Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters � 4150K and 4160K Series Wizard II Pressure Controllers and Transmitters Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Educational Services . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Standard Installation . . . . . . . . . . . . . . . . . . . . . . . 5 Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pipestand Mounting . . . . . . . . . . . . . . . . . . . . . . . 6 Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . 6 Pressure Connections . . . . . . . . . . . . . . . . . . . . . 6 Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6 Process Pressure . . . . . . . . . . . . . . . . . . . . . . . . 7 Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . 9 Proportional-Only Controllers . . . . . . . . . . . . . . . 9 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 W3525-1 / IL Adjustment: Set Point . . . . . . . . . . . . . . . . . . 9 Adjustment: Proportional Band . . . . . . . . . . . 9 � Calibration: Proportional-Only Controllers . . . 9 Figure 1. Wizard II Controller Yoke-Mounted on Control Startup: Proportional-Only Controllers . . . . . 12 Valve Actuator Proportional-Plus-Reset Controller . . . . . . . . . 12 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Startup: Transmitters . . . . . . . . . . . . . . . . . . . . . 20 Adjustment: Set Point . . . . . . . . . . . . . . . . . 12 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . 20 Adjustment: Proportional Band . . . . . . . . . . 13 Proportional-Only Controllers . . . . . . . . . . . . . . 20 Adjustment: Reset . . . . . . . . . . . . . . . . . . . . 13 Proportional-Plus-Reset Controllers . . . . . . . . 21 Adjustment: Anti-Reset Windup . . . . . . . . . 13 Controllers with Anti-Reset Windup . . . . . . . . . 21 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Differential Gap Controllers . . . . . . . . . . . . . . . . 22 Calibration: Proportional-Plus-Reset Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Calibration: Anti-Reset Windup . . . . . . . . . 15 Replacing Gauges . . . . . . . . . . . . . . . . . . . . . . . 23 Startup: Proportional-Plus-Reset Controllers 16 Replacing Bourdon Tube . . . . . . . . . . . . . . . . . . 24 Differential Gap Controllers . . . . . . . . . . . . . . . . 16 Replacing Bellows Sensing Element . . . . . . . . 24 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Changing Proportional or Reset Valve . . . . . . 25 Adjustment: Set Point . . . . . . . . . . . . . . . . . 16 Changing Anti-Reset Windup Differential Adjustment: Proportional Band . . . . . . . . . . 16 Relief Valve (4160KF) . . . . . . . . . . . . . . . . . . 26 Calibration: Differential Gap Controllers . . . . 16 Changing Action . . . . . . . . . . . . . . . . . . . . . . . . . 26 Startup: Differential Gap Controllers . . . . . . . 18 Proportional-Only to a Differential Transmitter Operation . . . . . . . . . . . . . . . . . . . . . 18 Gap Controller . . . . . . . . . . . . . . . . . . . . . . . 26 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Direct to Reverse Action . . . . . . . . . . . . . . . . . 26 Adjustment: Zero . . . . . . . . . . . . . . . . . . . . . . . 18 Relay Replacement . . . . . . . . . . . . . . . . . . . . . . 27 Adjustment: Span . . . . . . . . . . . . . . . . . . . . . . . 19 Changing Output Signal Range . . . . . . . . . . . . 27 Calibration: Transmitters . . . . . . . . . . . . . . . . . . 19 Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 www.Fisher.com D200151X012 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Educational Services Contents (Continued) Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 For information on available courses for 1450K and Controller Repair Kits . . . . . . . . . . . . . . . . . . . . . 29 4160K Series controllers and transmitters, as well as Relay Replacement Kits . . . . . . . . . . . . . . . . . . 29 a variety of other products, contact: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emerson Process Management Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Educational Services, Registration Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 29 P.O. Box 190; 301 S. 1st Ave. Mounting Parts for Panel, Wall, Pipestand Marshalltown, IA 50158-2823 or Actuator Mounting . . . . . . . . . . . . . . . . . . . 36 Phone: 800-338-8158 or Phone: 641-754-3771 FAX: 641-754-3431 e-mail: education@emersonprocess.com Introduction Note Scope of Manual � Neither Emerson , Emerson Process This instruction manual provides installation, � Management, Fisher , nor any of their operating, maintenance, and parts information for � affiliated entities assumes the 4150K and 4160K Series Wizard II pressure responsibility for the selection, use, controllers and transmitters shown in figure 1. Refer and maintenance of any product. to separate instruction manuals for information Responsibility for the selection, use, regarding the control valve, actuator, and and maintenance of any product accessories. remains with the purchaser and No person may install, operate, or maintain 4150K end-user. and 4160K Series Wizard II pressure controllers and transmitters without first � being fully trained and qualified in valve, actuator and accessory Installation installation, operation and maintenance, and � carefully reading and understanding the contents of this manual. If you have any questions about these WARNING instructions, contact your Emerson Process Management� sales office. To avoid personal injury or property damage resulting from the sudden release of pressure: Description � Always wear protective clothing, The 4150K and 4160K Series pneumatic pressure gloves, and eyewear when performing controllers and transmitters use a bellows or any installation operations. Bourdon tube sensing element to sense the gauge pressure, vacuum, compound pressure, or � Personal injury or property differential pressure of a liquid or gas. The controller damage may result from fire or or transmitter output is a pneumatic pressure signal explosion if natural gas is used as the that can be used to operate a final control element, supply medium and preventative indicating device, or recording device. measures are not taken. Preventative measures may include: Remote Unless otherwise noted, all NACE references are to venting of the unit, re-evaluating the NACE MR0175-2002. hazardous area classification, ensuring adequate ventilation, and the removal of any nearby ignition sources. For information on remote Specifications venting of this controller/transmitter, Specifications for the 4150K and 4160K Series refer to page 9. controllers and transmitters are listed in table 1. Table 2 explains available configurations and (Installation Warning continued on options. page 5) 2 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Table 1. Specifications Available Configurations Differential Gap Adjustment For Differential Gap Controllers: Full output See table 2 pressure change adjustable from 15% to 100% of (1) sensing element range Input Signal Type: � Gauge pressure, � vacuum, (1) Reset Adjustment � compound pressure, or � differential pressure For Proportional-Plus-Reset Controllers: of a liquid or gas Adjustable from 0.01 to 74 minutes per repeat Limits: See table 3 or 4 (100 to 0.01 repeats per minute) (1) Output Signal (1) Zero Adjustment (Transmitters Only) Proportional-Only or Proportional-Plus-Reset Continuously adjustable to position span of less Controllers and Transmitters: than 100% anywhere within the sensing element � 0.2 to 1.0 bar (3 to 15 psig) or range � 0.4 to 2.0 bar (6 to 30 psig) pneumatic pressure signal (1) Span Adjustment (Transmitters Only) Differential Gap Controllers: � 0 and 1.4 bar (0 and 20 psig) or Full output pressure change adjustable from 6 to � 0 and 2.4 bar (0 and 35 psig) pneumatic 100% of sensing element range pressure signal Action: Control action is field reversible between Performance � direct (increasing sensed pressure produces (1) Repeatability : 0.5% of sensing element range increasing output signal) and � reverse (1) Deadband (Except Differential Gap (increasing sensed pressure produces decreasing (4) Controllers : 0.1% of output span output signal). The suffix R is added to the type Typical Frequency Response at 100% number of a construction specified for reverse Proportional Band action. Output to Actuator: 0.7 Hz and 110 degree phase 3 3 shift with 1850 cm (113 inches ) volume, (2) Supply Pressure Requirements actuator at mid-stroke See table 5 Output to Positioner Bellows: 9 Hz and 130 degree phase shift with 0.2 to 1.0 bar (3 to 15 3 3 psig) output to 33 cm (2 inches ) bellows Supply Pressure Medium (3) Air or natural gas (2) Ambient Operating Temperature Limits (1) � Standard Construction: −40 to 93�C (−40 to Steady-State Air Consumption 200�F) See figure 2 � 4160KF (w/Reset Relief): −40 to 71�C (−40 to 160�F) Supply and Output Connections 1/4-inch NPT female Typical Ambient Temperature Operating Influence Common Signal Pressure Conversions Proportional Control only: Output pressure See table 6 changes �3.0% of sensing element range for each 28�C (50�F) change in temperature (1) Proportional Band Adjustment between −40 and 71�C (−40 and 160�F) for a controller set at 100% proportional band For Proportional-Only and Reset Control only: Output pressure changes Proportional-Plus-Reset Controllers: Full output pressure change adjustable from 3 to �2.0% of sensing element range for each 28�C 100% for a 0.2 to 1.0 bar (3 to 15 psig), or 6 to (50�F) change in temperature between −40 and 100% for a 0.4 to 2.0 bar (6 to 30 psig) of the 71�C (−40 and 160�F) for a controller set at 100% sensing element range. proportional band −Continued− 3 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Table 1. Specifications (continued) Typical Ambient Temperature Operating Approximate Weight Influence (continued) 8.2 kg (18 pounds) Transmitters only: Output pressure changes Options �3.0% of sensing element range for each 28�C Case pressure tested to 0.14 bar (2 psig) (50�F) change in temperature between −40 and 71�C (−40 and 160�F) for a transmitter set at Declaration of SEP 100% span Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 of the Pressure Equipment Directive Hazardous Area Classification (PED) 97 / 23 / EC. It was designed and manufactured in accordance with Sound Complies with the requirements of ATEX Group II Engineering Practice (SEP) and cannot bear the Category 2 Gas and Dust CE marking related to PED compliance. However, the product may bear the CE marking to indicate compliance with other applicable EC Refer to figure 22 for location of ATEX label Directives. 1. This term is defined in ISA Standard S51.1. 2. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded. 3. This product can be used with natural gas. Natural gas should not contain more than 20 ppm of H S. 2 4. An adjustable differential gap (differential gap controllers) is equivalent to an adjustable deadband. Table 2. Available Configurations (1) TYPE NUMBER Bourdon Tube DESCRIPTION Bellows Sensing Element Sensing Element Gauge Differential (Gauge Pressure Pressure Pressure Only) Proportional-only controller 4150K 4152K 4154K Without anti-reset windup 4160K 4162K 4164K Proportional-plus-reset controller With anti-reset windup 4160KF 4162KF - - - Differential gap controller 4150KS 4152KS - - - Transmitter 4157K 4158K 4155K 1. The suffix R is added to the type number of a construction specified for reverse action. Table 3. Bourdon Tube Pressure Ranges and Materials (2) (3) MAXIMUM ALLOWABLE STATIC PRESSURE LIMITS (1) PRESSURE RANGES (4) Standard With Optional Travel Stop MATERIAL Bar Psig Bar Psig Bar Psig 0 to 2.0 0 to 30 2.0 30 3.3 48 0 to 4.0 0 to 60 4.0 60 6.6 96 0 to 7.0 0 to 100 7.0 100 11 160 0 to 14 0 to 200 14 200 19 280 0 to 20 0 to 300 20 300 29 420 (5) 0 to 40 0 to 600 40 600 50 720 316 stainless steel (5) 0 to 70 0 to 1000 70 1000 83 1200 (5) 0 to 100 0 to 1500 100 1500 115 1650 0 to 200 0 to 3000 200 3000 230 3300 0 to 350 0 to 5000 350 5000 380 5500 0 to 550 0 to 8000 550 8000 550 8000 0 to 700 0 to 10.000 700 10,000 700 10,000 1. Range marked on Bourdon tube may be in kPa (1 bar = 100 kPa) 2. This term is defined in ISA Standard S51.1. 3. Bourdon tube may be pressurized to limit shown without permanent zero shift. 4. With travel stop set at 110% of the range. 5. These Bourdon tubes are also available in N05500 for sour service. 4 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Table 4. Bellows Pressure Ranges and Materials MAXIMUM ALLOWABLE STATIC PRESSURE RANGES (1) (2) PRESSURE LIMITS Brass Stainless Steel Construction Construction Bar Psig Bar Psig 0 to 150 mbar (0 to 60 inch wc) 1.6 20 --- --- Vacuum 0 to 340 mbar (0 to 10 inch Hg) 2.8 40 --- --- 0 to 1.0 bar (0 to 30 inch Hg) 2.8 40 6.9 100 75 mbar vac. to 75 mbar (30 inch wc vac. to 30 inch wc) 1.4 20 --- --- Compound Pressure 500 mbar vac. to 500 mbar (15 inch Hg vac. to 7.5 psig) 2.8 40 6.9 100 1.0 bar vac. to 1.0 bar (30 inch Hg vac. to 15 psig) 2.8 40 6.9 100 0 to 150 mbar (0 to 60 inch wc) 1.4 20 --- --- (3) Gauge Pressure 0 to 250 mbar (0 to 100 inch wc) 1.4 20 --- --- (4) 0 to 350 mbar (0 to 140 inch wc) 2.8 40 --- --- 0 to 0.35 bar (0 to 5 psig) 2.8 40 --- --- 0 to 0.5 bar (0 to 7.5 psig) 2.8 40 --- --- Positive pressure 0 to 0.7 bar (0 to 10 psig) 2.8 40 --- --- 0 to 1.0 bar (0 to 15 psig) 2.8 40 6.9 100 0 to 1.4 bar (0 to 20 psig) 2.8 40 --- --- 0 to 2.0 bar (0 to 30 psig) 2.8 40 6.9 100 0 to 300 mbar (0 to 80 inch wc) 1.4 20 --- --- 0 to 0.7 bar (0 to 10 psi) 2.8 40 --- --- (5) Differential Pressure 0 to 1.4 bar (0 to 20 psi) 2.8 40 --- --- 0 to 2.0 bar (0 to 30 psi) --- --- 6.9 100 1. This term is defined in ISA Standard S51.1. 2. Bellows may be pressured to limit shown without permanent zero shift. 3. Type 4158K transmitter only. 4. Except Type 4158K transmitter. 