Emerson Fisher KC Series User manual

www.Fisher.com
D200160X012
Instruction Manual
Form 5207
April 2007 4195KA, KB, KC, and KS Controllers
4195KA, KB, KC, and KS Series Gauge
Pressure Controllers
Contents
1. Introduction
Scope of Manual 1-3. . . . . . . . . . . . . . . . . . . . . . . .
Description 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Educational Services 1-4. . . . . . . . . . . . . . . . . . . .
2. Installation
Controller Mounting Orientation 2-1. . . . . . . . . . .
Pipestand Mounting 2-1. . . . . . . . . . . . . . . . . . . . .
Panel Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . .
Wall Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Mounting 2-1. . . . . . . . . . . . . . . . . . . . . .
Pressure Connections 2-2. . . . . . . . . . . . . . . . . . .
Process Pressure Connection 2-3. . . . . . . . . . .
Supply Pressure Connection 2-4. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Pressure Connection 2-4. . . . . . . . . . . . . . . .
External Feedback Pressure Connection
(4195KB Series Controllers Only) 2-4. . . . . .
Vent 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. 4195KA Series Proportional-Only Controllers
Adjustments for 4195KA Series Controllers 3-1.
Manual Set Point Adjustment 3-1. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Adjustment 3-1. . . . . . . . . . . . . . . . . . . . . . . . .
Proportional Band Adjustment (PB ADJ) 3-1. .
Changing Controller Action 3-2. . . . . . . . . . . . . .
Switching The Auto/Manual Station
(suffix letter E) 3-2. . . . . . . . . . . . . . . . . . . . . .
Prestartup Checks for 4195KA Series
Controllers 3-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Startup for 4195KA Series Controllers 3-3. . . . .
Calibration of 4195KA Series Controllers 3-4. . .
General Calibration Instructions 3-4. . . . . . . . .
Process Indicator Zero and Span
Calibration 3-4. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 3-6. . . . . . . . . . . .
Flapper Alignment 3-6. . . . . . . . . . . . . . . . . . . . .
Principle of Operation for 4195KA Series
Controllers 3-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Operation 3-7. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .
4. 4195KB Series Proportional-Plus-Reset
Controllers and 4195KC Series
Proportional-Plus-Reset-Plus-Rate Controllers
Adjustments for 4195KB and KC Series
Controllers 4-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Set Point Adjustment 4-1. . . . . . . . . . . .
Remote Set Point (suffix letter M)
Adjustment 4-1. . . . . . . . . . . . . . . . . . . . . . . . .
Proportional Band Adjustment (PB ADJ) 4-2. .
Changing Controller Action 4-2. . . . . . . . . . . . . .
Reset Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . .
Rate Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . . . .
Switching the Auto/Manual Station
(suffix letter E) 4-3. . . . . . . . . . . . . . . . . . . . . .
Prestartup Checks for 4195KB and
KC Series Controllers 4-3. . . . . . . . . . . . . . . . .
Startup for 4195KB and KC Series
Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of 4195KB and KC Series
Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .
General Calibration Instructions 4-5. . . . . . . . .
Process Indicator Zero and Span
Calibration 4-5. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 4-5. . . . . . . . . . . .
Flapper Alignment 4-7. . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Differential Relief Valve Calibration 4-9. . . .
Principle of Operation for 4195KB and
KC Series Controllers 4-10. . . . . . . . . . . . . . . .
Overall Operation 4-10. . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
External Feedback Operation 4-13. . . . . . . . . .

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-2
Contents (continued)
5. 4195KS Series Differential Gap Controllers
Operating Information 5-1. . . . . . . . . . . . . . . . . . .
Adjustments for 4195KS Series Differential
Gap Controllers 5-1. . . . . . . . . . . . . . . . . . . . . .
Manual Set Point 5-1. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (Option M) 5-1. . . . . . . . . . . .
Proportional Band (Differential Gap) 5-1. . . . . .
Changing Controller Action 5-1. . . . . . . . . . . . . .
