4160 pressure controller

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D20

0151

X01

2

4150K and 4160K Series Wizard� II PressureControllers and TransmittersContents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment: Set Point 9. . . . . . . . . . . . . . . . . . Adjustment: Proportional Band 9. . . . . . . . . . .

Calibration: Proportional-Only Controllers 9. . . Startup: Proportional-Only Controllers 12. . . . .

Proportional-Plus-Reset Controller 12. . . . . . . . . Adjustments 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment: Set Point 12. . . . . . . . . . . . . . . . . Adjustment: Proportional Band 13. . . . . . . . . . Adjustment: Reset 13. . . . . . . . . . . . . . . . . . . . Adjustment: Anti-Reset Windup 13. . . . . . . . .

Calibration 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration: Proportional-Plus-ResetControllers 13. . . . . . . . . . . . . . . . . . . . . . . . . . Calibration: Anti-Reset Windup 15. . . . . . . . .

Startup: Proportional-Plus-Reset Controllers 16Differential Gap Controllers 16. . . . . . . . . . . . . . . .

Adjustments 16. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment: Set Point 16. . . . . . . . . . . . . . . . . Adjustment: Proportional Band 16. . . . . . . . . .

Calibration: Differential Gap Controllers 16. . . . Startup: Differential Gap Controllers 18. . . . . . .

Transmitter Operation 18. . . . . . . . . . . . . . . . . . . . . Adjustments 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment: Zero 18. . . . . . . . . . . . . . . . . . . . . . . Adjustment: Span 19. . . . . . . . . . . . . . . . . . . . . . .

Calibration: Transmitters 19. . . . . . . . . . . . . . . . . .

W3525-1 / IL

Figure 1. Wizard� II Controller Yoke-Mounted on ControlValve Actuator

Startup: Transmitters 20. . . . . . . . . . . . . . . . . . . . . Principle of Operation 20. . . . . . . . . . . . . . . . . . . . . .

Proportional-Only Controllers 20. . . . . . . . . . . . . . Proportional-Plus-Reset Controllers 21. . . . . . . . Controllers with Anti-Reset Windup 21. . . . . . . . . Differential Gap Controllers 22. . . . . . . . . . . . . . . . Transmitters 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Gauges 23. . . . . . . . . . . . . . . . . . . . . . . Replacing Bourdon Tube 24. . . . . . . . . . . . . . . . . . Replacing Bellows Sensing Element 24. . . . . . . . Changing Proportional or Reset Valve 25. . . . . . Changing Anti-Reset Windup Differential

Relief Valve (4160KF) 26. . . . . . . . . . . . . . . . . . Changing Action 26. . . . . . . . . . . . . . . . . . . . . . . . .

Proportional-Only to a DifferentialGap Controller 26. . . . . . . . . . . . . . . . . . . . . . .

Direct to Reverse Action 26. . . . . . . . . . . . . . . . . Relay Replacement 27. . . . . . . . . . . . . . . . . . . . . . Changing Output Signal Range 27. . . . . . . . . . . .

Parts Ordering 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instruction ManualForm 5177March 2006 4150K and 4160K Controllers and Transmitters

4150K and 4160K Controllers and TransmittersInstruction Manual

Form 5177March 2006

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Contents (Continued)Parts Kits 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Repair Kits 29. . . . . . . . . . . . . . . . . . . . . Relay Replacement Kits 29. . . . . . . . . . . . . . . . . .

Parts List 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemblies 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Parts 29. . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Parts for Panel, Wall, Pipestand

or Actuator Mounting 36. . . . . . . . . . . . . . . . . . .

Introduction

Scope of ManualThis instruction manual provides installation,operating, maintenance, and parts information forthe 4150K and 4160K Series Wizard�

II pressurecontrollers and transmitters shown in figure 1. Referto separate instruction manuals for informationregarding the control valve, actuator, andaccessories.