5. The overrange limit for these sensing elements is a differential pressure equal to the maximum allowable static pressure limit. 2 PROPORTIONAL BAND WARNING SETTING OF 5 (Installation Warning, continued from page 2) � If installing into an existing PROPORTIONAL application, also refer to the WARNING BAND SETTING OF 0 at the beginning of the Maintenance OR 10 section in this instruction manual. � Check with your process or safety OUTPUT, PSIG 1 engineer for any additional measures 3 TO 15 PSIG (0.2 TO 1.0 BAR) OUTPUT SIGNAL RANGE that must be taken to protect against 2 process media. PROPORTIONAL BAND SETTING OF 5 Standard Installation The instruments are normally mounted vertical with PROPORTIONAL BAND the case/cover as shown in figure 1. If installing the SETTING OF 0 OR 10 instrument in any other position, be sure that the vent opening shown in figure 3 is facing downward. OUTPUT, PSIG 1 Panel Mounting 6 TO 30 (0.4 TO 2.0 BAR) OUTPUT SIGNAL RANGE Refer to figure 3. NOTES 1 TO CONVERT PSIG TO BAR, MULTIPLY BY 0.06895. 2 SCFH—STANDARD CUBIC FEET PER HOUR (60�F AND 14.7 PSIA). Cut a hole in the panel surface according to the 3 TO CONVERT TO NORMAL M /HR—NORMAL CUBIC METERS PER HOUR (0�C dimensions shown in figure 3. Remove the cap AND 1.01325 BAR, ABSOLUTE), MULTIPLY BY 0.0268 screws (key 252), brackets (key 251), and vent Figure 2. Steady-State Air Consumption assembly (key 15). Slide the controller or transmitter A7242 / IL 5 SUPPLY AIR FLOW, SCFH SUPPLY AIR FLOW, SCFH Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters into the cutout and reattach the brackets. Tighten the Pressure Connections cap screw located in the center of each bracket to draw the case snugly and evenly against the panel. Reinstall the vent unless a remote vent will be used. WARNING To avoid personal injury or property damage resulting from the sudden Wall Mounting release of pressure, do not install any Refer to figure 3. system component where service conditions could exceed the limits Drill four holes in the wall using the dimensions given in this manual. Use shown in figure 3. In the bracket (key 251) are 8.7 pressure-relieving devices as required mm (0.3438 inch) diameter holes. Back out the cap by government or accepted industry screw located in the center of each bracket. (The codes and good engineering practices. screws are used for panel mounting but are not required for wall mounting.) If tubing runs through All pressure connections on 4150K and 4160K the wall, drill holes in the wall to accommodate the Series instruments are 1/4-inch NPT female. Use 6 tubings. Figure 3 shows the pressure connection mm (1/4-inch) or 10 mm (3/8-inch) pipe or tubing for locations in the back of the case. supply and output piping. The pressure connection locations are shown in figure 3. Mount the controller to the bracket using the four cap screws (key 252) provided. Attach the bracket to the wall, using suitable screws or bolts. Supply Pressure WARNING Pipestand Mounting Refer to figure 3. Severe personal injury or property Attach the spacer spools (key 228) and the mounting damage may occur from an plate (key 213) to the controller with cap screws, uncontrolled process if the instrument lock washers, and nuts (keys 215, 221, and 216). supply medium is not clean, dry, Attach the controller to a 2-inch (nominal) pipe with oil-free and noncorrosive. While use pipe clamps (key 250). and regular maintenance of a filter that removes particles larger than 40 microns in diameter will suffice in Actuator Mounting most applications, check with an Emerson Process Management field Refer to figure 4. office and industry instrument supply Controllers specified for mounting on a control valve medium quality standards for use with actuator are mounted at the factory. If the instrument hazardous gas or if you are unsure is ordered separately for installation on a control about the proper amount or method of valve actuator, mount the instrument according to air filtration or filter maintenance. the following instructions. Supply pressure must be clean, dry air or Mounting parts for the different actuator types and noncorrosive gas that meets the requirements of ISA sizes vary. Two typical actuator-mounting Standard S7.3. Use a suitable supply pressure installations are shown in figure 4; see the parts list regulator to reduce the supply pressure source to for parts required for the specific actuator type and the normal operating supply pressure shown in table size involved. Attach the spacer spools (key 228) 5. Connect supply pressure to the SUPPLY and the mounting plate (key 213) to the controller connection at the back of the case. with machine screws, lock washers, and nuts (keys If operating the controller or transmitter from a high 215, 221, and 216). pressure source [up to 138 bar (2000 psig)], use a Attach the mounting bracket to the actuator yoke high pressure regulator system, such as the Type with cap screws (key 222) and, if needed, spacer 1367 High Pressure Instrument Supply System. For spools. On some designs, the mounting bracket is Type 1367 system installation, adjustment, and attached to the actuator diaphragm casing rather maintenance information, see the separate than to the yoke. instruction manual. 6 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 2 INCH (NOMINAL) PIPE VENT ASSEMBLY (KEY 15) BACK VIEW PIPESTAND MOUNTING 8.7 (11/32) MOUNTING HOLES FOUR HOLES CUTOUT FOR FOR WALL PANEL MOUNTING PANEL MOUNTING WALL MOUNTING MOUNTING NOTES: 1. ALL CONNECTIONS ARE 1/4-INCH NPT FEMALE. 2 mm HIGH-PRESSURE CONNECTION FOR DIFFERENTIAL-PRESSURE UNITS. (INCH) 3 LOW-PRESSURE CONNECTION FOR DIFFERENTIAL-PRESSURE UNITS. B1563-2 / IL GE07082-A Figure 3. Panel, Wall, and Pipestand Mounting The pressure connections to the controller depend Process Pressure upon the type of pressure sensing, gauge or differential. Gauge pressure controllers use either a WARNING Bourdon tube or bellows as the sensing element, as indicated in table 2. Differential pressure controllers To avoid personal injury or property use two bellows to sense differential pressure. damage resulting from the sudden release of pressure when using For gauge pressure instruments: The control corrosive media, make sure the tubing pressure block (key 8 in figure 18) has two and instrument components that connections. Process pressure can be connected contact the corrosive medium are of either to the CONTROL connection on the back of suitable noncorrosive material. the case, or to the connection on the left side of the Also refer to the Installation Warning case, shown in figure 3, depending on the at the beginning of this section. instrument application. Plug the unused connection. 7 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Table 5. Supply Pressure Requirements OUTPUT MAXIMUM ALLOWABLE SUPPLY NORMAL OPERATING SUPPLY SIGNAL RANGE PRESSURE TO PREVENT INTERNAL (1) PRESSURE PART DAMAGE 0.2 to 1.0 or 0 and 1.4 (differential gap) 1.4 2.8 Bar 0.4 to 2.0 or 0 and 2.4 (differential gap) 2.4 2.8 3 to 15 or 0 and 20 (differential gap) 20 40 Psig 6 to 30 or 0 and 35 (differential gap) 35 40 1. If this pressure is exceeded, control may be impaired. Table 6. Common Signal Pressure Conversions 2 Mps kg/cm bar kPa Psi (2) (1) 0.02 0.2 0.2 20 3 SUPPLY PRESSURE 0.03 0.3 0.3 35 5 REGULATOR (1) 0.04 0.4 0.4 40 6 0.05 0.5 0.5 50 7 0.06 0.6 0.6 60 9 0.07 0.8 0.8 75 11 0.08 0.8 0.8 80 12 0.09 1.0 1.0 95 14 (3) (2) (1) 0.10 1.0 1.0 100 15 0.12 1.3 1.2 125 18 0.14 1.4 1.4 140 20 0.15 1.5 1.5 150 22 0.17 1.8 1.7 170 25 0.18 1.9 1.9 185 27 (3) (1) 0.20 2.0 2.0 200 30 0.22 2.2 2.2 220 32 0.23 2.3 2.3 230 33 0.24 2.5 2.4 240 35 0.34 3.5 3.4 345 50 0.55 5.6 5.5 550 80 0.69 7.0 6.9 690 100 48B6020-A / DOC 1.03 10.5 10.3 1035 150 TYPICAL ROTARY ACTUATOR 1. Values as listed in ANSI/S7.4. 2. Values as listed in IEC Standard 382. 3. Values rounded to correspond with kPa values. For differential pressure instruments: Connect the low pressure line to the CONTROL connection on the side of the case and the high pressure line to the CONTROL connection on the back of the case as shown in figure 3. When installing process piping, follow accepted practices to ensure accurate transmission of the process pressure to the controller or transmitter. SUPPLY PRESSURE Install shutoff valves, vents, drains, or seal systems REGULATOR as needed in the process pressure lines. If the instrument is located such that the adjacent process pressure lines will be approximately horizontal, the lines should slope downward to the instrument for liquid-filled lines and upward to instruments for 38B6021-A / DOC gas-filled lines. This will minimize the possibility of air becoming trapped in the sensor with liquid-filled TYPICAL SLIDING STEM ACTUATOR lines or of condensation becoming trapped with gas-filled lines. The recommended slope is 83 mm per meter (1 inch per foot). Figure 4. Actuator Mounting 8 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters If a controller is being used in conjunction with a Controller Operation control valve to control pipeline pressure, connect the process pressure line in a straight section of pipe approximately 10 pipe diameters from the valve but Proportional-Only Controllers away from bends, elbows, and areas of abnormal fluid velocities. For pressure-reducing service, the This section describes the adjustments and process line must be connected downstream of the procedures for calibration and startup. Adjustment valve. For pressure-relief service, the process locations are shown in figure 5 unless otherwise pressure line must be connected upstream of the specified. All adjustments must be made with the control valve. Install a needle valve in the process cover open. When the adjustments and calibration pressure line to dampen pulsations. procedures are complete, close and latch the cover. To better understand the adjustments and overall operation of the controller, refer to the Principle of Vent Assembly Operation section in this manual for proportional-only controllers. Refer also to the schematic diagram in figure 14. WARNING Adjustments Personal injury or property damage could result from fire or explosion of Adjustment: Set Point accumulated gas, or from contact with hazardous gas, if a flammable or Adjust the pressure-setting knob by turning the knob hazardous gas is used as the supply clockwise to increase the set point and pressure medium. Because the counterclockwise to decrease the set point. Note: instrument case and cover assembly The dial setting and actual process pressure may do not form a gas-tight seal when the vary significantly, especially with a wide proportional assembly is enclosed, a remote vent band setting. line, adequate ventilation, and necessary safety measures should be Adjustment: Proportional Band used to prevent the accumulation of flammable or hazardous gas. However, To adjust the proportional band, rotate the a remote vent pipe alone cannot be proportional band knob to the desired value. relied upon to remove all flammable The proportional band adjustment determines the and hazardous gas. Vent line piping amount of change in controlled pressure required to should comply with local and regional cause the control valve to stroke fully. It may be codes, and should be be as short as adjusted from 3-100 percent of the nominal sensing possible with adequate inside diameter element pressure rating. and few bends to reduce case pressure buildup. Calibration: Proportional-Only Controllers CAUTION Unless otherwise indicated, key number locations are shown in figure 5. When installing a remote vent pipe, Provide a process pressure source capable of take care not to overtighten the pipe in simulating the process pressure range of the the vent connection. Excessive torque controller. If an output pressure gauge is not will damage the threads in the provided, install a suitable pressure gauge for connection. calibration purposes. The vent assembly (key 15, figure 3) or the end of a remote vent pipe must be protected against the Connect a pressure source to the supply pressure entrance of all foreign matter that could plug the regulator and be sure the regulator is delivering the vent. Use 13 mm (1/2-inch) pipe for the remote vent correct supply pressure to the controller. The pipe, if one is required. Check the vent periodically controller must be connected open loop (Open loop: to be certain it has not become plugged. The controller output pressure changes must be 9 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters PROPORTIONAL BAND ADJUSTMENT KNOB PRESSURE-SETTING KNOB (KEY 36) PRESSURE-SETTING DIAL (KEY 38) FLAPPER (KEY 45) CALIBRATION ADJUSTER (KEY 41) 48B6003-A NOZZLE (KEY 57) A6038-1 / IL ADJUSTER SCREWS (KEY 43) Figure 5. Proportional-Only Controller Adjustment Locations dead ended into a pressure gauge). The following 6. Adjust the nozzle (key 57) until the controller procedures use a 0.2 to 1.0 bar (3 to 15 psig) output output pressure is between 0.6 and 0.7 bar (8 pressure range as an example. For a 0.4 to 2.0 bar and 10 psig.) (6 to 30 psig) output range, adjust the values as 7. Apply an input pressure equal to the sensing appropriate. element upper range value. 1. Complete the above connections and provide a 8. Rotate the pressure-setting knob to the maximum process pressure equal to the sensing element value. range. 2. Rotate the proportional band knob, shown in Note figure 5, to 1.5 (15 percent proportional band). When performing the span adjustment 3. Verify that the calibration adjuster screws in step 9, do not watch the output (key 43) are at mid-position in the calibration gauge while changing the calibration adjuster (key 41) slots. adjuster. The change in output is not a good indication of the change in span. Depending upon the controller action, perform one While moving the calibration adjuster, or the other of the following procedures. the output pressure may change in the opposite direction than expected. For For direct-acting controllers: example, while moving the calibration 4. Apply an input pressure equal to the sensing adjuster to increase span, the output element lower range value. pressure may decrease. This should be disregarded since even though the 5. Rotate the pressure setting knob to the minimum output pressure decreases, the span is value. increasing. 