Fisher 4195 KB Series User manual

D200160X012
Fisher Controls International, Inc. 1983, 1997; All Rights Reserved
Fisher, Fisher-Rosemount, and Managing The Process Better are marks
owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc.
All other marks are the property of their respective owners.
4195KA, K B , a n d K C S eries Gaug e P ressure
Controllers
Contents
1. Introduction
Scope of Manual 1–3. . . . . . . . . . . . . . . . . . . . . . . . . .
Description 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 2–1. . . . . . . . . . . . . . . . . . . . .
Process Pressure Connection 2–1. . . . . . . . . . . . .
Supply Pressure Connection 2–3. . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Pressure Connection 2–3. . . . . . . . . . . . . . . . . . .
External Feedback Pressure Connection
(4195KB Series Controllers Only) 2–4. . . . . . . .
Vent 2–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. 4195KA Series Proportional-Only Con-
trollers
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 3–3. . . . .
General Calibration Instructions 3–3. . . . . . . . . . . .
Process Indicator Zero and Span
Calibration 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 3–4. . . . . . . . . . . . . .
Flapper Alignment 3–6. . . . . . . . . . . . . . . . . . . . . . .
Principle of Operation for 4195KA Series
Controllers 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Operation 3–6. . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Operation 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 4195KB Series Proportional-Plus-Re-
set Controllers and 4195KC Series Pro-
portional-Plus-Reset-Plus-Rate Control-
lers
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) 4–1. . . .
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) 4–2. . . . . . . . . . . . . . . . . . . . . . . .
Prestartup Checks for 4195KB and
KC Series Controllers 4–3. . . . . . . . . . . . . . . . . . .
Startup for 4195KB and KC Series
Controllers 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of 4195KB and KC Series
Controllers 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Calibration Instructions 4–4. . . . . . . . . . . .
Process Indicator Zero and Span
Calibration 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Zero and Span Calibration 4–6. . . . . . . . . . . . . .
Flapper Alignment 4–6. . . . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Differential Relief Valve Calibration 4–8. . . . . .
Principle of Operation for 4195KB and
KC Series Controllers 4–9. . . . . . . . . . . . . . . . . . .
Overall Operation 4–9. . . . . . . . . . . . . . . . . . . . . . . .
Anti-Reset Windup (suffix letter F)
Operation 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual
Form 5207
March 1997 4195KA, KB, and KC Series