Auto/Manual Switching (Option E) 5-1. . . . . . .
Prestartup Checks 5-2. . . . . . . . . . . . . . . . . . . . . .
Startup 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Zero and Span Adjustment 5-3. . . . . .
Remote Set Point Zero and Span
(Option M) 5-4. . . . . . . . . . . . . . . . . . . . . . . . .
Setting Switching Points 5-5. . . . . . . . . . . . . . . .
Direct-Acting Controllers 5-5. . . . . . . . . . . . . . .
Reverse-Acting Controllers 5-5. . . . . . . . . . . . .
Principle of Operation 5-7. . . . . . . . . . . . . . . . . . .
Overall Operation 5-7. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (Option M) 5-8. . . . . . . . . . . .
Auto/Manual Option 5-8. . . . . . . . . . . . . . . . . . . .
6. Maintenance
Inspection and Maintenance 6-1. . . . . . . . . . . . . .
Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . .
Replacing Common Controller Parts 6-1. . . . . . .
Replacing the Process Pressure Scale 6-5. . .
Replacing the Relay 6-6. . . . . . . . . . . . . . . . . . . .
Replacing the Case and Cover 6-6. . . . . . . . . .
Replacing the Gauges 6-6. . . . . . . . . . . . . . . . . .
Replacing the Supply Gauge, Proportional,
Reset, Reset Valve and Positive Tubing
Feedback Assemblies 6-7. . . . . . . . . . . . . . .
Replacing the Proportional Band Adjustment
Knob, Nozzle Assembly, and Set Point
Beam Assembly 6-7. . . . . . . . . . . . . . . . . . . . .
Replacing the Flapper Assembly and
Flapper Flexure Pivot Assembly 6-11. . . . . .
Replacing the Proportional or Reset
Bellows 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Reset Restriction Valve
(4195KB Series) 6-17. . . . . . . . . . . . . . . . . . .
Replacing the Rate/Reset Valve Assembly
(4195KC Series) 6-18. . . . . . . . . . . . . . . . . . .
Replacing the Anti-Reset Windup
(suffix letter F) Differential Relief Valve 6-19
Replacing the Anti-Reset Windup
(suffix letter F) Relief Valve Tubing
Assembly 6-19. . . . . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Maintenance
and Calibration 6-20. . . . . . . . . . . . . . . . . . . . . .
Replacing the Bourdon Tube 6-20. . . . . . . . . . .
Replacing Bourdon Tube Controller Links 6-20
Replacing Link 1 6-20. . . . . . . . . . . . . . . . . . . .
Replacing Link 2 6-21. . . . . . . . . . . . . . . . . . . .
Replacing Link 3 6-22. . . . . . . . . . . . . . . . . . . .
Replacing Link 4 6-22. . . . . . . . . . . . . . . . . . . .
Bourdon Tube Travel Stop Installation
and Adjustment 6-23. . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Calibration:
Zero and Span Adjustment 6-24. . . . . . . . . .
Capsular Element Controller Maintenance
and Calibration 6-27. . . . . . . . . . . . . . . . . . . . . .
Replacing the Capsular Element
Assembly 6-27. . . . . . . . . . . . . . . . . . . . . . .
Replacing Capsular Element Parts 6-27. . . .
Replacing the Long Pivot Assembly 6-27. . .
Replacing the Short Pivot Assembly 6-28. . .
Replacing the Process Drive Flexure 6-28. .
Replacing the Process Tubing 6-29. . . . . . . .
Replacing Capsular Element
Controller Links 6-29. . . . . . . . . . . . . . . . . .
Replacing Link 1 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 2 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 3 6-30. . . . . . . . . . . . . . . . . . . .
Replacing Link 4 6-31. . . . . . . . . . . . . . . . . . . .
Replacing Link 5 6-31. . . . . . . . . . . . . . . . . . . .
Capsular Element Controller
Maintenance Calibration 6-32. . . . . . . . . . . . .