10 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 6. Adjust the nozzle (key 57) until the controller IF OUTPUT IS: output pressure is between 0.6 and 0.7 bar (8 and 10 psig). 7. Apply an input pressure equal to the sensing element lower range value. BELOW ABOVE 8 TO 10 PSIG 8 TO 10 PSIG (0.6 TO 0.7 BAR) (0.6 TO 0.7 BAR) 8. Rotate the pressure-setting knob to the minimum MOVE ADJUSTER MOVE ADJUSTER value. LEFT RIGHT FLAPPER NOZZLE Note When performing the span adjustment NOTE: in step 9, do not watch the output 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST gauge while changing the calibration VALUES AS APPROPRIATE. A6154 / IL adjuster. The change in output is not a good indication of the change in span. While moving the calibration adjuster, Figure 6. Direct-Acting Controller Span the output pressure may change in the Adjustment—Proportional-Only Controllers opposite direction than expected. For example, while moving the calibration Proper controller response depends adjuster to increase span, the output on nozzle-to-flapper alignment. pressure may decrease. This should be disregarded since even though the When performing span adjustments, output pressure decreases, the span is carefully loosen both calibration increasing. adjuster screws while holding the calibration adjuster in place. Then Proper controller response depends move the calibration adjuster slightly on nozzle-to-flapper alignment. in the required direction by hand or When performing span adjustments, using a screwdriver. Verify proper carefully loosen both calibration nozzle-to-flapper alignment and hold adjuster screws while holding the the calibration adjuster in place while calibration adjuster in place. Then tightening both adjustment screws. move the calibration adjuster slightly 9. If the output is not between 0.6 and 0.7 bar (8 in the required direction by hand or and 10 psig), adjust the controller span by loosening using a screwdriver. Verify proper the two adjusting screws (key 43) and moving the nozzle-to-flapper alignment and hold calibration adjuster (key 41) a small distance as the calibration adjuster in place while indicated in figure 6. tightening both adjustment screws. 10. Repeat steps 4 through 9 until no further 9. If the output is not between 0.6 and 0.7 bar (8 adjustment is necessary. and 10 psig), adjust the controller span by loosening 11. Proceed to the startup procedure for the two adjusting screws (key 43) and moving the proportional controllers. calibration adjuster (key 41) a small distance as indicated in figure 7. For reverse-acting controllers: 4. Apply an input pressure equal to the sensing 10. Repeat steps 4 through 9 until no further element upper range value. adjustment is necessary. 5. Rotate the pressure setting knob to the maximum 11. Proceed to the startup procedure for value. proportional controllers. 11 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 4. Proportional Action IF OUTPUT IS: Disturb the system by tapping the flapper lightly or change the set point a small amount and check for system cycling. If the system does not cycle then lower the proportional band (raising the gain) and disturb the system again. Continue this procedure until the system cycles. At that point, double the ABOVE BELOW 8 TO 10 PSIG 8 TO 10 PSIG proportional band setting. (0.6 TO 0.7 BAR) (0.6 TO 0.7 BAR) MOVE ADJUSTER MOVE ADJUSTER LEFT RIGHT Note FLAPPER Proportional band adjustment affects NOZZLE the set point. Proportional-only controllers will show some offset from NOTE: set point depending upon proportional 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. band setting and process demand. FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST VALUES AS APPROPRIATE. After adjusting the proportional band, A6155-1 / IL re-zero by carefully rotating the nozzle (key 57) until the steady-state process pressure equals the process pressure knob reading. Figure 7. Reverse-Acting Controller Span Adjustment — Proportional-Only Controllers This tuning procedure may be too conservative for some systems. The recommended proportional band setting should be checked for stability by introducing a disturbance and monitoring the process. Startup: Proportional-Only Controllers (General Tuning Guidelines) Calibrate the controller prior to this procedure. Proportional-Plus-Reset Controllers 1. Be sure that the supply pressure regulator is This section describes the adjustments and delivering the proper supply pressure to the procedures for calibration and startup. The controller. adjustment locations are shown in figure 8 unless otherwise specified. All adjustments must be made 2. Rotate the pressure-setting knob to the desired with the cover open. When the adjustments and set point. calibration procedures are complete, close and latch the cover. To better understand the adjustments and 3. Set the proportional band adjustment to 100 overall operation of the controller, refer to the percent for fast processes (example: liquid pressure Principle of Operation section in this manual for or liquid flow). For slow processes (example: proportional-plus-reset controllers. Refer also to the temperature), calculate the percentage from the schematic diagram in figure 14. equation below: For a slow process, determine the initial proportional band setting in percent from the following equation: Adjustments 200� Allowable Overshoot Adjustment: Set Point � P.B. Pressure Span Adjust the pressure-setting knob by turning the knob For example: clockwise to increase the set point and counterclockwise to decrease the set point. 200�2psig 200� 1.4 bar � 13% Rotate the knob until the indicator points to the � 13% ( ) 30 psig 2.1 bar desired set point pressure value. The pressure setting dial will reflect the desired set point if the (1.3 proportional band setting) controller is accurately calibrated. 12 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters RESET ADJUSTMENT KNOB PROPORTIONAL BAND ADJUSTMENT KNOB PRESSURE SETTING KNOB (KEY 36) PRESSURE SETTING DIAL (KEY 38) CALIBRATION ADJUSTER (KEY 41) FLAPPER (KEY 45) 48B6002-A ADJUSTER SCREWS (KEY 43) A5433-3 / IL NOZZLE (KEY 57) Figure 8. Proportional-Plus-Reset Controller Adjustment Locations Adjustment: Proportional Band a proportional increase (or decrease) caused by a change in set point or process pressure. To adjust the proportional band, rotate the Adjustment: Anti-Reset Windup proportional band knob to the desired value. The externally mounted differential relief valve can The proportional band adjustment determines the be mounted to relieve on increasing or decreasing amount of change in controlled pressure required to output pressure. cause the control valve to stroke fully. It may be adjusted from 3-100 percent of the nominal sensing Calibration element pressure rating. Calibration: Proportional-Plus-Reset Controllers Adjustment: Reset Unless otherwise indicated, key number locations are shown in figure 8. To adjust reset action turn the knob clockwise to decrease the minutes per repeat. Turn the knob Before starting this procedure: counterclockwise to increase the minutes per repeat. � Provide a process pressure source capable of Increasing the minutes per repeat provides a slower simulating the process pressure range of the reset action. controller. The reset adjustment dial is calibrated in minutes per repeat. By definition, this is the time in minutes � If an output pressure gauge is not provided, required for the reset action to produce an output install a suitable pressure gauge for calibration change which is equal to the change produced by purposes. The controller must be connected open proportional control action. This is in effect, the time loop (Open loop: The controller output pressure in minutes required for the controller to increase (or changes must be dead ended into a pressure decrease) its output pressure by an amount equal to gauge). 13 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Note IF OUTPUT IS: Type 4160KF and 4162KF (anti-reset windup) controllers are supplied with two O-rings (key 367, not shown), an anti-reset windup cover (key 369, not shown), and two machine screws (key 368, not shown). Use these parts in the BELOW ABOVE 8 TO 10 PSIG 8 TO 10 PSIG next step. (0.6 TO 0.7 BAR) (0.6 TO 0.7 BAR) 1. For controllers with anti-reset windup (Type MOVE ADJUSTER MOVE ADJUSTER LEFT 4160KF and 4162KF), record the direction of the RIGHT arrow on the anti-reset windup assembly (key 186, in figure 19). Remove the assembly and install the two FLAPPER O-rings (key 367, not shown), and cover (key 369, NOZZLE not shown) supplied with the controller. Secure the cover with the two machine screws (key 368, not NOTE: shown) provided. 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST 2. Connect regulated supply pressure to the VALUES AS APPROPRIATE. A6154 / IL controller. Do not exceed the normal operating Figure 9. Direct-Acting Controller Span Adjustment pressure in table 5. —Proportional-Plus-Reset Controllers 3. Rotate the reset knob to 0.01 minutes per repeat the output pressure may change in the (fastest setting). opposite direction than expected. For 4. Rotate the proportional band knob to 1.5 (15 example, while moving the calibration percent proportional band). adjuster to increase span, the output pressure may decrease. This should 5. Verify that the calibration adjuster screws be disregarded since even though the (key 43) are at mid-position in the calibration output pressure decreases, the span is adjuster (key 41) slots. increasing. Depending upon the controller action, perform one Proper controller response depends or the other of the following procedures. on nozzle-to-flapper alignment. For direct-acting controllers: When performing span adjustments, carefully loosen both calibration 6. Apply an input pressure equal to the sensing adjuster screws while holding the element lower range value. calibration adjuster in place. Then move the calibration adjuster slightly 7. Rotate the pressure setting knob to the minimum in the required direction by hand or value. using a screwdriver. Verify proper 8. Adjust the nozzle (key 57) until the controller nozzle-to-flapper alignment and hold output pressure is between 0.6 and 0.7 bar (8 the calibration adjuster in place while and 10 psig). tightening both adjustment screws. 9. Apply an input pressure equal to the sensing 11. If the output pressure is not between 0.6 and 0.7 element upper range value. bar (8 and 10 psig), adjust the controller span by loosening the two adjusting screws (key 43) and 10. Rotate the pressure-setting knob to the moving the calibration adjuster (key 41) a small maximum value. distance as indicated in figure 9. 12. Repeat steps 6 through 11 until no further Note adjustment is necessary. When performing the span adjustment 13. For controllers with anti-reset windup (Type in step 11, do not watch the output 4160KF and 4162KF), remove the two machine gauge while changing the calibration screws, anti-reset windup cover, and two O-rings adjuster. The change in output is not a installed in step 1 of this procedure. Install the good indication of the change in span. anti-reset windup assembly (key 186) with the arrow While moving the calibration adjuster, pointing in the direction recorded in step 1. 14 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 14. Proceed to the Startup procedures for IF OUTPUT IS: proportional-plus-reset controllers. For reverse-acting controllers: 6. Apply an input pressure equal to the sensing element upper range value. ABOVE BELOW 8 TO 10 PSIG 8 TO 10 PSIG (0.6 TO 0.7 BAR) (0.6 TO 0.7 BAR) 7. Rotate the pressure setting knob to the maximum value. MOVE ADJUSTER MOVE ADJUSTER LEFT RIGHT 8. Adjust the nozzle (key 57) until the controller FLAPPER output pressure is between 0.6 and 0.7 bar (8 and 10 psig). NOZZLE NOTE: 9. Apply an input pressure equal to the sensing 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. element lower range value. FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST VALUES AS APPROPRIATE. A6155-1 / IL 10. Rotate the pressure-setting knob to the minimum Figure 10. Reverse-Acting Controller Span Adjustment— value. Proportional-Plus-Reset Controllers moving the calibration adjuster (key 41) a small distance as indicated in figure 10. Note 12. Repeat steps 6 through 11 until no further When performing the span adjustment in step 11, do not watch the output adjustment is necessary. gauge while changing the calibration 13. For controllers with anti-reset windup (Type adjuster. The change in output is not a good indication of the change in span. 4160KF and 4162KF), remove the two machine While moving the calibration adjuster, screws, anti-reset windup cover, and two O-rings the output pressure may change in the installed in step 1 of this procedure. Install the opposite direction than expected. For anti-reset windup assembly (key 186) with the arrow example, while moving the calibration pointing in the direction recorded in step 1. adjuster to increase span, the output pressure may decrease. This should 14. Proceed to the Startup procedures for be disregarded since even though the proportional-plus-reset controllers. output pressure decreases, the span is increasing. Calibration: Anti-Reset Windup Proper controller response depends Controllers with anti-reset windup have a differential on nozzle-to-flapper alignment. relief valve assembly (figure 19). This relief valve is set at the factory to relieve at a 0.3 bar (5 psi) When performing span adjustments, pressure difference between the reset bellows carefully loosen both calibration pressure and the proportional bellows pressure. The adjuster screws while holding the valve can be adjusted to relieve from 0.14 to 0.4 bar calibration adjuster in place. Then (2 to 7 psig). move the calibration adjuster slightly in the required direction by hand or The relief valve can relieve on either rising controller using a screwdriver. Verify proper output pressure or falling controller output pressure. nozzle-to-flapper alignment and hold If the arrow on the relief valve points toward the the calibration adjuster in place while bottom of the controller case as shown in figure 19, tightening both adjustment screws. the valve will relieve on falling output pressure. If the arrow points in the opposite direction, the valve will 11. If the output pressure is not between 0.6 and 0.7 relieve on rising output pressure. The valve can be bar (8 and 10 psig), adjust the controller span by removed and reinstalled with the arrow pointing in loosening the two adjusting screws (key 43) and the opposite direction to change the relief action. 