4195KA, KB, and KC Series
1–2
Contents (continued)
Remote Set Point (suffix letter M)
Operation 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E)
Operation 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . .
External Feedback Operation 4–12. . . . . . . . . . . . .
5. Maintenance
Inspection and Maintenance 5–1. . . . . . . . . . . . . . . .
Troubleshooting 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Common Controller Parts 5–1. . . . . . . . .
Replacing the Process Pressure Scale 5–1. . . . . .
Replacing the Relay 5–5. . . . . . . . . . . . . . . . . . . . . .
Replacing the Case and Cover 5–5. . . . . . . . . . . .
Replacing the Gauges 5–6. . . . . . . . . . . . . . . . . . . .
Replacing the Supply Gauge, Proportional,
Reset, and Reset Valve, Tubing
Assemblies 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Proportional Band Adjustment
Knob, Nozzle Assembly, and Set Point
Beam Assembly 5–6. . . . . . . . . . . . . . . . . . . . . . .
Replacing the Flapper Assembly and
Flapper Flexure Pivot Assembly 5–10. . . . . . . .
Replacing the Proportional or Reset
Bellows 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Reset Restriction Valve
(4195KB Series) 5–15. . . . . . . . . . . . . . . . . . . . .
Replacing the Rate/Reset Valve Assembly
(4195KC Series) 5–15. . . . . . . . . . . . . . . . . . . . .
Replacing the Anti-Reset Windup
(suffix letter F) Differential Relief Valve 5–16. .
Replacing the Anti-Reset Windup
(suffix letter F) Relief Valve Tubing
Assembly 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Maintenance
and Calibration 5–16. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Bourdon Tube 5–16. . . . . . . . . . . . .
Replacing Bourdon Tube Controller Links 5–17. .
Replacing Link 1 5–17. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 2 5–18. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 3 5–18. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 4 5–19. . . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube Travel Stop Installation
and Adjustment 5–20. . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube Controller Calibration:
Zero and Span Adjustment 5–21. . . . . . . . . . . .
Capsular Element Controller Maintenance
and Calibration 5–23. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Capsular Element
Assembly 5–23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Capsular Element Parts 5–23. . . . . . . .
Replacing the Long Pivot Assembly 5–23. . . . . .
Replacing the Short Pivot Assembly 5–24. . . . . .
Replacing the Process Drive Flexure 5–24. . . . .
Replacing the Process Tubing 5–24. . . . . . . . . . .
Replacing Capsular Element
Controller Links 5–25. . . . . . . . . . . . . . . . . . . . . .
Replacing Link 1 5–25. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 2 5–25. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 3 5–26. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 4 5–26. . . . . . . . . . . . . . . . . . . . . . .
Replacing Link 5 5–27. . . . . . . . . . . . . . . . . . . . . . .
Capsular Element Controller
Maintenance Calibration 5–27. . . . . . . . . . . . . . .
Precalibration Procedure 5–27. . . . . . . . . . . . . . .
Aligning the Drive Bracket Assembly 5–27. . . . .
Setting the Travel Stops 5–28. . . . . . . . . . . . . . . .
Aligning the Linkage 5–28. . . . . . . . . . . . . . . . . . .
Capsular Element Controller
Zero and Span Adjustment 5–29. . . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance 5–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Remote Set Point
Assembly 5–30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Remote Set Point
Assembly Parts 5–30. . . . . . . . . . . . . . . . . . . . . .
Replacing Pivot Assembly A (key 114) 5–30. . . .
Replacing Pivot Assembly B (key 115) 5–32. . . .
Replacing the Drive Flexure 5–32. . . . . . . . . . . . .
Replacing the Remote Set Point Tubing 5–32. .
Replacing Link A 5–32. . . . . . . . . . . . . . . . . . . . . .
Replacing Link B 5–32. . . . . . . . . . . . . . . . . . . . . .
Remote Set Point (suffix letter M)
Maintenance Calibration 5–33. . . . . . . . . . . . . . . .
Precalibration Procedure 5–33. . . . . . . . . . . . . . . . .
Aligning the Flexures 5–33. . . . . . . . . . . . . . . . . . . .
Setting the Travel Stops 5–33. . . . . . . . . . . . . . . . .
Aligning the Linkage 5–33. . . . . . . . . . . . . . . . . . . . .
Remote Set Point Zero and Span
Adjustment 5–34. . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point Linearity Adjustment 5–34. . . .
Auto/Manual Station (suffix letter E)
Maintenance 5–35. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Auto/Manual Station 5–35. . . . . . . .
Replacing the Switch Body Assembly,
Lever O-Ring, Switch Body O-Ring,
and Tubing Assembly 5–35. . . . . . . . . . . . . . . . .
Replacing the Loader Range Spring,
Diaphragm Assembly, Ball Seat,
Tubing, and Ball 5–36. . . . . . . . . . . . . . . . . . . . . .
Replacing the Loader Valve Plug and
Valve Plug Spring 5–37. . . . . . . . . . . . . . . . . . . .
6. Parts
Parts Ordering 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations Used In The Parts List 6–1. . . . . . .
Controller Common Parts 6–1. . . . . . . . . . . . . . . . .
Process and Set Point Indicator
Assembly 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Assembly 6–6. . . . . . . . . . . . . . . . . . . . . . .
Capsular Element Assembly 6–7. . . . . . . . . . . . . .
Type 83U Relay 6–7. . . . . . . . . . . . . . . . . . . . . . . . .
Remote Set Point Assembly
(suffix letter M) 6–7. . . . . . . . . . . . . . . . . . . . . . . .
Auto/Manual Station (suffix letter E) 6–8. . . . . . . .

4195KA, KB, and KC Series
1–3
Figure 1–1. 4195K Series Gauge Pressure Controllers
NAMEPLATE
W5663-1 / IL W6831 / IL
Contents (continued)
Internal/External Set Point Assembly
(Option) 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Mounting Parts 6–9. . . . . . . . . . . . . . . . .
Pipestand Mounting 6–9. . . . . . . . . . . . . . . . . . . . .
Pipestand Mounting with Regulator 6–9. . . . . . .
Panel Mounting 6–9. . . . . . . . . . . . . . . . . . . . . . . .
Wall Mounting 6–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Mounting Parts for Actuator
with Casing-Mounted Controller 6–9. . . . . . . .
Controller Mounting Parts for Actuator
with Yoke-Mounted Controller 6–9. . . . . . . . . .
Regulator Mounting Parts 6–9. . . . . . . . . . . . . . . . .
Regulator Mounting Parts for
Casing-Mounted Regulator 6–9. . . . . . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator (Mounting
Bracket Not Required) 6–9. . . . . . . . . . . . . . . .
Regulator Mounting Parts for
Yoke-Mounted Regulator
(With Mounting Bracket) 6–9. . . . . . . . . . . . . . .
Fittings 6–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1
Introduction
Scope of Manual
This instruction manual provides installation, operat-
ing, calibration, maintenance, and parts ordering infor-
mation for 4195KA, 4195KB, and 4195KC Series
gauge pressure indicating controllers.
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 suf-
fixes) is located on the nameplate shown in figure 1–1.
Refer to table 1–2 for the definition of each 4195K Se-
ries type number.
Only personnel qualified through training or experience
should install, operate, and maintain this controller. If
there are any questions concerning these instructions,
contact your Fisher Controls sales representative or
sales 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
These controllers show process pressure and set point
on an easy-to-read process scale. The controller out-
put is a pneumatic signal that operates a final control
element.
Specifications
Specifications for the 4195KA, KB, and KC Series
controllers are listed in table 1–1.

