psig, a pressure source is not required.

Instruction Manual
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4195K Controllers
July 2018
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7. The controller output pressure should be 0 bar (0 psig).
8. Rotate the proportional band to 5 percent REVERSE.
9. The controller output should be within 0.14 bar (2 psig) of the supply pressure.
10. If the controller output is within tolerance, adjust the proportional band to 400 percent in the desired action, secure
the proportional band indicator cover (key 36) with the machine screws (key 6), and go to the startup procedure. If
the controller output pressure is not within tolerance, go to the 4195KA calibration procedure for recalibration.
Startup for 4195KA Controllers
Perform the prestartup checks and, if necessary, calibrate the controller prior to this procedure.
Note
When performing the startup procedures, keep in mind that 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:
Manual set point:
Move the set point adjustment to the desired set point.
Remote set point:
a. See figure 2‐5 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.
3. Set the proportional band adjustment to 100 percent for fast processes. For slow processes, calculate the
proportional band percentage from the equation below:
P.B. +200 Allowable Overshoot
Pressure Span
For example:
200 0.14 bar
2.1 bar ^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 x2).
5. Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring
the process.
Calibration of 4195KA 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.

Instruction Manual
D200160X012
4195K Controllers
July 2018
19
General Calibration Instructions
Note
If the controller has the auto/manual station (suffix letter E), be sure the controller is in the automatic mode before performing
calibration.
If the prestartup checks, or startup, reveal faulty controller operation, perform the calibration described in this section.
These instructions are valid for either shop or field calibration, provided that open process loop conditions exist. Unless
otherwise noted, key numbers are found in figure 7‐1.
Do not use the gauges supplied with the controller during calibration. Monitor process pressure, supply pressure,
controller output pressure, and if applicable, remote set point pressure with external gauges.
Process Indicator Zero and Span Calibration
Before starting this procedure:
D Provide a regulated process pressure to the controller and a means of measurement external to the controller.
D Provide a means of measuring the controller output pressure by connecting the controller output to a pressure
gauge (open loop conditions must exist). Provide a regulated supply pressure to the controller. Do not exceed the
normal operating pressure in table 1‐6.
Refer to figures 3‐1 and 3‐3 for adjustment locations.
Note
Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment.

Instruction Manual
D200160X012
4195K Controllers
July 2018
20
Figure 3‐3. Fisher 4195KA Controller Calibration Adjustment Locations
PROCESS
POINTER SPAN
ADJUSTMENT
REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)
SCREW 1
SCREW 2
SCREW 3
SIDE VIEW OF SET POINT/
PROCESS INDICATOR ASSEMBLY
SIDE VIEW OF CONTROLLER
SHOWING FLAPPER LEVELING SCREWS
56A9752‐S SHT 1
39A1126‐B
A6730
POINTER ZERO
ADJUSTMENT
POINTER ZERO
ADJUSTMENT
LOCKING SCREW
PROCESS POINTER
SPAN ADJUSTMENT
REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)
REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)
FRONT VIEW
W6832