15 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Startup: Proportional-Plus-Reset Differential Gap Controllers Controllers (General Tuning Guidelines) This section describes the adjustments and procedures for calibration and startup. The Calibrate the controller prior to this procedure. adjustment locations are shown in figure 5 unless 1. Be sure that the supply pressure regulator is otherwise specified. The output of each controller is delivering the proper supply pressure to the checked at the factory before the instrument is controller. shipped. To convert a differential gap controller to a 2. Rotate the pressure-setting knob to the desired proportional-only controller or vice versa, refer to the set point. appropriate procedure in the Maintenance section. 3. Start with a reset setting of 0.05 minutes per If the process pressure can be varied through all or repeat (m/r) for fast processes, and 0.5 m/r for slow part of the sensing element range or through the two processes. desired switching points, use the process pressure 4. Set the proportional band adjustment to 100 for calibration. If not, provide a pressure source to percent for fast processes (example: liquid pressure simulate the process pressure range for calibration or liquid flow). For a slow process (example: procedures. temperature), calculate the percentage from the To better understand the adjustments and overall equation below: operation of the controller, refer to the Principle of For a slow process, determine the initial proportional Operation section in this manual for differential gap band setting in percent from the following equation: controllers and the schematic diagram in figure 14. 200� Allowable Overshoot � P.B. Adjustments Pressure Span Adjustment: Set Point For example: The position of the pressure-setting knob determines 200�2psig 200� 1.4 bar the location of the differential gap within the range of � 13% � 13% ( ) 30 psig 2.1 bar the pressure sensing element. Move the pointer to the desired pressure where the output of the controller should switch from zero to full supply (1.3 proportional band setting) pressure with rising process pressure (direct-acting 5. Proportional Action: controllers) or with falling process pressure (reverse-acting controllers). Disturb the system by tapping the flapper lightly or change the set point a small amount and check for Adjustment: Proportional Band system cycling. If the system does not cycle then lower the proportional band (raising the gain) and The proportional band adjustment shown in figure 5 disturb the system again. Continue this procedure determines the width of the differential gap. The until the system cycles. At that point, double the width of the gap is the difference between the proportional band setting and begin tuning the reset. process pressures at which the controller output will switch from zero to full supply pressure, or from full 6. Reset Action: supply pressure to zero. The relationship between the proportional band dial setting and the differential Disturb the system. If the system does not cycle then gap is shown in figure 11. speed up the reset and disturb the system again. Continue this procedure until the system cycles. When the system cycles multiply the reset time Calibration: Differential Gap Controllers setting by a factor of three (3) and slow the reset The output of each controller is checked at the down to the new value. The reset is now tuned. factory before the unit is shipped. Before placing the This tuning procedure may be too conservative for controller in control of a process loop, check to verify some systems. The recommended proportional band that the controller is calibrated correctly for the and reset setting should be checked for stability by application. The controller must be connected open introducing a disturbance and monitoring the loop (Open loop: The controller output pressure process as previously described. For some changes must be dead ended into a pressure applications, tighter control may be desirable. gauge). 16 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters falling pressure. (This is for a direct-acting controller.) The differential gap is: 5.5 bar� 1.3 bar � 100� 60% 6.9 bar 80 psig� 20 psig � 100� 60% () 100 psig From figure 11, the proportional band dial setting should be approximately 4.5; rotate the proportional band knob to 4.5. 5. Setting the process pressure DIFFERENTIAL GAP (PERCENT OF ELEMENT RANGE) A2202-3 / IL For a Direct-Acting Controller: Figure 11. Differential Gap Adjustment for Differential Gap a. Rotate the pressure-setting knob to the Controllers pressure at which the controller output is to switch to the upper switching point (zero to full 1. Temporarily convert the differential gap controller supply pressure) with rising process pressure. In to a proportional-only controller by disconnecting the the above example, this pressure is 5.5 bar (80 proportional tubing (key 104, figure 16) from the psig). mounting base. Reinstall the tubing into the other connection in the mounting base as shown in b. Increase pressure to the sensing element figure 16. Do not invert the reversing block (key 59, while monitoring the output pressure gauge. The figure 16). controller output pressure should switch from zero to full supply pressure when the upper 2. Use the calibration procedures for switching point is reached with rising input proportional-only controllers. pressure. 3. Upon completion of the calibration procedures, reinstall the tubing (key 104) in its original location, and continue with the following procedures. Note If the upper switching point is not correct, adjust the nozzle to correct Note the error. Repeat step 5b until the input pressure and upper switching After reinstalling the tubing (key 104) point are at the desired setting. in step 3 a slight offset of the output pressure will be noticed due to c. With falling input pressure, the output should switching from the proportional switch from full supply pressure back to zero bellows to the reset bellows. This is when the lower switching point is reached. because the effective area and spring rate of the two bellows may not match. Reverse-acting controllers produce the opposite Performing step 5b below adjusts for response. this offset. 6. Vary the process pressure and observe the 4. Refer to figure 11 to determine the proportional switching points. Widen or narrow the differential band dial setting required for the desired differential gap by rotating the proportional band knob, then gap. repeat the above steps. For example, assume that a 0 to 100 psig sensing element is being used and the controller is to switch If the output is within the limits stated, refer to the from zero to full supply pressure at a process startup procedures in this section. If the output pressure of 80 psig with rising process pressure and pressure cannot be adjusted within the limits stated, from full supply pressure to zero at 20 psig with refer to the maintenance procedures. 17 PROPORTIONAL BAND KNOB SETTING Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters SPAN ADJUSTMENT KNOB ZERO ADJUSTMENT KNOB (KEY 36) PRESSURE SETTING DIAL (KEY 38) ADJUSTER SCREWS (KEY 43) FLAPPER (KEY 45) 48B6004-B CALIBRATION ADJUSTER (KEY 41) A6039-3 / IL NOZZLE (KEY 57) Figure 12. Transmitter Adjustment Locations When the adjustments and calibration procedures Startup: Differential Gap Controllers are complete, close and latch the cover. Calibrate the controller prior to this procedure. To better understand the adjustments and overall 1. Be sure that the supply pressure regulator is operation of the transmitter, refer to the Principle of delivering the proper supply pressure to the Operation section in this manual for transmitters. controller. Refer also to the schematic diagram in figure 14. 2. Adjust the proportional band knob for the proper differential gap (see figure 11). Adjustments 3. If the controller is used in conjunction with a control valve, slowly open the upstream and Adjustment: Zero downstream manual shutoff valves, and close the The pressure-setting dial is marked ZERO bypass valves. ADJUSTMENT PRESSURE SETTING. Zero is in the center of the dial, and the pressure values increase 4. To change the differential gap, perform steps 1 to the right and left of the center as shown in figure through 4 of the calibration for differential gap 12. To set the zero, rotate the pointer around the controllers procedure. pressure setting dial. Rotate the pointer clockwise to increase or counterclockwise to decrease the output depending on transmitter action and desired setting. For direct-acting transmitters, zero adjustment determines the process pressure at which the Transmitter Operation transmitter output signal will be at its lower range limit. This section describes the adjustments and procedures for calibration and startup. Refer to The dial (key 38) graduations are approximate figure 12 for the adjustment locations. All indications of the transmitter zero setting. When adjustments must be made with the cover open. making adjustments, do not rely solely on the dial 18 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters setting. Monitor the process pressure and output For direct-acting transmitters: pressure to be sure the desired settings are attained. 4. Rotate the zero adjustment knob to zero. 5. Set the input pressure to zero. Adjustment: Span 6. Adjust the nozzle (key 57) until the transmitter The span adjustment dial is graduated from 0 to 10. output pressure is at 0.1 bar (3 psig). A setting of 10 on the dial represents a span setting of 100 percent of the process sensing element 7. Apply an input pressure equal to the sensing range. The transmitter achieves the highest element upper range value. accuracy when the span is 100 percent. The transmitter span adjustment shown in figure 12 Note is the same as the controller proportional band Proper transmitter response depends adjustment. on nozzle-to-flapper alignment. When performing the span adjustment Calibration: Transmitters in step 8, carefully loosen both The output of each transmitter is checked at the calibration adjuster screws while factory before the unit is shipped. The transmitter holding the calibration adjuster in provides an output signal that is proportional to the place. Then move the calibration pressure applied to the sensing element. The output adjuster slightly in the required pressure has no direct effect on the process direction by hand or using a pressure. screwdriver. Verify proper nozzle-to-flapper alignment and hold The transmitter is calibrated at the factory and the calibration adjuster in place while should not need additional adjustment. Use the tightening both adjustment screws. following calibration procedures when the sensing element has been changed or other maintenance 8. If the output pressure is not 15 psig, adjust the procedures have altered the calibration of the span by loosening the two adjusting screws (key 43) transmitter. The following procedures use a 0.1 to and moving the calibration adjuster (key 41) a small 1.0 bar (3 to 15 psig) output pressure range as an distance as indicated in figure 13. example. For other output pressure ranges [such as 9. Repeat steps 4 through 8 until no further 0.2 to 2.0 bar (6 to 30 psig)] adjust the values to adjustment is necessary. match the application. 10. Proceed to the startup procedure for Provide a process pressure source capable of transmitters. simulating the process pressure range of the transmitter. If an output pressure gauge is not For reverse-acting transmitters: provided, install a suitable pressure gauge for (1) calibration purposes . Connect a pressure source 4. Rotate the zero adjustment knob to zero. to the supply pressure regulator and be sure the regulator is delivering the correct supply pressure to 5. Apply an input pressure equal to the sensing the transmitter. element upper range limit. Unless otherwise indicated, key number locations are shown in figure 12. 6. Adjust the nozzle (key 57) until the transmitter output pressure is at 0.1 bar (3 psig). 1. Complete the above connections and provide a process pressure equal to the sensing element 7. Set the input pressure equal to zero. range. 2. Rotate the span adjustment knob to 10 on the Note dial (100 percent span). 3. Verify that the calibration adjuster screws Proper transmitter response depends (key 43) are at mid-position in the calibration on nozzle-to-flapper alignment. adjuster (key 41) slots. When performing the span adjustment Depending upon the transmitter action, perform one in step 8, carefully loosen both or the other of the following procedures. calibration adjuster screws while 1. For stability, some transmitter applications will require additional volume than just the 3 3 gauge. Provide a minimum volume of approximately 25 cm (1.5 in ) or greater if stability is a problem. 