4195KA, KB, and KC Series
1–4
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: 3 to
15 psig or 6 to 30 psig (0.2 to 1.0 bar or 0.4 to 2.0
bar)
Action: Field-reversible between direct(increasing
sensed process pressure increases output pres-
sure) or reverse(increasing sensed process pres-
sure decreases output pressure).
Process Scale
Standard scale is matched to the range of the sens-
ing element, with the exception of receiver control-
lers. Optional(2) scales are available.
Process Connections
Standard: 1/4-inch NPT, female, stainless steel (all
input ranges)
Optional: 1/2-inch NPT. See table 1–5.
Supply and Output Connections
1/4-inch NPT, female
Supply Pressure Requirements
See table 1–6.
Remote Set Point Pressure Ranges
3 to 15 psig or 6 to 30 psig (0.2 to 1.0 bar or 0.4 to
2.0 bar)
Controller Adjustments
Proportional Band(1):5 to 500% of process input
span
Reset(1):Adjustable from 0.01 to more than 74 min-
utes per repeat (from 100 to less than 0.0135 re-
peats per minute)
Rate(1):Adjustable from 0 to 20 minutes
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 10 feet (3.05 m) of 1/4-inch
(6.4 mm) tubing and 100 cubic inch (1639 cm3) vol-
ume
Steady-State Air Consumption(1,3,4)
3 to 15 Psig (0.2 to 1.0 Bar) Output: 3.5 scfh (0.1
m3/hr)
6 to 30 Psig (0.4 to 2.0 Bar) Output: 5.0 scfh (0.14
m3/hr)
Delivery Capacity(3)
3 to 15 Psig (0.2 to 1.0 Bar) Output: 240 scfh (5.9
m3/hr)
6 to 30 Psig (0.4 to 2.0 Bar) Output: 350 scfh (10.4
m3/hr)
Exhaust Capacity(3)
3 to 15 Psig (0.2 to 1.0 Bar) Output: 186 scfh (4.6
m3/hr)
6 to 30 Psig (0.4 to 2.0 Bar) Output: 295 scfh (7.0
m3/hr)
Operative Ambient Temperature Limits(1)
–40 to 160_F (–40 to 71_C)
Mounting
Controller can be mounted on actuator, panel, wall,
or pipestand.
Approximate Weight
10 pounds (4.5 kg)
1. These terms are defined in ISA Standard S51.1-1979.
2. Consult your Fisher sales office or sales representative for additional information.
3. Scfh—Standard cubic feet per hour (60_F and 14.7 psia). Normal m3/hr—Normal cubic meters per hour (0_C and 1.01325 bar, absolute).
4. Without auto/manual station. With auto/manual station, air consumption is 10.0 Scfh (0.28 normal m3/hr for either output range.

4195KA, KB, and KC Series
1–5
Table 1–2. A vailable Configurations for 4195KA, 4195KB, and 4195KC Series Controllers
MODES OPTIONS
SERIES TYPE
NUMBER(1)
Proportional-
Only
(One-Mode
Controllers)
Proportional-
Plus-Reset
(Two-Mode
Controllers)
Proportional-
Plus-Reset-
Plus-Rate
(Three-Mode
Controllers)
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
1. Reverse–acting constructions are designated by the suffix letter R added to the type number.