Precalibration Procedure 6-32. . . . . . . . . . . .
Aligning the Drive Bracket Assembly 6-32. .
Setting the Travel Stops 6-32. . . . . . . . . . . . .
Aligning the Linkage 6-33. . . . . . . . . . . . . . . .
Capsular Element Controller
Zero and Span Adjustment 6-34. . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance 6-36. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Remote Set Point
Assembly 6-36. . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Remote Set Point
Assembly Parts 6-36. . . . . . . . . . . . . . . . . .
Replacing Pivot Assembly A (key 114) 6-36.
Replacing Pivot Assembly B (key 115) 6-37.
Replacing the Drive Flexure 6-37. . . . . . . . . .
Replacing the Remote Set Point Tubing 6-38
Replacing Link A 6-38. . . . . . . . . . . . . . . . . . .
Replacing Link B 6-38. . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance Calibration 6-38. . . . . . . . . . . . . .
Precalibration Procedure 6-38. . . . . . . . . . . . . .
Aligning the Flexures 6-39. . . . . . . . . . . . . . . . . .
Setting the Travel Stops 6-39. . . . . . . . . . . . . . .
Aligning the Linkage 6-39. . . . . . . . . . . . . . . . . .
Remote Set Point Zero and Span
Adjustment 6-40. . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point Linearity Adjustment 6-41. .
Auto/Manual Station (suffix letter E)
Maintenance 6-41. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Auto/Manual Station 6-41. . . . . .

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-3
NAMEPLATE
W5663-1 / IL W6831 / IL
Figure1-1. 4195K Series Gauge Pressure Controllers
Contents (continued)
Replacing the Switch Body Assembly,
Lever O-Ring, Switch Body O-Ring,
and Tubing Assembly 6-42. . . . . . . . . . . . . . .
Replacing the Loader Range Spring,
Diaphragm Assembly, Ball Seat,
Tubing, and Ball 6-43. . . . . . . . . . . . . . . . . . . .
Replacing the Loader Valve Plug and
Valve Plug Spring 6-44. . . . . . . . . . . . . . . . . .
7. Parts
Parts Ordering 7-1. . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations Used In The Parts List 7-1. . . . .
Controller Common Parts 7-1. . . . . . . . . . . . . . .
Process and Set Point Indicator
Assembly 7-11. . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Assembly 7-14. . . . . . . . . . . . . . . . . . .
Capsular Element Assembly 7-14. . . . . . . . . . .
Remote Set Point Assembly
(suffix letter M) 7-16. . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E) 7-17. . . . .
Controller Mounting Parts 7-19. . . . . . . . . . . . . .
Pipestand Mounting 7-19. . . . . . . . . . . . . . . . .
Pipestand Mounting with Regulator 7-19. . .
Panel Mounting 7-19. . . . . . . . . . . . . . . . . . . .
Wall Mounting 7-19. . . . . . . . . . . . . . . . . . . . . .
Controller Mounting Parts for Actuator
with Casing-Mounted Controller 7-19. . . .
Controller Mounting Parts for Actuator
with Yoke-Mounted Controller 7-19. . . . . .
Regulator Mounting Parts 7-19. . . . . . . . . . . . . .
Regulator Mounting Parts for
Casing-Mounted Regulator 7-19. . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator (Mounting
Bracket Not Required) 7-19. . . . . . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator
(With Mounting Bracket) 7-19. . . . . . . . . . .
Fittings 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1
Introduction
Scope of Manual
This instruction manual provides installation,
operating, calibration, maintenance, and parts
ordering information for 4195KA, KB, KC, and KS
Series gauge pressure indicating controllers.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-4
Portions of this manual apply only to specific 4195K
Series 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 Series type number.
Do not install, operate, or maintain this product
without first Dbeing fully trained and qualified in
valve, actuator, and accessory installation,
operation, and maintenance, and Dcarefully reading
and understanding the contents of this manual. If
you have any questions about these instructions,
contact your Emerson Process Managementtsales
office before proceeding.