19 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters IF OUTPUT IS: downstream manual shutoff valves, and close the bypass valves. BELOW ABOVE Principle of Operation 15 PSIG 15 PSIG (1.0 BAR) (1.0 BAR) The following sections describe the operation of a controller or transmitter using a Bourdon tube MOVE ADJUSTER MOVE ADJUSTER sensing element. The operation is the same for an LEFT RIGHT instrument using a bellows sensing element (key 71, figure 21) except that movement of the beam is caused by expansion or contraction of the bellows or differential bellows. NOTE: 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST Proportional-Only Controllers VALUES AS APPROPRIATE. A6156 / IL As shown in figure 14, supply pressure enters the relay and bleeds through the fixed orifice before escaping through the nozzle. Nozzle pressure also Figure 13. Transmitter Span Adjustment registers on the large relay diaphragm, and loading pressure (controller output pressure) registers on the small relay diaphragm. holding the calibration adjuster in place. Then move the calibration A change in the process pressure moves the beam adjuster slightly in the required and flapper with respect to the nozzle by either direction by hand or using a expanding or contracting the Bourdon tube arc. An screwdriver. Verify proper increasing process pressure with direct action (or nozzle-to-flapper alignment and hold decreasing pressure with reverse action) produces a the calibration adjuster in place while nozzle-flapper restriction that increases the loading tightening both adjustment screws. on the large relay diaphragm and opens the relay valve. Additional supply pressure flows through the 8. If the output pressure is not 15 psig, adjust the relay chamber to increase the loading pressure on span by loosening the two adjusting screws (key 43) the control valve actuator. A decreasing process and moving the calibration adjuster (key 41) a small pressure with direct action (or increasing pressure with reverse action) produces a nozzle-flapper distance as indicated in figure 13. opening that bleeds off pressure on the large relay diaphragm and opens the relay valve to exhaust 9. Repeat steps 4 through 8 until no further controller output pressure from the actuator. adjustment is necessary. This controller output pressure change feeds back to the proportional bellows, countering the pressure 10. Proceed to the startup procedure for change in the nozzle and equalizes the relay diaphragm pressure differential. The relay valve transmitters. maintains a new loading pressure according to the change in sensed pressure. If the proportional valve is wide open, all of the Startup: Transmitters controller output pressure change feeds back to the 1. Be sure that the supply pressure regulator is proportional bellows. The more the proportional delivering the proper supply pressure to the valve is closed, the more the controller output transmitter. pressure change bleeds out through the proportional valve exhaust and the less there is to feed back to 2. Refer to the calibration procedures for the the proportional bellows. A fully open proportional transmitter initial settings. valve results in a proportional band of 100 percent; 3. If the transmitter is used in conjunction with a closing the proportional valve reduces the control valve, slowly open the upstream and proportional band. 20 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters INLET END OF CONSTANT SUPPLY PRESSURE RELAY VALVE SMALL DIAPHRAGM LARGE DIAPHRAGM EXHAUST FIXED ORIFICE EXHAUST END OF RELAY VALVE PROPORTIONAL BELLOWS PIVOTING CROSS SPRINGS BOURDON TUBE FIXED PIVOT NOZZLE RESET VALVE BEAM AND FLAPPER RESET BELLOWS VENT PROPORTIONAL VALVE PROPORTIONAL VALVE EXHAUST PROPORTIONAL-PLUS-RESET CONTROLLER PROPORTIONAL-ONLY CONTROLLER 28A2970-A 28A2971-A SENSED LOADING NOZZLE PROPORTIONAL RESET B1561-3 / IL PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE Figure 14. Schematic of Direct-Acting Proportional-Only and Proportional-Plus-Reset Controllers controlled variable. Anti-reset windup minimizes this Proportional-Plus-Reset Controllers delay and permits returning the controlled variable to Action of a proportional-plus-reset controller is set point more quickly with minimal overshoot. similar to that of a proportional-only controller except that feedback from the controller output pressure is As shown in figure 15 a proportional-plus-reset piped to a reset bellows as well as to the controller with anti-reset windup includes a proportional bellows as shown at the right in figure differential relief valve. The valve consists of two 14. pressure chambers separated by a spring-loaded diaphragm. With an increasing controller output pressure, For the controller shown in figure 15, proportional pressure in the reset bellows increases. Increases in pressure registers rapidly on the spring side of the reset bellows pressure moves the beam and flapper relief valve diaphragm as well as in the proportional closer to the nozzle, starting another increase of bellows, and reset pressure registers on the pressure throughout the system. Pressure buildup opposite side of the relief valve diaphragm. As long continues until the controlled pressure is brought as controlled pressure changes are slow enough for back to the set point. The reset valve is adjustable to normal proportional and reset action, the relief valve vary the amount of delay in the reset action. Closing spring will keep the relief valve diaphragm from the reset valve increases the delay in reset action. opening. However, a large or rapid decrease in controller pressure will cause the relay to exhaust Controllers with Anti-Reset Windup loading pressure from the control device rapidly, and During a prolonged difference between set point and also from the proportional system and spring side of the controlled variable, such as encountered with the relief diaphragm. If this decrease on the spring intermittent control applications (e.g., batch side of the diaphragm is greater than the relief valve temperature control or wide open monitors on spring setting, the diaphragm will move off the relief pressure control), reset ramps the controller output valve orifice and permit the proportional pressure on to either zero or full supply pressure; this condition is the opposite side of the relief valve diaphragm to reset windup. When the controlled variable crosses bleed rapidly into the reset bellows. The anti-reset the set point, there will be a delay before the windup action also can be reversed to relieve with controller output responds to the change in an increasing proportional pressure. 21 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters CONSTANT SUPPLY RELIEF VALVE ADJUSTING PRESSURE SPRING SCREW EXHAUST RESET BELLOWS RELIEF VALVE ORIFICE DIAPHRAGM TO FINAL CONTROL RESET ELEMENT VALVE PROPORTIONAL BELLOWS SENSED WITH ARROW DOWN- PROPORTIONAL PRESSURE RELIEVES ON VALVE DECREASING OUTPUT RESET SENSED LOADING NOZZLE PROPORTIONAL (OUTPUT AT SUPPLY PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE DURING SHUTDOWN) 38B6006-C B1562-5 / IL Figure 15. Schematic of Reverse-Acting Proportional-Plus-Reset Controller with Anti-Reset Windup Differential Gap Controllers Maintenance With a differential gap controller, feedback pressure If the installation includes a 67 Series filter regulator, does not counteract the change in flapper position periodically open the drain on the filter regulator to as it does in a proportional-only controller. Instead, drain accumulated moisture. Also, push the cleaner feedback pressure is piped through the proportional wire on the relay orifice (key 88, not shown). Check valve to the bellows located on the side of the beam the opening of the vent assembly (key 15, figure 3) and flapper opposite the nozzle (the lower bellows in or the opening of the remote vent pipe, if one is figure 14 for direct-acting controllers). Then, as used. If necessary, clean the openings. controller output pressure increases, feedback Parts are subject to normal wear and must be pressure moves the flapper closer to the nozzle to inspected and replaced as necessary. The again increase controller output pressure. This frequency of inspection and parts replacement process continues rapidly until the controller output depends upon the severity of the service conditions. pressure is at the upper range limit. The action of a differential gap controller is so rapid that output pressure changes from zero to maximum as soon as WARNING the switching point is reached. The action is similar with falling output pressure. Lower feedback pressure lowers the bellows pressure, which moves The following maintenance procedures the flapper away from the nozzle. This again require taking the controller out of reduces the output pressure and continues until the service. To avoid personal injury and output pressure is zero. property damage caused by the release of pressure or process fluid, observe the following before starting maintenance: � Always wear protective clothing, Transmitters gloves, and eyewear. Action of a pneumatic transmitter is similar to that of � Provide some temporary means a proportional-only controller. Since the output of control for the process before pressure of the transmitter has no effect on the taking the controller out of service. process pressure, transmitter output pressure is a proportional measure of the process pressure. The � Provide a means of containing the proportional valve determines the span of the process fluid before removing any transmitter, and the pressure setting mechanism measurement devices from the determines the zero of the transmitter. process. 22 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters � Use lock-out procedures to be The pressure control block (key 8) is different to sure that the above measures stay in accommodate a different control tubing assembly effect while you work on the (key 132) with a pressure connection (key 107) for a equipment. process pressure gauge. If a supply pressure gauge is required, a gauge with a 1/4-inch connecting stem � Personal injury or property (key 14) must be mounted on the supply pressure damage may result from fire or regulator. explosion if natural gas is used as the supply medium and preventative measures are not taken. Preventative CAUTION measures may include: Remote venting of the unit, re-evaluating the hazardous area classification, Before performing this procedure, be ensuring adequate ventilation, and the sure the replacement gauges are the removal of any nearby ignition correct range so they are not damaged sources. For information on remote by overpressure. venting of this controller/transmitter, refer to page 9. � Check with your process or safety Note engineer for any additional measures that must be taken to protect against Key 13 is used as both a supply gauge process media. and an output gauge on units without a process pressure gauge. A quantity of 2 is required for these units. On Replacing Gauges units with a process pressure gauge (key 106), key 13 is used for the output gauge. A quantity of 1 is required for these units. WARNING Use key 14 for supply pressure indication when a process pressure Refer to the WARNING at the gauge is installed. Key 14 installs on beginning of the Maintenance Section. the supply pressure regulator. Refer to figures 18 and 19 for key number locations 1. Shut off the supply pressure and process lines to unless otherwise directed. the controller or transmitter. Three gauge configurations are available for 4150K 2. Remove the gauge to be replaced: and 4160K units. � Unscrew the output or supply gauge (key 13) � Output and supply pressure indications from the relay base. � Output and process pressure indications � Unscrew the process pressure gauge (key 106) from the process connection (key 107). � Output, process, and supply pressure indications � Unscrew the supply gauge (key 14) from the supply pressure regulator. One gauge type (key 13) is used for both output and supply pressure indications when the gauges are 3. Coat the threads of the replacement gauge with a installed inside the controller case. Key 13 features a sealant. 1/8-inch connecting stem that matches the threaded gauge boss extending from the relay base. 4. Screw the replacement gauge into the relay base, process connection, or supply pressure regulator. In some cases, a process pressure gauge (key 106) covers the position of the internal supply pressure 5. Check for leaks by applying the correct supply gauge. The supply pressure gauge has been pressure with the nozzle capped to produce full removed and replaced with a pipe plug (key 108). output pressure. 23 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters install a new gauge with the appropriate Replacing Bourdon Tube measurement capability. 11. Check all tubing connections for leaks and the WARNING Bourdon tube machine screws, tighten as necessary. Perform the appropriate calibration procedures. Refer to the WARNING at the beginning of the Maintenance Section. Refer to figure 20 for key number locations unless Replacing Bellows Sensing Element otherwise directed. 1. Shut off the supply pressure and process lines to WARNING the controller or transmitter. 2. Unscrew the machine screw (key 63) to Refer to the WARNING at the disconnect the link (key 64) and bearing (key 65) beginning of the Maintenance Section. from the beam (key 44). Be careful to avoid losing Refer to figure 21 for key number locations unless the bearing (key 65). Washer(s) (key 370) for the otherwise directed. machine screw (key 63) are at times furnished for 1. Shut off the supply pressure and process lines to insertion at the beam (key 44) connection to ensure the controller or transmitter. alignment of the connecting link (key 64). 