4195KA, KB, and KC Series
1–6
Table 1–3. Process Sensor (Capsular Element) Pressure Ratings
CAPSULE CAPSULAR SPAN(1) OPERATING RANGE OPERATING
(2)
CAPSULE
MATERIAL
CAPSULAR
ST ANDARD RANGES
Min Max Min Max
OPERATING
LIMIT(2)
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
U.S. units 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
Compound –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
N09902
(Ni-Span C)
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
Positive
pressure
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
Metric units 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
Compound –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
-Continued-

4195KA, KB, and KC Series
1–7
Table 1–3. Process Sensor (Capsular Element) Pressure Ratings (Continued)
CAPSULE CAPSULAR SPAN(1) OPERATING RANGE OPERATING
(2)
CAPSULE
MATERIAL
CAPSULAR
ST ANDARD RANGES
Min Max Min Max
OPERATING
LIMIT(2)
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
–5 inch Hg
–10 inch Hg
–20 inch Hg
–30 inch Hg
–30 inch Hg
2.5 psig
5 psig
10 psig
15 psig
15 psig
3.75 psig
7.5 psig
15 psig
22.5 psig
22.5 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
0 psig
–30 inch Hg
20 psig
30 psig
30 psig
30 psig
45 psig
45 psig
U.S. units 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
–5 inch Hg
–10 inch Hg
–20 inch Hg
–30 inch Hg
2.5 psig
5 psig
15 psig
15 psig
3.75 psig
7.5 psig
15 psig
22.5 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
–5 inch Hg
–10 inch Hg
–20 inch Hg
2.5 psig
5 psig
10 psig
3.75 psig
7.5 psig
15 psig
Compound –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
15 psig
20 psig
30 psig
22.5 psig
30 psig
45 psig
S31600
(316 SST)
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
–170 mbar
–700 mbar
–0.7 bar
–1 bar
–1 bar
170 mbar
700 mbar
0.7 bar
1 bar
1 bar
255 mbar
1 bar
1 bar
1.5 bar
1.5 bar
Positive
pressure
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
0 bar
–1 bar
1.4 bar
2 bar
2 bar
2 bar
2 bar
3 bar
3 bar
3 bar
Metric units 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
–170 mbar
–340 mbar
–0.7 bar
–0.7 bar
–1 bar
170 mbar
340 mbar
0.7 bar
0.7 bar
1 bar
255 mbar
510 mbar
1 bar
1 bar
1.5 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
–170 mbar
–340 mbar
–700 mbar
–0.7 bar
170 mbar
340 mbar
700 mbar
0.7 bar
255 mbar
510 mbar
1 bar
1 bar
Compound –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 bar
1.4 bar
2 bar
2 bar
1.5 bar
2 bar
3 bar
3 bar
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 5 psig (0 to 350 mbar) sensing element is used
and the minimum span of 2.5 psig (175 mbar) is set, the process indicaion can be calibrated to a range of –10 inch Hg to –6 inch Hg (–340 mbar to –203 mbar), 0 to 2.5 psig (0 to 172
mbar), 2.5 to 5 psig (172 to 345 mbar), 4.5 to 7 psig (305 to 480 mbar), or any value between minimum and maximum values of operating range.
2. Capsules with the travel stops set may be pressured to this value without permanent zero shift.

4195KA, KB, and KC Series
1–8
Table 1–4. Process Sensor (Bourdon T ube) Pressure Ratings and Materials
BOURDONTUBES
SPAN(1) OPERATING RANGE(2) OPERATING
(4)
STANDARD
BOURDON TUBES Minimum Maximum Minimum Maximum(3)
OPERATING
LIMITS(4) STANDARD
MATERIAL
Psig Psig Psig Inch Hg Psig Psig
MATERIAL
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
U.S. units
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
S31600 (316 SST)
U
.
S
.
units
0 to 3000
0 to 5000 2200 3700 3000 5000 0 03900 6000 4500 7000
0 to 8000
0 to 10,000 6000 7500 8000 10,000 0 09600 12,000 11,200 14,000 N09902 Nickel Alloy (Ni-Span C)
0 to 600
0 to 1000
0 to 1500
300
750
1100
600
1000
1500
0
0
0
840
1300
1950
960
1500
2250
K-Monel
(for NACE)
Bar
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
Metric units
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 S31600 (316 SST)
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
0 to 550
0 to 600 420 520 550 700 0 0670 830 772 965 N09902 Nickel Alloy (Ni-Span C)
0 to 40
0 to 60
0 to 100
20
55
76
40
70
100
0
0
0
60
90
135
66
103
155
K-Monel
(for NACE)
1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 30 psig (0 to 2 bar) sensing element is used
and the minimum span of 15 psig (1 bar) is set, the process indication can be calibrated to a range of –30 inch Hg to 0 psig (–1 to 0 bar), 0 to 15 psig (0 to 1 bar), 15 to 30 psig (1 to 2
bar), 27 to 42 psig (2 to 3 bar) or any value between the operating range minimum and maxi mum values.
2. Travel stops should be used when the maximum or minimum process pressure will be 5% over or under the calibrated range. For example, a 0 to 30 psig (0 to 2 bar) sensing
element is calibrated for 10 to 30 psig (0.7 to 2 bar), the desired range. The minimum expected pressure is 0 psig and the maximum expected pressure is 40 psig (2.8 bar). Travel
stops must be used to prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5% of the 20 psig (1.4 bar) span
which is ±1 psig (70 mbar).
3. Bourdon tube without travel stops may be pressured to this value without permanent zero shift.
4. Bourdon tube with travel stops set may be pressured to this value without permanent zero shift.
Table 1–5. Optional Process Connections
PSIG INPUT BAR INPUT CONNECTION
PSIG
INPUT
RANGE
BAR
INPUT
RANGE Size Material
Up to
0 to 5000 Up to 0 to 400
J1/2-inch NPT male
or J1/2-inch NPT
female
JSteel or
Jstainless
steel
0 to 5000 to
0 to 10,000 0 to 400 to 0 to 600 1/2-inch NPT female Stainless steel
0 to 5000 to
0 to 10,000 0 to 400 to 0 to 600 1/2-inch NPT male Stainless steel
T able 1–6. Supply Pressure Data
Output Signal
Range Normal Operating Supply Pressure(1) Maximum Pressure Limit(2)
Psig 3 to 15 20 40
Psig
6 to 30 35 40
Bar 0.2 to 1.0 1.4 2.8
Bar
0.4 to 2.0 2.4 2.8
1. If this pressure is exceeded, control may be impaired.
2. If this pressure is exceeded, damage to the controller may result.