Description
The controllers described in this manual provide
gauge pressure control with the options as shown in
table 1-2.
D4195KA Series: Proportional-only control
D4195KB Series: Proportional-plus-reset control
D4195KC Series:
Proportional-plus-reset-plus-rate control
D4195KS Series: 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 the 4195KA, KB, KC, and KS
Series controllers are listed in table 1-1.
Educational Services
For information on available courses for the 4195KA,
4195KB, 4195KC, and 4195KS Series gauge
pressure indicating controllers, as well as a variety
of other products, contact:
Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158−2823
Phone: 800−338−8158 or
Phone: 641−754−3771
FAX: 641−754−3431
e-mail: [email protected]
Note
Neither Emerson, Emerson Process
Management, nor any of their affiliated
entities assumes responsibility for the
selection, use, and maintenance of
any product. Responsibility for the
selection, use, and maintenance of
any product remains with the
purchaser and end-user.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-5
Table1-1. Specifications
Available Configurations
See table 1-2
Input Signal (Process Sensor Range(1))
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(1)
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(2) 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(3)
See table 1-6
Supply Pressure Medium
Air or natural gas(4)
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(1):5 to 500% of process
input span
Reset(1):Adjustable from 0.01 to more than 74
minutes per repeat (from 100 to less than 0.0135
repeats per minute)
Rate(1):Adjustable from 0 to 20 minutes
Differential Gap(1) Controllers: Adjustable from
5 to 100% of process scale range
Set Point: Adjustable from 0 to 100% of the scale
span
Controller Performance
Repeatability(1):0.4% of output span
Dead Band(1):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(1,5,6)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 0.1 normal
m3/hr (3.5 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 0.14 normal
m3/hr (5.0 scfh)
Delivery Capacity(5)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 5.9 normal
m3/hr (240 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 10.4 normal
m3/hr (350 scfh)
Operative Ambient Temperature Limits(1,3,7)
−40 to 71_C (−40 to 160_F)
Exhaust Capacity(5)
0.2 to 1.0 Bar (3 to 15 Psig) Output: 4.6 normal
m3/hr (186 scfh)
0.4 to 2.0 Bar (6 to 30 Psig) Output: 7.0 normal
m3/hr (295 scfh)
Hazardous Area Classification
Complies with the requirements of ATEX Group II
Category 2 Gas and Dust
continued

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-6
Table1-1. 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 3
paragraph 3 of the Pressure Equipment Directive
(PED) 97 / 23 / EC. 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.
1. These terms are defined in ISA Standard S51.1.
2. Consult your Emerson sales office for additional information.
3. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded.
4. This product can be used with natural gas. Natural gas should not contain more than 20 ppm of H2S.
5. 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).
6. Without auto/manual station. With auto/manual station, air consumption is 0.28 normal m3/hr (10.0 Scfh) for either output range.
7. Also use these temperatures for transportation and storage limits.
Table 1-2. Available Configurations for 4195KA, 4195KB, 4195KC, and 4195KS Series Controllers
SERIES 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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-7
Table 1-3. Process Sensor (Capsular Element) Pressure Ratings
CAPSULE
MATERIAL CAPSULAR STANDARDRANGES 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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
1-8
Table 1-4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials
BOURDONTUBES 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 SIGNAL
RANGE 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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-1
Section 2
Installation
WARNING
To avoid personal injury or property
damage resulting from the sudden
release of pressure:
DAlways wear protective clothing,
gloves, and eyewear when performing
any installation operations.
DPersonal injury or property
damage may result from fire or
explosion if natural gas is used as the
supply medium and preventative
measures are not taken. Preventative
measures may include: 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 2-5.
DCheck with your process or
safety engineer for any additional
measures that must be taken to
protect against process media.
DIf 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
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.