2. Disconnect the tubing from the mounting base 3. Disconnect the control tubing (key 132). Unscrew (key 30) and calibration adjuster (key 41). two screws (key 77) and washers (key 76), and Disconnect the tubing that connects the pressure remove the Bourdon tube (key 62). block (key 8, figure 18) to the bellows assembly 4. Unscrew the machine screw (key 63), and (key 71), at the pressure block end. remove the link and bearing (keys 64 and 65) from 3. Unscrew the four machine screws (key 28, the Bourdon tube. Be careful to avoid losing the figure 18 or 19), and remove the pressure sensing bearing (key 65). subassembly from the case. 5. Attach the link and bearing to the replacement 4. Remove the bellows yoke machine screws and Bourdon tube. washers (keys 75 and 76), and move the bellows 6. Attach the Bourdon tube with two machine yoke to the right to permit access to the link screw. screws and washers (keys 77 and 76). 5. Disconnect the link (key 71M) and bearing (key 71L) from the beam. Be careful to avoid losing 7. Connect the link and bearing to the beam the bearing. (key 44). 6. Loosen the nuts that secure the bellows 8. After connecting the link to the beam, make sure assembly (key 71), and remove this assembly from the nozzle is centered in the slot in the beam. If not, the bellows yoke (key 70). carefully loosen the machine screw (key 63) enough so that you can slip a washer (key 370) between the 7. For a gauge-pressure sensing element (only one bearing (key 65) and beam (key 44). Retighten the bellows in the assembly), install the proper bellows machine screw and check the nozzle and beam spring (key 80) into the bellows assembly if the input alignment. signal range is being changed. See the parts list for the correct part number. 9. Check to be sure that the beam is parallel with the bottom of the case and that the link (key 64) is in 8. Install the new bellows assembly into the bellows tension. If the beam is not parallel with the case, yoke. loosen the machine screws (key 77), reposition the 9. Attach the link and bearing to the bellows Bourdon tube to get the beam parallel, and retighten assembly. Position the bellows yoke (key 70) on the the screws. mounting base (key 30), and attach the link and 10. If a Bourdon tube with a different range was bearing to the beam. Start but do not tighten the four installed, remove the machine screw and washer machine screws (key 75) with washers (key 76) that (keys 40 and 39) and dial (key 38). Install a new dial attach the yoke to the mounting base. Slide the yoke having an adjustment range corresponding to the up or down as necessary to position the beam range of the Bourdon tube. If an optional process horizontally, as shown in figure 21. Tighten the pressure gauge (key 106, figure 18) is being used, machine screws. 24 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters PROPORTIONAL RELAY TUBING (KEY 103) PROPORTIONAL TUBING TUBING (KEY 104) (KEY 104) REVERSING BLOCK (KEY 59) DIRECT REVERSE ACTING POSITION BELLOWS POSITION BEAM (KEY 44) (KEY 52) FLAPPER/SCREW (KEY45) REVERSE FLAPPER/SCREW ACTING POSITION (KEY 45) REVERSING BLOCK (KEY 59) DIRECT ACTING REVERSE ACTING PROPORTIONAL-ONLY CONTROLLER OR TRANSMITTER PROPORTIONAL RESET VALVE TUBING RELAY TUBING (KEY 103) PROPORTIONAL TUBING REVERSING (KEY 104) BLOCK (KEY 59) DIRECT ACTING POSITION RESET TUBING (KEY 117) RESET BEAM (KEY 44) TUBING FLAPPER/SCREW FLAPPER/SCREW (KEY 45) (KEY 45) REVERSE ACTING NOTES: POSITION P = PROPORTIONAL REVERSING BELLOWS DIRECT ACTING BLOCK (KEY 59) REVERSE ACTING R = RESET BELLOWS X = NO PRESSURE B1564-5 / IL PROPORTIONAL-PLUS-RESET CONTROLLER 10C2008-B Figure 16. Direct/Reverse Acting Tubing Connections 10. Replace the subassembly in the case and Changing Proportional or Reset Valve secure with the four machine screws (key 28, figure 18 or 19). Reconnect all tubing. WARNING 11. If a bellows assembly with a different range is Refer to the WARNING at the installed, remove the machine screws and washer beginning of the Maintenance Section. (keys 40 and 39) and dial (key 38), and install a new dial having an adjustment range corresponding to 1. Disconnect the appropriate tubing and remove the range of the bellows. If an optional process the proportional band valve assembly (figure 18 pressure gauge (key 106, figure 18) is being used, or 19) or the reset restriction valve assembly install a new gauge with the appropriate (figure 19) by unscrewing it from the relay base measurement capability. (key 4, figure 18 or 19). Install the desired replacement assembly. 12. Check all tubing connections for leaks and the 2. Connect the tubing, check all connections for bellows yoke machine screws, tighten as necessary. leaks and perform the appropriate calibration Perform the appropriate calibration procedures. procedures. 25 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters PROPORTIONAL TUBING (KEY 104) RELAY TUBING (KEY 103) REVERSE POSITION REVERSING BLOCK (KEY 59) DIRECT ACTING POSITION BEAM (KEY 44) FLAPPER/SCREW FLAPPER/SCREW (KEY45) (KEY 45) REVERSE ACTING POSITION NOTES: REVERSING P = PROPORTIONAL BLOCK (KEY 59) DIRECT ACTING REVERSE ACTING BELLOWS X = NO PRESSURE B2671 / IL DIFFERENTIAL GAP CONTROLLER 10C2008-B Figure 16. Direct/Reverse Acting Tubing Connections (Continued) 1. Isolate the controller from process, control, and Changing Anti-Reset Windup supply pressure. Vent any trapped pressure from the Differential Relief Valve (4160KF) controller before proceeding with the following steps. 2. Disconnect the proportional tubing (key 104) from WARNING the mounting base (key 30, figure 20 or 21) and reinstall it in the other connection in the mounting base. Refer to the WARNING at the 3. Do not invert the reversing block unless also beginning of the Maintenance Section. changing the controller action. Refer to figure 19 for key number locations. 4. Check all connections for leaks with a 1. Note the controller output pressure (zero or soap-and-water solution. Perform the appropriate supply) when the process is shut down. calibration procedure. 2. Remove the differential relief valve assembly. Direct to Reverse Action 3. Refer to figure 19. Install the replacement relief Use the numbered steps below to change from valve with the arrow positioned so that the controller direct action (increasing pressure produces output will be as noted in step 1 when the process is increasing output pressure) to reverse action shut down. (increasing pressure produces decreasing output pressure), or vice versa. Changing the action is accomplished by reversing the positions of the Changing Action reversing block and bellows tubing(s). Refer to figure 16 for key number locations unless otherwise directed. WARNING 1. Isolate the controller or transmitter from process, control, and supply pressure. Vent any trapped Refer to the WARNING at the pressure from the controller or transmitter before beginning of the Maintenance Section. proceeding with the following steps. 2. Locate the new tubing and reversing block Proportional-Only to a Differential Gap positions for the action desired. Controller 3. Locate the two bellows and the reversing block A proportional-only controller may be changed to a (key 59, figure 16). differential gap controller, or vice versa, by changing 4. Disconnect the tubing: the position of the proportional tubing (key 104, figure 16). Refer to figure 16 for key number a. For a proportional-only controller or for a locations. transmitter, disconnect the proportional tubing 26 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters (key 104) from the mounting base (key 30, figure 3. Unscrew the output or supply pressure gauge 20 or 21) and reconnect it in the opposite hole. (key 13). b. For a proportional-plus-reset controller, 4. To remove the relay assembly, unscrew two disconnect the proportional tubing (key 104) and Phillips-head machine screws (key 81, not shown) reset tubing (key 117) from the mounting base located behind the relay on the back of the case. (key 30, figure 20 or 21), and reconnect them in 5. Remove the relay gasket (key 7, figure 18). the opposite hole. 5. Change the reversing block assembly (key 59): 6. A new relay can be installed as a replacement. If a new relay is being installed, continue with the next a. Remove the sealing screw (key 56, figure 20 step. or 21). Inspect the O-ring (key 55, figure 20 or 21) located in the recessed area under the sealing 7. Attach the replacement relay and new relay screw head. Replace the O-ring if necessary. gasket with machine screws inserted through the back of the case. Reinstall the output or supply b. Remove the reversing block screw (key 61, gauge. figure 20 or 21) and reversing block assembly (key 59). Inspect the O-rings (key 55) located in 8. Connect the tubing, and check all connections for the recessed area under the reversing block leaks. Perform the appropriate calibration screw head and between the reversing block procedures. assembly and the calibration adjuster (key 41, figure 20 or 21). Replace these O-rings, if necessary. c. Position the reversing block assembly, with Changing Output Signal Range O-ring, on the calibration adjuster (key 41) so that the nozzle is on the opposite side of the beam (key 44, figure 20 or 21) from which it was removed. Properly position the reversing block WARNING assembly so that the alignment pin engages the hole in the calibration adjuster. Install the reversing block screw (key 61) with O-ring (key 55). Refer to the WARNING at the beginning of the Maintenance Section.. d. Install the sealing screw (key 56) with O-ring in the hole previously covered by the reversing Use the following information and subsequent block assembly. procedures when changing the output signal range of the controller or transmitter. Use the following 6. Check all connections for leaks with a procedure: soap-and-water solution. Perform the appropriate calibration procedures. � For a controller or transmitter, use this procedure to change from a 0.2 to 1.0 bar (3 to 15 Relay Replacement psig) to a 0.4 to 2.0 bar (6 to 30 psig) output signal range or vice versa. WARNING � For a differential gap controller, use this Refer to the WARNING at the procedure to change from a 0 and 1.0 bar (0 and 20 beginning of the Maintenance Section. psig) to a 0 and 2.4 bar (0 and 35 psig) output signal range or vice versa. Key numbers used in this procedure are shown in figure 18 or 19 except where indicated. 1. Shut off the supply pressure and process � When changing the supply pressure source to pressure line(s) to the controller or transmitter. a new range, refer to table 5 for supply pressure 2. Disconnect the tubing (key 103) from the relay. requirements for the output signal range selected. 27 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 0-RING Note (KEY 55) The bellows screw (key 54) has an O-ring (key 55) installed beneath the bellows screw head as shown in figure 17. Be sure this O-ring is in place before installing the screw into the mounting base. 8. Compress the bellows, and install them into the mounting base (key 30). With the beam parallel with the mounting base, secure the bellows with the bellows screws (key 54). A6281-1 / IL 9. After tightening the bellows screws, make sure that the nozzle (key 57) is centered on the flapper Figure 17. Bellows Screw Detail (key 45). 10. Replace the subassembly in the case and Also, make appropriate changes to the nameplate of secure with the machine screws (key 28, figure 18 the controller or transmitter, reflecting the new range or 19). Install the Bourdon tube if it was removed; selections. Refer to figure 20 or 21 for key number refer to the Replacing Bourdon Tube section if locations unless otherwise directed. needed. Reconnect all tubing. 1. Shut off the supply pressure and process lines to 11. Unscrew the supply and output gauges (key 13, the controller or transmitter. figure 18 or 19) and install new gauges with correct ranges. 2. Disconnect the tubing from the mounting base 12. Check all tubing connections and the bellows (key 30) and calibration adjuster (key 41). machine screws for leaks, tighten as necessary. Disconnect the tubing that connects the pressure block (key 8, figure 18 or 19) to the Bourdon tube or Perform the appropriate calibration procedures. bellows assembly (key 62 or 71), at the pressure block end. 3. Unscrew the machine screws (key 28, figure 18 or 19), and remove the subassembly from the case. Parts Ordering Whenever corresponding with your Emerson 4. If the controller or transmitter uses a Bourdon Process Management sales office about this tube sensing element, disconnect the Bourdon tube equipment, mention the serial number of the unit. from the beam (key 44) by removing the screw The serial number can be found on the nameplate (key 63). Be careful to avoid losing the bearing (key 22, figure 18). When ordering replacement (key 65). Unscrew the machine screws (key 77), and parts, also state the complete 11-character part remove the washers and Bourdon tube (keys 76 number of each part required as found in the and 62). following parts list. 5. Unscrew the bellows screws (key 54) from each end of the mounting base (key 30). [Note: The Note bellows screws (key 54) have an O-ring (key 55, figure 17) installed beneath the bellows screw head. Use only genuine Fisher replacement Remove the O-ring and obtain a replacement when parts. Components that are not re-assembling the bellows.] supplied by Emerson Process Management should not, under any 6. Compress the bellows so that the end of the circumstances, be used in any Fisher bellows and beam can be removed from the end of instrument. Use of components not the mounting base (key 30) and unscrewed from the supplied by Emerson Process stud (key 51, not shown) that connects the bellows. Management will void your warranty, 7. With the stud that connects the two bellows in might adversely affect the place in the spacer (key 50), screw the new bellows performance of the instrument, and onto the stud. Install new gaskets (key 53) on each might jeopardize worker and bellows. workplace safety. 