4195KA, KB, and KC Series
2–1
Section 2
Installation
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 pro-
vided 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 con-
troller to the 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 con-
troller using three cap screws (key 66) and lock wash-
ers (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.
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.
MOUNTING
PLATE
TYPE 657
ACTUATOR
TYPE 4195K
CONTROLLER
TYPE 67FR
FILTER
REGULATOR
W5661 / IL
Figure 2–1. Typical Actuator Mounting
Pressure Connections
WARNING
To avoid personal injury or property
damage resulting from the sudden re-
lease of pressure, do not install any sys-
tem component where service condi-
tions could exceed the limits given in
this manual. Use pressure-relieving de-
vices as required by government or ac-
cepted industry codes and good engin-
nering practices.
Refer to figure 2–5 for pressure connection locations.
Supply, output, remote set point, external feedback,
and vent connections are 1/4-inch NPT, female. Pro-
cess pressure connections are 1/4- or 1/2-inch NPT
(optional). Use 1/4-inch or 3/8-inch pipe or tubing for
supply, output, remote set point, and external feed-
back 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 applica-
tions. See figure 2–5 for the location of the A and B
connections.

4195KA, KB, and KC Series
2–2
Figure 2–2. Pipestand Mounting
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)
 
49A3196-A
A6732 / IL  
Figure 2–3. Panel Mounting
HEX HEAD
CAP SCREW
(KEY 66)
LOCK
WASHER
(KEY 67)
ROUND HEAD
MACHINE
SCREW
(KEY 70)
BRACKET
(KEY 68)
 
36A9760-A
A6733 / IL
3.29
(84)
2.49
(63)
12.06
(306)
0.56 R
(14)
9.31
(236)
INCH
(mm)
0.50
(13)
2.43
(62)
   
 
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
BRACKET
(KEY 68)
 
36A9761-B
A6734 / IL
6.35
(161)
10.25
(260)
6.00
(152)
2.43
(62)
0.50
(13)
0.50
(13)
 
INCH
(mm)
Figure 2–4. Wall Mounting

4195KA, KB, and KC Series
2–3
When installing process piping, follow accepted prac-
tices to ensure accurate transmission of the process
pressure to the controller. Install a three-valve bypass,
shutoff valves, vents, drains, or seal systems as need-
ed 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 pro-
cess pressure lines are approximately horizontal, the
lines should slope downward to the instrument for liq-
uid-filled lines and upward toward the instrument for
gas-filled lines. This reduces the possibility of air be-
coming trapped in the sensor with liquid-filled lines or
of condensation becoming trapped in gas-filled lines.
The recommended slope is 1 inch per foot (83 millime-
ters per m).
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 ab-
normal fluid velocities. For pressure-reducing service,
the process pressure line must be connected down-
stream of the control valve. For pressure-relief service,
the process pressure line must be connected up-
stream of the control valve.
Supply Pressure Connection
WARNING
Personal injury or property damage may
occur from an uncontrolled process if
the supply medium is not clean, dry, oil-
free, or a non-corrosive gas. Industry
instrument air quality standards de-
scribe acceptable dirt, oil, and moisture
content. Due to the variability in nature
of the problems these influences can
have on pneumatic equipment, Fisher
Controls has no technical basis to rec-
ommend the level of filtration equipment
required to prevent performance degra-
dation of pneumatic equipment. A filter
or filter regulator capable of removing
particles 40 microns in diameter should
suffice for most applications. Use of
suitable filtration equipment and the es-
tablishment of a maintenance cycle to
monitor its operation is recommended.
Figure 2–5. Connection Locations
10.25
(260)
4.00
(102)
5.13
(130) 2.00 (51)
13.00
(330)
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
5.80
(147)
2.56
(66)
1.22
(31)
1/4 NPT 4 HOLES
1/4-18
NPT VENT
CONNECTION INCH
(mm)
   