MOUNTING
PLATE
TYPE 657
ACTUATOR
TYPE 4195K
CONTROLLER
TYPE 67CFR
FILTER
REGULATOR
W8462−1
Figure2-1. Typical Actuator Mounting
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.
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.
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-2
49A3196-A
A6732 / IL
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
Figure2-2. Pipestand Mounting
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.
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.
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-3
HEX HEAD
CAP SCREW
(KEY 66)
LOCK
WASHER
(KEY 67)
ROUND
HEAD
MACHINE
SCREW
(KEY 70)
BRACKET
(KEY 68)
TOP VIEW
36A9760-A
A6733 / IL
84
(3.29)
63
(2.49)
306
(12.06)
14 R
(0.56)
236
(9.31)
mm
(INCH)
13
(0.50)
62
(2.43)
REAR VIEW DIMENSIONS OF
PANEL CUTOUT
Figure2-3. Panel Mounting
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,
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
BRACKET
(KEY 68)
TOP VIEW
36A9761-B
A6734 / IL
161
(6.35)
260
(10.25)
152
(6.00)
62
(2.43)
13
(0.50)
REAR VIEW
mm
(INCH)
13
(0.50)
Figure2-4. Wall Mounting
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-4
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
microns in diameter will suffice in
most applications, check with an
Emerson Process Management 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.
Supply pressure must be clean, dry air or
noncorrosive gas that meets the requirements of
ISA Standard S7.3. 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.
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:
1/4-18 NPT PROCESS CONNECTION (MARKED A) FOR ALL
BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR
ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.
1/4-18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR
ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND
PRESSURE APPLICATIONS.
FOR THE EXTERNAL FEEDBACK CONNECTIONS (4195KB CONTROLLERS
ONLY), EITHER THE A OR B CONNECTION IS USED, DEPENDING ON THE
LOCATION OF THE PROCESS CONNECTION.
1
46A9765-A
A2892-4 / IL
2
3
Figure2-5. Connection Locations
External Feedback Pressure Connection
(4195KB Series 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).

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-5
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
2-6

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-1
METAL BALL
SWITCHING ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
W3679 / IL
AUTO/MANUAL STATION
(SUFFIX LETTER E)
SET POINT
INDICATOR
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE
GAUGE
W6832 / IL
Figure3-1. 4195KA Series Controller Adjustment Locations
Section 3
4195KA Series Proportional-Only
Controllers
Adjustments for 4195KA Series
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.
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.
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-2
W3439 / IL Figure3-2. Changing Controller Action on
4195KA Series Controllers
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.
Bourdon Tube or Capsular Element Controllers
for Positive or Compound Pressure
DFor direct control action:
An increasing sensed pressure increases output
pressure.
DFor reverse control action:
An increasing sensed pressure decreases output
pressure.
Capsular Element Controllers for Vacuum
Pressure
DFor direct control action:
An increasing sensed vacuum increases output
pressure.
DFor 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 Series
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.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-3
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.
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
Series calibration procedure for recalibration.
Startup for 4195KA Series 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
×2).
5. Check the stability of the recommended
proportional band setting by introducing a
disturbance and monitoring the process.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-4
Calibration of 4195KA Series
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
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:
DProvide a regulated process pressure to the
controller and a means of measurement external to
the controller.
DProvide 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.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply process pressure equal to the process
scale span lower limit.
4. The process pointer should indicate the process
scale lower limit. If not, adjust the process pointer to
the process scale lower limit by loosening the zero
adjustment locking screw and turning the zero
adjustment screw. Tighten the zero adjustment
locking screw.
5. Apply process pressure equal to the process
scale span upper limit.
6. The process pointer should indicate the process
scale upper limit. If not, adjust the span screw to
correct one-half of the error as follows: clockwise to
increase span for a low indication (below the upper
limit); counterclockwise to decrease span for a high
indication (above the upper limit).
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate the mid-scale mark, ±2
percent of span. If the error is greater than ±2
percent, refer to the Maintenance section and
perform the appropriate zero and span adjustment
procedure for a Bourdon tube or capsular element
controller.