28 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Note Common Parts (Figures 18, 19, 20, and 21) Neither Emerson, Emerson Process Management, Fisher, nor any of their Key Description Part Number affiliated entities assumes responsibility for the selection, use, 1 Case and Cover Assembly, aluminum and maintenance of any product. Responsibility for the selection, use, Note and maintenance of any product remains with the purchaser and Refer to Assemblies for Case and Cover end-user. Assembly part numbers. 7* Relay Gasket, for all series Parts Kits Std Temp, chloroprene 1C897403012 High Temp, silicone 1N873804142 Key Description Part Number 8 Control Pressure Block Controller Repair Kits For gauge pressure instruments, sst Kit contains keys 5, 9, 10, 21, 24, 45, 46, 53, w/o process pressure gauge 16A0979X012 55, 56, 57, 58, 59, 60, 61, 63, 64, and 65 9* O-Ring, nitrile, for all series 1C376206992 Standard Temperature R4150X00L12 10* Gasket, chloroprene, for all series (not shown) 1C328603012 High Temperature R4150X00H22 11* Sealing Washer (not shown) Use w/0.14 bar (2 psi) Relay Replacement Kits pressure-tested case and cover (2 req’d) 1J186999012 Kit contains key 7 and 43 and the replacement relay Standard Temperature RRELAYX0L22 High Temperature RRELAYX0H22 Case Assembly Seal Kit Note Kit contains 3 Manifold Seals, 1 Manifold Seal Cover, and 10 Mounting Screws R4150KX0012 Key 13 is used as both a supply gauge and an output gauge on units without a process pressure gauge. A quantity of 2 is required for these units. On units with a process pressure gauge (key 106), key 13 is used for Parts List the output gauge. A quantity of 1 is required for these units. Key Description Part Number Use key 14 for supply pressure indication Assemblies (Figures 18 and 19) when a process pressure gauge is installed. Case & Cover Std. Ass’y GE09600X012 Key 14 installs on the supply pressure Case & Cover Ass’y w/ Anti-Reset, regulator. −40 to 71�C (−40 to 160�F) GE09601X012 13* Supply and Output Pressure Gauge, w/o process pressure gauge (1/8-inch connecting stem), Case & Cover Std. Ass’y, ABS plastic, black enamel/polycarbonate/nitrile (2 req’d) 2 Psig Pressure tested GE09600X022 Dual scale Case & Cover Std. Ass’y, 2 0-2.0 kg/cm 0 and 0-30 psig 11B8577X042 2 Psig Pressure tested, w/ Anti-Reset, 2 0-4.0 kg/cm 0 and 0-60 psig 11B8577X052 −40 to 71�C (−40 to 160�F) GE09601X032 Triple scale Proportional Band Valve or Span Adjustment Assembly 0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8577X012 Std and High Temperature, aluminum 10A9122X032 0-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8577X022 Stainless steel construction 10A9122X082 13* Output Pressure Gauge, w/process pressure Reset Restriction Valve Assembly gauge (1/8-inch connecting stem) (1 req’d) Standard Temperature Triple scale For all except Type 4160KF and 62KF 19A4361X012 0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8577X012 Reset Restriction Valve Assembly 0-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8577X022 Standard Temperature 14* Supply Pressure Gauge, w/process pressure gauge (1/4-inch connecting stem), ABS plastic, black For Type 4160KF and 62KF 19A4363X012 Relay Assembly enamel/polycarbonate/nitrile Standard Temperature 22B0463X012 Triple scale High Temp, Type 4150K, 50KS, 52K, 52KS, 0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8579X022 57K, 60K, 62K, and 64K 22B0462X012 0-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8579X032 w/sst instrument construction 15 Vent Ass’y 27A5516X012 Standard Temp 22B0463X032 22 Plate, Instruction, aluminum 12B6338X0A2 High Temp, Type 4150K, 50KS, 57K, 60K 22B0462X022 28 Machine Screw, steel pl (4 req’d) 1E985428982 w/process pressure gauge 1J251035072 30 Mounting Base, aluminum 26A7668X012 For differential pressure instruments, sst 1H673035072 31 Flexure Strip, sst 1C897836012 *Recommended spare parts 29 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters SPAN ADJUSTMENT RELAY ASSEMBLY ASSEMBLY 48B6005-A OPTIONAL PROCESS PRESSURE INDICATION 48B6004-B / DOC SUBASSEMBLY (KEY NOS. SHOWN IN FIGURE 20 OR 21) NOTE: KEYS 10, 81, 105 AND 108 TRANSMITTER ARE NOT SHOWN Figure 18. Typical Direct-Acting 4150K Series Assembly (Refer to figure 22 for the Front View of the Case & Cover Assembly) B2651-1 / IL Key Description Part Number Key Description Part Number 32 Flexure Strip Washer, steel pl (2 req’d) 16A7671X012 33 Machine Screw, steel pl (4 req’d) 14B4995X012 38 Dial, aluminum 34 Pressure Set Arm, steel pl 36A7669X012 For Bourdon tube controllers (continued) 35 Rotary Spring, sst 1J423437022 0-35,000 kPa 16A7662X232 36 Knob, PPS 36A7670X012 0-55,000 kPa 16A7662X242 37 Knob Spring, steel pl 1C221527022 0-70,000 kPa 16A7662X252 38 Dial, aluminum 0-100% 16A7662X272 For Bourdon tube controllers 0-2 bar 16A7662X482 0-30 psig 16A7662X012 0-4 bar 16A7662X442 0-60 psig 16A7662X022 0-7 bar 16A7662X472 0-100 psig 16A7662X032 0-14 bar 16A7662X462 0-150 psig 16A7662X412 0-20 bar 16A7662X492 0-200 psig 16A7662X042 0-40 bar 16A7662X452 0-300 psig 16A7662X052 0-70 bar 16A7662X502 0-600 psig 16A7662X062 0-100 bar 16A7662X512 0-1000 psig 16A7662X072 0-200 bar 16A7662X522 0-1500 psig 16A7662X082 0-350 bar 16A7662X532 0-3000 psig 16A7662X092 0-550 bar 16A7662X542 0-5000 psig 16A7662X102 0-700 bar 16A7662X552 0-8000 psig 16A7662X112 For bellows sensing element controllers 0-10,000 psig 16A7662X122 Gauge pressure 0-200 kPa 16A7662X142 0-60 inches wc 16A7662X282 0-400 kPa 16A7662X152 0-140 inches wc 16A7662X292 0-700 kPa 16A7662X162 0-5 psig 16A7662X302 0-1400 kPa 16A7662X172 0-10 psig 16A7662X312 0-2000 kPa 16A7662X182 0-15 psig 16A7662X322 0-4000 kPa 16A7662X192 0-20 psig 16A7662X332 0-7000 kPa 16A7662X202 0-30 psig 16A7662X012 0-10,000 kPa 16A7662X212 0-200 kPa 16A7662X142 0-20,000 kPa 16A7662X222 0-10 inches Hg vacuum 16A7662X342 30 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters PILOT RELAY PROPORTIONAL 2 PSIG LABEL (USED 22 BAND WITH 2 PSIG CASE & ADJUSTMENT COVER ASSEMBLY SUBASSEMBLY (KEY NOS. SHOWN IN FIGURE 19 OR 20) CHANGE ACTION LABEL NOTE: KEYS: 10, 81, 105 NOT SHOWN PROPORTIONAL-ONLY CONTROLLER 48B6003-A B2652 / IL Figure 18.Typical Direct-Acting 4150K Series Assembly (continued) Key Description Part Number Key Description Part Number 52* Feedback Bellows Ass’y 38 Dial, aluminum Brass For bellows sensing element controllers 0.2-1.0 bar (3-15 psig) (2 req’d) 14A5726X012 Gauge pressure (continued) 0.4-2.0 bar (6-30 psig) (2 req’d) 14A5726X032 0-30 inches Hg vacuum 16A7662X352 Stainless steel 30-0-30 inches wc compound 16A7662X362 0.2-1.0 bar (3-15 psig) (2 req’d) 14A5726X022 15 in. Hg vacuum-0-7.5 psig compound 16A7662X372 0.4-2.0 bar (6-30 psig) (2 req’d) 14A5726X042 30 in. Hg vacuum-0-15 psig compound 16A7662X382 53* Gasket 0-60 inches wc vacuum 16A7662X392 Std Temp, chloroprene (2 req’d) 1D397003012 Differential pressure High Temp, silicone (2 req’d) 1N873604142 0-80 inches wc 16A7662X402 54 Bellows Screw (2 req’d) 0-10 psig 16A7662X312 Brass 22B8036X012 0-20 psig 16A7662X332 Stainless steel 22B8036X022 0-30 psig 16A7662X012 0-200 kPa 16A7662X142 0-2 bar 16A7662X482 Note For all Type 4155K, 57K, and 58K transmitters 16A7664X012 39 Washer, steel pl 1R982025072 A total of 5 O-rings (key 55) are used. 1 40 Machine Screw, steel pl 1E175828982 O-ring is used under the sealing screw (key 56), 1 O-ring is used under the reversing 41 Calibration Adjuster, steel pl 2H266244012 blockscrew (key 61), 1 O-ring is used 42 Washer, steel (2 req’d) 1E873028992 between the reversing block ass’y (key 59) 43 Machine Screw, steel pl (2 req’d) 1A5733X0012 and the calibration adjuster (key 41), and 1 44 Beam, steel 1H266825072 O-ring is used in the recessed area under the 45 Flapper, K93602 nickel alloy 1H266941132 head of each of the bellows screws (key 54). 46 Machine Screw, steel pl 1B275128992 47 Cross Spring, sst (2 req’d) 1H266037032 55* O-Ring, 48 Washer, steel pl (4 req’d) 1H267128982 Std Temp, nitrile (5 req’d) 1D687506992 49 Machine Screw, steel pl (4 req’d) 1A346128982 High Temp, fluoroelastomer (5 req’d) 1N430406382 50 Spacer, zinc 1H265944012 56 Sealing Screw, sst 14A5721X012 51 Bellows Stud, brass (not shown) 1H265814012 57* Nozzle, sst 1U639135132 *Recommended spare parts 31 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters RESET RESTRICTION PILOT RELAY VALVE ASSEMBLY PROPORTIONAL 2 PSIG LABEL (USED 22 BAND WITH 2 PSIG CASE & ADJUSTMENT COVER ASSEMBLY SUBASSEMBLY (KEY NOS. CHANGE ACTION LABEL SHOWN IN FIGURE 20 OR 21) NOTE: KEYS: 10, 81, 105, 115 NOT SHOWN PROPORTIONAL-PLUS-RESET CONTROLLER 48B6002-A WITHOUT ANTI-RESET WINDUP B2653-1 / IL Figure 19. Typical Direct-Acting 4160K Series Assembly (Refer to figure 22 for the Front View of the Case & Cover Assembly) Key Description Part Number Key Description Part Number 58* Nozzle O-Ring, (1) 71* Gauge Pressure Bellows (input) Std Temp, nitrile 1E222606992 Brass High Temp, fluoroelastomer 1N838706382 0-150 mbar (0-60 inches wc) positive, 0-150 mbar 59 Reversing Block, steel pl 26A0975X012 (6-60 inches wc) vacuum, and 75-0-75 mbar 60 Sleeve, POM 16A0976X012 (30-0-30 inches wc) compound 1L3780000A2 61 Reversing Block Screw, sst 24A5720X012 0-250 mbar (0-100 inches wc) positive, 62* Bourdon Tube See table 7 Type 4158K only 1L3788000A2 63 Machine Screw, steel pl 0-0.35 mbar (0-5 psig) positive and for Bourdon tube instruments only (2 req’d) 1A331928982 0-350 mbar (0-10 inches Hg) vacuum 1L3781000A2 64* Connecting Link, Bourdon tube instruments only 0-0.5 bar (0-7.5 psig) positive, 4158K only 1L3789000A2 Std., N04400 1L379641012 0-0.7 bar (0-10 psig) positive 1L3782000A2 Bourdon tube w/optional travel stop, 0-1.0 bar (0-15 psig) positive, 0-1.0 bar Stainless steel 1L611235022 (0-30 inches Hg) vacuum, and 500-0-500 mbar 65* Link bushing, sst (15-0-7.5 psig) compound 1L3783000A2 Bourdon tube instruments only (2 req’d) 1L379546202 0-1.4 bar (0-20 psig) positive 1L3784000A2 66 Travel Stop Assembly, steel 0-2.0 bar (0-30 psig) positive and 1.0-0-1.0 bar optional w/Bourdon tube 1H7793000A2 (30-0-15 psig) compound 1L3785000A2 67 Lockwasher, steel pl (2 req’d) Stainless steel, Use w/optional Bourdon tube travel stop 1H267228982 0-1.0 bar (0-15 psig) positive, 0-1.0 bar 68 Machine Screw, steel pl (2 req’d) (0-30 inches Hg) vacuum, and 500-0-500 mbar Use w/optional Bourdon tube travel stop 1H267628982 (15-0-7.5 psig) compound 1L3786000A2 69 Cap Screw, steel pl 0-2.0 bar (0-30 psig) positive, 1.0-0-1.0 bar Use w/optional Bourdon tube travel stop 1H779232982 (30-0-15 psig) compound 1L3787000A2 70 Bellows Yoke, zinc Use w/gauge and differential pressure bellows 2H453844012 *Recommended spare parts 1. If ordering the bellows (key 71) to change the range of a gauge pressure controller, also order the appropriate bellows spring (key 80). Also order keys 72, 32 73, and 74, if you do not have them. Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters 2 NOTES: 1 ARROW DOWN—RELIEVES ON DECREASING OUTPUT (OUTPUT @ SUPPLY DURING SHUTDOWN) 2 ARROW UP—RELIEVES ON INCREASING OUTPUT (OUTPUT @ ZERO DURING SHUTDOWN) KEYS 367, 368, AND 369 NOT SHOWN 48B6001-B / DOC 1 PROPORTIONAL-PLUS-RESET CONTROLLER WITH DIFFERENTIAL RELIEF VALVE ASSEMBLY FOR ANTI-RESET WINDUP Figure 19. Typical Direct-Acting 4160K Series Assembly (continued) Key Description Part Number Key Description Part Number 71* Differential-Pressure Bellows (input) 76 Washer, steel pl Brass for Bourdon tube instruments (2 req’d) 1H267228982 0-200 mbar (0-80 inches wc) 2L3790000A2 for bellows sensing instruments (4 req’d) 1H267228982 0-0.7 bar (0-10 psi) 2L3791000A2 77 Machine Screw, steel pl 0-1.4 bar (0-20 psi) 2L3792000A2 Bourdon tube instruments only (2 req’d) 1H267728982 Stainless steel, 79 Screw, nylon Transmitters only 1A3461X0042 0-2.0 bar (0-30 psi) 2L3793000A2 80 Spring, gauge pressure bellows instruments only (2) 71K Machine Screw, steel pl Steel pl bellows sensing instruments only (2 req’d) 1A331928982 0-150 mbar (0-60 inches wc) positive, (2) 71L* Bearing 0-150 mbar (0-60 inches wc) vacuum, bellows sensing instruments only (2 req’d) 1L379546202 75-0-75 mbar, and (2) 71M* Link bellows sensing instruments only 1L379641012 (30-0-30 inches wc) compound 1J729227022 72 Jam Nut, steel pl 0-250 mbar (0-100 inches wc) positive, Gauge pressure bellows instruments only 1A946324122 0-0.35 bar (0-5 psig) positive, and 73 Washer, steel pl 0-350 mbar (0-10 inches Hg) vacuum 1H448227022 Gauge pressure bellows instruments only 1B865928982 0-0.5 bar (0-7.5 psig) positive 1K525727022 74 Spring Seat, pl brass 0-0.7 bar (0-10 psig) positive 1K493427022 Gauge pressure bellows instruments only 1H453214022 0-1.0 bar (0-15 psig) positive, 75 Machine Screw, steel pl 0-1.0 bar (0-30 inches Hg) vacuum, Gauge and differential pressure 500-0-500 mbar (15-0-7.5 psig) compound 1H448327022 bellows instruments (4 req’d) 1H267628982 0-1.4 bar (0-20 psig) positive 1K525927022 *Recommended spare parts 2. This part is part of the bellows assembly, key 71 33 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters A A A B SHOWN B WITH SECTION A-A A C CONTROLLER DIAL, SECTION B-B KEY 38 C VIEW A-A 26A7689-A / DOC BOURDON TUBE TRAVEL STOP SUBASSEMBLY 26A7677-B / DOC NOTES: KEY 51, BELLOWS STUD NOT SHOWN: KEY 52 IS FEEDBACK BELLOWS 1. THERE IS AN O-RING (KEY 55) BETWEEN THE REVERSING BLOCK (KEY 59) AND THE CALIBRATION ADJUSTER (KEY 41). 