   
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.
3
2
1
46A9765-A
A2892-4 / IL
Supply pressure must be clean, dry air or noncorrosive
gas that meets the requirements of ISA Standard
S7.3-1975 (R1981). 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 3 to 15
psig (0.2 to 1.0 bar) remote set point pressure range
for a 3 to 15 psig (0.2 to 1.0 bar) controller output sig-
nal range or a 6 to 30 psig (0.4 to 2.0 bar) remote set
point pressure range for a 6 to 30 psig (0.4 to 2.0 bar)
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 regu-
lator and remote set point connection to prevent pres-
sure variations due to regulator lock-up.

4195KA, KB, and KC Series
2–4
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 sec-
ondary controller. Connect the external feedback con-
nection of the secondary controller to the output of the
customer-supplied high or low select relay (see figures
2–5 and 4–9).
Vent
WARNING
If a flammable, toxic, or reactive gas is
to be used as the supply pressure me-
dium, personal injury and property dam-
age could result from fire or explosion
of accumulated gas or from contact with
a toxic or reactive gas. The controller
case and cover assembly do not form a
gas-tight seal, and when the assembly
is enclosed, a remote vent line, ade-
quate ventilation, and necessary safety
measures should be used. However, a
remote vent pipe alone cannot be relied
upon to remove all 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 3/4 inches (19 mm) for runs up to
20 feet (6.1 meters) and a minimum inside diameter of
1 inch (25 mm) for runs from 20 to 100 feet (6.1 to
30.5 meters).
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 mate-
rial that could plug it. Check the vent periodically to be
certain it is not plugged.

4195KA, KB, and KC Series
3–1
Figure 3–1. 4195KA Series Controller Adjustment Locations
METAL BALL
SWITCHING ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
W3679 / IL
 
  
SET POINT
INDICATOR
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE
GAUGE
W6832 / IL
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. Ad-
justment locations are shown in figures 3–1 and 3–3.
To better understand the adjustments and overall con-
troller operation, refer to the principle of operation sec-
tion and the schematic diagrams in figures 3–4 and
3–5. Unless otherwise noted, key numbers given in
this section are found in figure 5–24.
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 de-
sired 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.
If the controller is equipped with the optional internal or
external set point adjustment, turn the adjustment
knob clockwise to increase the process set point and
counterclockwise to decrease the process set point.
Remote Set Point (suffix letter M)
Adjustment
CAUTION
Do not manually move the set point in-
dicator on controllers with remote set
point. Manually moving the set point in-
dicator could damage the controller.
If the controller is equipped with remote set point (suf-
fix letter M), vary the remote set point pressure to
change the set point. Increase the pressure to in-
crease 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.

4195KA, KB, and KC Series
3–2
Figure 3–2. Changing Controller Action
(4195KA Series Controllers)
W3439 / IL
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 pro-
vides direct controller action; setting porportional band
in the black portion provides reverse controller action.
Bourdon Tube or Capsular Element Controllers for
Positive or Compound Pressure
For direct control action:
An increasing sensed pressure increases output pres-
sure.
For reverse control action:
An increasing sensed pressure decreases output pres-
sure.
Capsular Element Controllers for Vacuum Pressure
For direct control action:
An increasing sensed vacuum increases output pres-
sure.
For reverse control action:
An increasing sensed vacuum decreases output pres-
sure.
After changing the action, tighten the screws on the
proportional band indicator cover.
Switching The Auto/Manual Station
(suffix letter E)
CAUTION
Switching the controller between auto-
matic and manual mode without balanc-
ing can disturb the process and cause
controller cycling.
Refer to figure 3–1 if the controller has the auto/manu-
al 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 out-
put. 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 5–24 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 con-
trol signal to the controller.
Note
If the controller has the auto/manual sta-
tion (suffix letter E), be sure the control-
ler is in the automatic mode before per-
forming the prestartup checks.
1. Provide a means of measuring the controller output
pressure by connecting the controller output to a pres-
sure gauge. Connect supply pressure to the supply
pressure regulator and be sure it is delivering the
proper supply pressure to the controller. Do not ex-
ceed the normal operating pressure in table 1–6.
2. For a controller with remote set point (suffix letter
M), connect regulated pressure of 3 to 15 psig (0.2 to