9. Adjust the process pointer to within ±1 percent of
the mid-scale mark by loosening the locking screw
and turning the zero adjustment screw. This
distributes the error over the entire scale span and
brings all points within ±1 percent of the process
input span.
10. Apply process pressure equal to the process
scale span lower limit.
11. The process pointer should indicate the process
scale lower limit ±1 percent of the scale span.
12. Apply process pressure equal to the process
scale span upper limit.
13. The process pointer should indicate the process
scale upper limit ±1 percent of the scale span.
14. If the error is greater than ±1 percent, repeat
steps 3 through 13.

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-5
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 / IL
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 / IL
Figure3-3. 4195KA Series Controller Calibration Adjustment Locations

4195KA, KB, KC, and KS Controllers
Instruction Manual
Form 5207
April 2007
3-6
Remote Set Point (suffix letter M) Zero
and Span Calibration
Refer to figures 3-1 and 3-3 for adjustment
locations. Refer to figure 7-1 for key number
locations.
Note
Any adjustment of the remote set
point span adjustment screw requires
readjustment of the remote set point
zero adjustment screw.
1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).
2. Set the proportional band between DIRECT and
REVERSE.
3. Apply remote set point pressure equal to the
lower range limit.
4. The set point indicator should indicate the
process scale lower limit. If not, loosen the remote
set point zero adjustment locking screw and adjust
the remote set point zero adjustment screw until the
set point indicator aligns with the process scale
lower limit. Tighten the zero adjustment locking
screw.
5. Apply remote set point pressure equal to the
upper range limit.
6. The set point indicator should indicate the
process scale upper limit. If not, adjust the remote
set point span adjustment screw to correct one-half
the error as follows: clockwise to increase span for a
low indication; counterclockwise to decrease span
for a high indication.
7. Repeat steps 3 through 6 until the error is
eliminated.
8. Apply remote set point pressure equal to the
mid-range value.
9. Make sure the set point indicator is within ±1
percent of the mid-scale mark and if so, proceed to
step 12. If the set point indicator is not within 1
percent, but is within ±2 percent of the mid-scale
mark, then proceed with step 10. If the set point
indicator is not within ±2 percent, proceed to the
remote set point calibration procedure in the
Maintenance section.
10. Loosen the remote set point zero adjustment
locking screw and adjust the remote set point zero
adjustment screw to correct for half the error at
mid-scale. Tighten the zero adjustment locking
screw.
11. Apply remote set point pressure equal to the
lower and upper range limits and make sure the set
point indicator is within ±1 percent.
12. If necessary, perform the process indicator zero
and span calibration procedure in this section.
Otherwise, perform the flapper alignment procedure
in this section.
Flapper Alignment
Note
Perform the process indicator zero
and span calibration procedure and,
for controllers with remote set point
(suffix letter M), the remote set point
zero and span calibration procedure
before the flapper alignment.
Flapper leveling screw numbers and adjustments
are shown in figure 3-3. Key number locations are
shown in figure 7-1.
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. After performing the flapper
alignment procedure, go to the startup procedure.
1. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point
(suffix letter M), adjust the remote set point pressure
until the set point indicator is at the mid-scale mark
on the process scale.
2. Apply process pressure equal to the mid-scale
value of the process scale span. If pressure is not
available to pressure the input element to the
mid-scale value, an alternate method is to
disconnect link number 1 at the input element and
tape the process pointer at the mid-scale mark on
the process scale. If the controller has a capsular
input element, note the hole from which link number
1 was removed for proper replacement. This method
should only be used if pressure is not available to
pressure the input element to the mid-scale value.
3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).
4. Adjust the proportional band between DIRECT
and REVERSE.
5. The controller output should be 0.62 ±0.007 bar
(9 ±0.10 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 2 (the screw nearest the nozzle) until
the output is within tolerance.
6. Set the proportional band to 30 percent DIRECT.