26A7681-A /DOC 2. THERE MAY BE AN O-RING (KEY 55) UNDER THE BELLOWS SCREW (KEY 54). SEE NOTE PRECEDING KEY 54 IN THE PARTS LIST. SECTION C-C Figure 20. Controller Subassembly with Bourdon Tube Sensing Element Key Description Part Number Key Description Part Number Note 80 Spring, gauge pressure bellows instruments only (continued) Controllers with bellows sensing element 0-2.0 bar (0-30 psig) positive, use only the 2.0 bar, 0 to 0.2 MPa, and 0 to 0 1.0-0-1.0 bar (30-0-15 psig) compound 1H448427022 to 30 psig triple scale brass and stainless 316 SST steel process pressure gauges. Differential 0-1.0 bar (0-15 psig) positive, pressure controllers do not use a process pressure gauge. 0-1.0 bar (0-30 inches Hg) vacuum, 500-0-500 mbar (15-0-7.5 psig) compound 1H641137012 106* Process Pressure Gauge (use only when specified) 0-2.0 bar (0-30 psig) positive, Triple scale 1.0-0-1.0 bar (30-0-15 psig) compound 1H641237012 ABS plastic/Brass 81 Machine Screw, steel pl (not shown) (2 req’d) 1H527128982 0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8578X012 82 Machine Screw, steel pl (4 req’d) 1C333328982 0-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8578X022 101 Lockwasher, steel pl (4 req’d) 1C225628982 0-11 bar, 0-1.1 MPa, and 0-160 psig 11B8578X032 103 Relay Tubing Assembly, sst 1H6861000A2 0-20 bar, 0-2.0 MPa, and 0-300 psig 11B8578X042 104 Compensator Tubing Assembly, sst 0-40 bar, 0-4.0 MPa, and 0-600 psig 11B8578X052 Types 4150K, 50KS, 52K, 52KS, 0-69 bar, 0-6.9 MPa, and 0-1000 psig 11B8578X062 54K, 55K, 57K, and 58K 1H6864000A2 ABS plastic/Stainless steel Types 4160K, 60KF, 62K, 62KF and 64K 1H6870000A2 0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8584X022 105 Plug, S31600 (316 SST), (not shown) 0-20 bar, 0-2.0 MPa, and 0-300 psig 11B8584X012 used with gauge pressure only 1A767535072 0-69 bar, 0-6.9 MPa, and 0-1000 psig 11B8584X032 34 *Recommended spare parts Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters A SHOWN WITH SECTION A-A TRANSMITTER DIAL & SCREW, A KEY 38 & 79 C SCREW C 1 (KEY 71K) 1 LINK (KEY 71M) LINK (KEY 71M) 1 SCREW (KEY 71K) 1 BEARING BEARING 1 (KEY 71L) (KEY 71L) 1 26A7675-B / DOC 26A7683-B / DOC SIDE VIEW OF SUBASSEMBLY SIDE VIEW OF SUBASSEMBLY WITH DIFFERENTIAL PRESSURE WITH GAUGE-PRESSURE BELLOWS SENSING ELEMENT BELLOWS SENSING ELEMENT NOTES: 26A7681-A /DOC KEYS 46 AND 51 NOT SHOWN: KEY 52 IS FEEDBACK BELLOWS SECTION C-C 1 KEYS 71K, 71L, & 71M ARE PART OF THE BELLOWS ASSEMBLY (KEY 71) Figure 21. Controller Subassembly with Either Gauge-Pressure Bellows or Differential-Pressure Bellows Sensing Element Key Description Part Number Key Description Part Number 107 Pressure Connection, sst 132 Control Tubing Assembly Use w/process gauge 1J251235162 For Bourdon tube instruments 108 Pipe Plug, steel pl (not shown) w/o process pressure gauge Use w/process gauge, Stainless steel 1H3011000A2 not used w/Bourdon tube protector 1E823128982 N05500 (not used on Type 4151K) 1H3011X0022 115 Mounting Screw for reset restriction valve w/process pressure gauge, sst 1J2530000A2 Type 4160K, 60KF, 62K, 62KF, and 64K For gauge-pressure bellows instruments, sst 1/4-20 UNC, steel pl (not shown) 1H527028982 w/o process pressure gauge 1H4526000A2 116 Reset Tubing Ass’y, sst w/process pressure gauge 1J2553000A2 Type 4160K, 60KF, 62K, 62KF, and 64K 1H6866000A2 For differential-pressure 117 Compensator Tubing Ass’y, sst 1H6868000A2 bellows instruments, sst 1H4526000A2 127 Tubing Assembly, sst 133 Control Tubing Assembly, sst Type 4160KF and 4162KF only 27B9975X012 For differential-pressure instruments only 1H6732000A2 129 Tubing Assembly, sst 167 Label, Use w/2 psi (0.14 bar) pressure-tested Type 4160KF and 4162KF only 27B9976X012 case and cover 12A9842X012 35 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Key Description Part Number Key Description Part Number 186 Anti-Reset Windup Ass’y 220 Mounting Bracket, steel pl (not shown) For Type 4160KF and 4162KF 21A6447X0A2 For casing mounting on Types 126, 127, 657, 667, 365 Label, bellows sensing instruments only 1051 and 1052 and for casing-mounted filter Gauge pressure instruments regulator on Types 1051 and 1052 1F401225072 0-60 inches wc 11B5655X062 221 Lockwasher, steel pl (specify quantity req’d) 1C225728982 0-100 inches wc 11B5655X272 222 Cap Screw, steel pl (specify quantity req’d) 0-140 inches wc 11B5655X082 5/16 UNC X 3/4 inch 1A381624052 0-5 psig 11B5655X012 5/16 UNC X 1 inch 1A352624052 0-7.5 psig 11B5655X262 5/16 UNC X 1-1/8 inches 1C379124052 0-10 psig 11B5655X022 5/16 UNC X 1-1/4 inches 1B787724052 0-15 psig 11B5655X032 5/16 UNC X 1-3/4 inches 1A553424052 0-20 psig 11B5655X042 5/16 UNC X 2-1/2 inches 1C870224052 0-30 psig 11B5655X052 5/16 UNC X 3-5/8 inches 1C398824052 Differential pressure instruments 3/8 UNF X 1-1/8 inches 1A582824052 0-80 inches wc 11B5655X222 223 Cap Screw, steel pl 0-60 inches wc 11B5655X062 Types 1051 and 1052 with either case or 0-10 psi 11B5655X232 yoke mounted regulator and Type 1061 0-20 psi 11B5655X242 with yoke mounted regulator (2 req’d) T14109T0012 0-30 psi 11B5655X252 228 Spacer Spool, steel (specify quantity req’d) 366 Pipe Plug, Use w/0.14 bar (2 psi) pressure-tested Types 470, 472, 480, 513, 656, 657, 667, case and cover (2 req’d) 1P2796X0012 pipe stand 1051, 1052 and 1061 1F906724092 367* O-Ring (not shown) Type 115 Type 4160KF and 4162KF only (2 req’d) 1C853806992 W/o regulator or w/one regulator 1K153424092 368 Machine Screw (not shown) W/two regulators 1K414424092 Type 4160KF and 4162KF only (2 req’d) 1U8842X0012 Type 115C 1K654724092 369 Anti-Reset Windup Cover (not shown) 229 Cap Screw, steel pl (not shown) (specify quantity req’d) Type 4160KF and 4162KF only (2 req’d) 2V597308012 Type 115 370 Plain Washer, brass 1H339718992 w/o regulator or w/one regulator 1F960324052 w/two regulators 1C870224052 Type 115C 1D770424052 Mounting Parts for Panel, Wall, Types 126 and 127 1B227524052 Pipestand, or Actuator Mounting Types 1051 and 1052 casing-mounted controller 1A582824052 (Figures 3 and 4) 230 Cap Screw, steel pl (not shown) 213 Mounting Plate, steel Types 126 and 127 1C595824052 For yoke mounting on 231 Pipe Nipple, steel (not shown) (specify quantity req’d) Types 470, 472, 513, 656, 657 and 667 1C221825022 For casing mounting on Types 126 and 127 For yoke mounting on Type 480 W/Types 67FR, 67R, 254, 254F and 1301 11A3740X012 Vertical 3L276725092 232 Pipe Tee, steel (not shown) Horizontal 3J854725012 For casing mounting on Types 126 and 127 For yoke mounting on Types 1051 and 1052 W/Types 67R, 254 and 1301 1B8606X0012 Size 40, positions 1 and 3 w/switch and 238 Mounting Plate, steel Size 60, position 1 w/switch 23A8891X012 For yoke-mounted filter regulator All others 1C221825022 Types 1051, 1052 and 1062 sizes 40 and 60 1C221825022 For yoke mounting on Type 1061 Types 1061 size 30 23A8891X012 Size 30, positions 1 and 3 w/switch and position 1 w/o 240 Cap Screw, steel switch, Size 40, position 1 w/switch and For yoke-mounted filter regulator on Sizes 80 and 100, position 3 w/o switch 23A8891X012 Types 1051 and 1052 sizes 40 and All others 1C221825022 60 (2 req’d) 1A553424052 For pipe stand mounting 3N975725092 241 Spacer Spool, steel For mounting on Type 115 3J779825012 For yoke mounted filter regulators on For mounting on Type 115C 2K654825022 Types 1051 and 1052 sizes 40 and 215 Machine Screw, steel pl (specify quantity req’d) 60 (2 req’d) 1C559024092 5/16 UNC X 1 inch 1C639128982 242 Spacer Spool, steel (not shown) 5/16 UNC X 1-1/2 inches 1H304728982 For yoke mounting on 5/16 UNC X 2 inches 1B762424052 Types 1051 and 1052 size 40 (2 req’d) 1V102624092 216 Hex Nut, steel pl (specify quantity req’d) Type 1061 sizes 30, 80 and 100 (2 req’d) 1J830724092 For casing mounting on Types 126 and 127 and 243 Street Elbow, pl galvanized malleable iron (not shown) for filter regulator mounting on For mounting on Types 470, 472, 480, 513, 656, Types 1051, 1052 and 1061 1A352724122 657, 667, panel, pipe stand, 1051, 1052 and 1061 All other types and mountings 1C332828982 w/nipple-mounted filter regulator 1A913221992 36 *Recommended spare parts Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters COMPRESSION PLUGS SECTION B-B B A 2X ROLL PIN B COVER ASSEMBLY SECTION A-A CASE ATEX LABEL A ASSEMBLY GE09600 Rev. A Figure 22. Front View of Case and Cover Assembly Key Description Part Number Key Description Part Number Note 244 Pipe Nipple, pl galvanized steel (not shown) For mounting on Types 470, 472, 480, 513, 656, Specify quantity of fittings. 657, panel, pipe stand, 1051, 1052 and 1061 Connector, Brass w/nipple-mounted filter regulator 1D239726232 1/8-inch NPT X 1/4-inch od tubing 1A395914012 250 Clamp, Steel 1/4-inch NPT X 1/4-inch od tubing 1A636814012 For pipe stand mounting (2 req’d) 1P427028982 1/4-inch NPT X 3/8-inch od tubing 1B885618992 251 Bracket Assembly, steel Elbow, Brass For panel or wall mounting (2 req’d) 1H2892000A2 1/8-inch NPT X 1/4-inch od tubing 1A685018992 252 Cap Screw, steel pl 1/4-inch NPT X 1/4-inch od tubing 1A397118992 For panel or wall mounting (4 req’d) 1B848024052 1/4-inch NPT X 3/8-inch od tubing 1B884618992 Table 7. Key 62* Bourdon Tube PRESSURE RANGE MATERIAL (1) kPa Psig Stainless Steel N05500 0-200 0-30 32B1243X012 --- 0-400 0-60 32B1243X022 --- 0-700 0-100 32B1243X032 --- 0-1400 0-200 32B1243X042 --- 0-2000 0-300 32B1244X052 --- 0-4000 0-600 32B1244X062 32B1244X202 0-7000 0-1000 32B1244X072 32B1244X212 0-10,000 0-1500 32B1245X082 32B1245X222 0-20,000 0-3000 32B1245X092 --- 0-35,000 0-5000 32B1245X102 --- 0-55,000 0-8000 32B1245X112 --- 0-70,000 0-10,000 32B1245X122 1. For NACE applications. *Recommended spare parts 37 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters A subassembly with Bourdon tube sensing element indicated in table 8, one of each of the following key as shown in figure 20 contains the following key numbered parts must also be ordered to complete numbers: 30 through 37, 39 through 61, 63, 65, 76, the subassembly: dial, key 38; Bourdon tube, key and 77. When ordering the subassembly as 62; and connecting link, key 64. Table 8. Subassemblies with Bourdon Tube Sensing Element OUTPUT PRESSURE RANGE FEEDBACK HIGH STANDARD BELLOWS MATERIAL TEMPERATURE Bar Psig Brass 26A7677X012 26A7677X022 0.2 to 1/0 or 0 and 1.4 3 to 15 or 0 and 20 differential gap differential gap Stainless steel 26A7677X052 26A7677X062 Brass 26A7677X032 26A7677X042 0.4 to 2.0 or 0 and 2.4 6 to 30 or 0 and 35 differential gap differential gap Stainless steel 26A7677X072 26A7677X082 A subassembly with gauge pressure bellows sensing are also included with the bellows assembly, key 71. element as shown in figure 21 contains the following When ordering the subassembly as indicated in key numbers: 30 through 37, 39 through 61, 71K, table 9, one of each of the following key numbered and 71L. The machine screws, key 77, quantity of 2, parts, unless other quantities are indicated, must and washers, key 76, quantity of 2, also come with also be ordered to complete the subassembly: dial, the subassembly. The two washers, key 76, may be key 38; bellows yoke, key 70; bellows assembly, key used with the machine screws, key 75, but four 71; jam nut, key 72; washer, key 73; spring seat, key washers and machine screws are required so two 74; machine screw, key 75, quantity of 4; washer, more washers must be ordered. The machine key 76, quantity of 2; and spring, key 80. The link, screws, key 77, are not used on subassemblies with key 71M, is included with the bellows assembly, key bellows input so they may be discarded. Although 71. If ordering parts for a transmitter, a screw, key two machine screws, key 71K, and two bearings, 79, must also be ordered. key 71L, are included with the subassembly, they Table 9. Subassemblies with Gauge-Pressure Sensing Element OUTPUT PRESSURE RANGE FEEDBACK HIGH STANDARD BELLOWS MATERIAL TEMPERATURE Bar Psig Brass 26A7677X012 26A7677X022 0.2 to 1/0 or 0 and 1.4 3 to 15 or 0 and 20 differential gap differential gap Stainless steel 26A7677X052 26A7677X062 Brass 26A7677X032 26A7677X042 0.4 to 2.0 or 0 and 2.4 6 to 30 or 0 and 35 differential gap differential gap Stainless steel 26A7677X072 26A7677X082 38 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters A subassembly with differential pressure bellows and two bearings, key 71L, are included with the sensing element as shown in figure 21 contains the subassembly, they are also included with the following key numbers: 30 through 37, 39 through bellows assembly, key 71. When ordering the 61, 71K, and 71L. The machine screws, key 77, subassembly as indicated in table 10, one of each of quantity of 2, and washers, key 76, quantity of 2, the following key numbered parts, unless other also come with the subassembly. The two washers, quantities are indicated, must also be ordered to key 76, may be used with the machine screws, key complete the subassembly: dial, key 38; bellows 75, but four washers and machine screws are yoke, key 70; bellows assembly, key 71; machine required so two more washers must be ordered. the screw, key 75, quantity of 4; and washer, key 76, machine screws, key 77, are not used on quantity of 2. The link, key 71M, is included with the subassemblies with bellows input so they may be bellows assembly, key 71. If ordering parts for a discarded. Although two machine screws, key 71K, transmitter, a screw, key 79, must also be ordered. Table 10. Subassemblies with Differential-Pressure Bellows Sensing Element OUTPUT PRESSURE RANGE FEEDBACK HIGH STANDARD BELLOWS MATERIAL TEMPERATURE Bar Psig Brass 26A7677X012 26A7677X022 0.2 to 1/0 or 0 and 1.4 3 to 15 or 0 and 20 differential gap differential gap Stainless steel 26A7677X052 26A7677X062 Brass 26A7677X032 26A7677X042 0.4 to 2.0 or 0 and 2.4 6 to 30 or 0 and 35 differential gap differential gap Stainless steel 26A7677X072 26A7677X082 39 Instruction Manual Form 5177 March 2006 4150K and 4160K Controllers and Transmitters Wizard and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, Fisher, 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. Emerson Process Management Fisher Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 www.Fisher.com 40 �Fisher Controls International LLC 1982, 2006; All Rights Reserved Printed in USA