4195KA, KB, and KC Series
3–3
1.0 bar) or 6 to 30 psig (0.4 to 2.1 bar) to the remote
set point connection at the top of the controller case.
3. 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 pro-
cess 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 psig.
8. Rotate the proportional band to 5 percent RE-
VERSE.
9. The controller output should be within 2 psig (0.14
bar) 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 cal-
ibration procedure for recalibration.
Startup for 4195KA Series Controllers
Perform the prestartup checks and, if necessary, cali-
brate the controller prior to this procedure.
Note
When performing the startup proce-
dures, keep in mind that the initial set-
tings are guidelines. They will vary de-
pending 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 per-
cent 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 2psig
30 psig 13%
4. Create a load upset by momentarily changing the
set point. Check for system cycling. If the system does
not cycle, lower the proportional band setting (thus
raising the gain) and disturb the system again by
changing the set point. Continue this procedure until
the system cycles. At this point, double the proportion-
al band setting (proportional band setting ×2).
5. Check the stability of the recommended proportion-
al band setting by introducing a disturbance and moni-
toring the process.
Calibration of 4195KA Series Controllers
General Calibration Instructions
Note
If the controller has the auto/manual sta-
tion (suffix letter E), be sure the control-
ler is in the automatic mode before per-
forming calibration.
If the prestartup checks, or startup, reveal faulty con-
troller 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 5–24.
Do not use the gauges supplied with the controller dur-
ing calibration. Monitor process pressure, supply pres-
sure, controller output pressure, and if applicable, re-
mote set point pressure with external gauges.
Process Indicator Zero and Span
Calibration
Before starting this procedure:
Provide a regulated process pressure to the con-
troller and a means of measurement external to the
controller.
Provide a means of measuring the controller out-
put 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.

4195KA, KB, and KC Series
3–4
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 pro-
portional 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 adjust-
ment 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 cor-
rect one-half of the error as follows: clockwise to in-
crease span for a low indication (below the upper lim-
it); counterclockwise to decrease span for a high
indication (above the upper limit).
7. Repeat steps 3 through 6 until the error is elimi-
nated.
8. Apply process pressure equal to the mid-scale val-
ue 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.
Remote Set Point (suffix letter M) Zero
and Span Calibration
Refer to figures 3–1 and 3–3 for adjustment locations.
Refer to figure 5–24 for key number locations.
Note
Any adjustment of the remote set point
span adjustment screw requires read-
justment of the remote set point zero
adjustment screw.
1. Remove the two screws (key 6) and lift off the pro-
portional 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 indi-
cator 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 indica-
tion; counterclockwise to decrease span for a high in-
dication.
7. Repeat steps 3 through 6 until the error is elimi-
nated.
8. Apply remote set point pressure equal to the mid-
range value.
9. Make sure the set point indicator is within ±1 per-
cent 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 pro-
ceed 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 lock-
ing screw and adjust the remote set point zero ajust-
ment 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 low-
er 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. Other-
wise, perform the flapper alignment procedure in this
section.

4195KA, KB, and KC Series
3–5
Figure 3–3. 4195KA Series 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-SSHT 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

4195KA, KB, and KC Series
3–6
Flapper Alignment
Note
Perform the process indicator zero and
span calibration procedure and, for con-
trollers with remote set point (suffix let-
ter 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 5–24.
Provide a means of measuring the controller output
pressure by connecting the controller output to a pres-
sure 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 let-
ter M), adjust the remote set point pressure until the
set point indicator is at the mid-scale mark on the pro-
cess scale.
2. Apply process pressure equal to the mid-scale val-
ue of the process scale span. If pressure is not avail-
able to pressure the input element to the mid-scale
value, an alternate method is to disconnect link num-
ber 1 at the input element and tape the process point-
er 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 re-
placement. This method should only be used if pres-
sure 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 9 ±0.10 psig (0.62
±0.007 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or
18 ±0.2 psig (1.2 ±0.01 bar) for a 6 to 30 psig (0.4 to
2.0 bar) 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.
7. The controller output should be 9 ±0.25 psig (0.62
±0.02 bar) or 18 ±0.5 psig (1.2 ±0.04 bar). If not, ad-
just flapper leveling screw 3 (the screw nearest the
nozzle).
8. Set the proportional band to 30 percent REVERSE.
9. The controller output should be 9 ±0.25 psig (0.62
±0.02 bar) or 18 ±0.5 psig (1.2 ±0.04 bar). If not, ad-
just flapper leveling screw 1 (the screw nearest the
nozzle).
10. Repeat steps 4 through 9 until the controller out-
put remains in tolerance without further leveling screw
adjustments.
11. If link 1 was disconnected, remove the tape and
reconnect link 1 to the input element.
12. Set the proportional band to 400 percent in the
desired controller action and replace the proportional
band indicator cover.
Principle of Operation for 4195KA Series
Controllers
Overall Operation
Refer to the schematic diagram in figure 3–4.
The input element is connected to the process pointer
and to the flapper by connecting links. As the process
pressure increases (in a direct-acting controller), the
flapper moves toward the nozzle, restricting flow
through the nozzle and increasing nozzle pressure.
When this occurs, relay action increases the output
pressure (delivery) of the controller. Output pressure is
fed back to the proportional bellows. The action of the
proportional bellows counteracts the flapper move-
ment that resulted from the process pressure change
and backs the flapper away from the nozzle until equi-
librium is reached.
Moving the set point indicator changes the distance
between the nozzle and flapper as does a change in
process pressure, except that when the set point is
changed, the nozzle moves with respect to the flapper.
The proportional band adjustment positions the nozzle
on the flapper. Increasing (widening) the proportional
band moves the nozzle to a position on the flapper
where less input and more feedback motion occurs,
which decreases the gain of the controller. Decreasing
(narrowing) the proportional band moves the nozzle
toward a position where more input and less feedback
motion occurs, which increases the gain. The control-
ler action is changed from direct to reverse by turning
the proportional band adjustment to position the
nozzle on the flapper quadrant to a point where the
direction of the flapper motion versus input motion is
reversed as shown in the flapper detail of figure 3–4.
With the controller in the reverse-acting mode, an in-
crease in process pressure causes a decrease in out-
put pressure.

4195KA, KB, and KC Series
3–7
Figure 3–4. 4195KA Series Controller Schematic
SET POINT INDICATOR RESET BELLOWS (VENTED) REVERSE ACTION
QUADRANT
PROPORTIONAL
BELLOWS PROPORTIONAL
BAND ADJUSTMENT
FLAPPER PIVOT
DIRECT ACTION
QUADRANT
FLAPPER
NOZZLE
BEAM
CONNECTING
LINK
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
SUPPLY
PRESSURE
RELAY
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
SUPPLY PRESSURE
OUTPUT PRESSURE
PROPORTIONAL PRESSURE
NOZZLE PRESSURE
FEEDBACK
LINK
FEEDBACK
MOTION
INPUT
MOTION
 
46A9764-A
B1489-2 / IL
Remote Set Point (suffix letter M)
Operation
The capability to adjust the controller set point from a
remote location is available with all 4195KA Series
controllers. This option is designated by the letter M in
the type number.
A control pressure is applied to the capsular element
within the remote set point assembly. The expansion
and contraction of the capsule moves the set point
adjustment via a connecting linkage. Increasing the
control pressure to the capsule increases the set point
setting and decreasing the control pressure reduces
the set point setting.
Auto/Manual Station (suffix letter E)
Operation
A controller with the auto/manual station (designated
by the suffix letter E in the type number) has piping on
the output side of the relay as shown in figure 3–5.
Supply pressure to the relay is also applied to the
manual loader. The manual loader, functioning as a
regulator, applies pressure to one side of the plastic
tube and to the auto/manual switch. Output pressure
from the relay registers on the other side of the plastic
tube as well as in the auto/manual switch.
When the auto/manual switch is in the MANUAL posi-
tion, the manual loader output is channeled through
the auto/manual switch and becomes the controller
output. When the auto/manual switch is in the AUTO
position, the relay output is channeled through the
switch to become the controller output.
Before the auto/manual switch is operated, the relay
output must equal the manual loader output to avoid
bumping the process. Adjusting the set point varies
the pressure on the left-hand side of the plastic tube.
Adjusting the manual loader knob varies the pressure
on the right-hand side. When the pressures are equal,
the metal ball is centered in the tube and it is held in
place by a small magnet. A pressure imbalance forces
the ball to one end of the tube where it forms a seal,
blocking air flow through the tube.

4195KA, KB, and KC Series
3–8
Figure 3–5. Auto/Manual Station Schematic (4195KA Series)
AUTOMATIC
POSITION
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
SUPPLY
PRESSURE
RELAY
AUTO/MANUAL
SWITCH
MANUAL LOADER
MANUAL
LOADER
KNOB
MANUAL
POSITION
AUTO/MANUAL
SWITCH
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
PLASTIC TUBE
METAL BALL
RELAY OUTPUT PRESSURE
SUPPLY PRESSURE
MANUAL LOADER OUTPUT PRESSURE
48A5230-A
A2999-1 / IL