No person may install, operate, or maintain 4150Kand 4160K Series Wizard II pressure controllersand transmitters without first � being fully trainedand qualified in valve, actuator and accessoryinstallation, operation and maintenance, and �carefully reading and understanding the contents ofthis manual. If you have any questions about theseinstructions, contact your Emerson ProcessManagement� sales office.

DescriptionThe 4150K and 4160K Series pneumatic pressurecontrollers and transmitters use a bellows orBourdon tube sensing element to sense the gaugepressure, vacuum, compound pressure, ordifferential pressure of a liquid or gas. The controlleror transmitter output is a pneumatic pressure signalthat can be used to operate a final control element,indicating device, or recording device.

Unless otherwise noted, all NACE references are toNACE MR0175-2002.

SpecificationsSpecifications for the 4150K and 4160K Seriescontrollers and transmitters are listed in table 1.Table 2 explains available configurations andoptions.

Educational ServicesFor information on available courses for 1450K and4160K Series controllers and transmitters, as well asa variety of other products, contact:

Emerson Process ManagementEducational Services, RegistrationP.O. Box 190; 301 S. 1st Ave.Marshalltown, IA 50158-2823Phone: 800-338-8158 orPhone: 641-754-3771 FAX: 641-754-3431e-mail: [email protected]

Note

Neither Emerson�, Emerson ProcessManagement, Fisher�, nor any of theiraffiliated entities assumesresponsibility for the selection, use,and maintenance of any product.Responsibility for the selection, use,and maintenance of any productremains with the purchaser andend-user.

Installation

WARNING

To avoid personal injury or propertydamage resulting from the suddenrelease of pressure:

� Always wear protective clothing,gloves, and eyewear when performingany installation operations.

� Personal injury or propertydamage may result from fire orexplosion if natural gas is used as thesupply medium and preventativemeasures are not taken. Preventativemeasures may include: Remoteventing of the unit, re-evaluating thehazardous area classification,ensuring adequate ventilation, and theremoval of any nearby ignitionsources. For information on remoteventing of this controller/transmitter,refer to page 9.

(Installation Warning continued onpage 5)

4150K and 4160K Controllers and TransmittersInstruction ManualForm 5177March 2006

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Table 1. Specifications

Available Configurations

See table 2

Input Signal(1)

Type: � Gauge pressure, � vacuum,� compound pressure, or � differential pressureof a liquid or gasLimits: See table 3 or 4

Output Signal(1)

Proportional-Only or Proportional-Plus-ResetControllers and Transmitters:� 0.2 to 1.0 bar (3 to 15 psig) or� 0.4 to 2.0 bar (6 to 30 psig) pneumaticpressure signalDifferential Gap Controllers:� 0 and 1.4 bar (0 and 20 psig) or� 0 and 2.4 bar (0 and 35 psig) pneumaticpressure signalAction: Control action is field reversible between� direct (increasing sensed pressure producesincreasing output signal) and � reverse(increasing sensed pressure produces decreasingoutput signal). The suffix R is added to the typenumber of a construction specified for reverseaction.

Supply Pressure Requirements(2)

See table 5

Supply Pressure Medium

Air or natural gas(3)

Steady-State Air Consumption(1)

See figure 2

Supply and Output Connections

1/4-inch NPT female

Common Signal Pressure Conversions

See table 6

Proportional Band(1) Adjustment

For Proportional-Only andProportional-Plus-Reset Controllers: Fulloutput pressure change adjustable from 3 to100% for a 0.2 to 1.0 bar (3 to 15 psig), or 6 to100% for a 0.4 to 2.0 bar (6 to 30 psig) of thesensing element range.

Differential Gap Adjustment

For Differential Gap Controllers: Full outputpressure change adjustable from 15% to 100% ofsensing element range

Reset(1) Adjustment

For Proportional-Plus-Reset Controllers:Adjustable from 0.01 to 74 minutes per repeat(100 to 0.01 repeats per minute)

Zero(1) Adjustment (Transmitters Only)

Continuously adjustable to position span of lessthan 100% anywhere within the sensing elementrange

Span(1) Adjustment (Transmitters Only)

Full output pressure change adjustable from 6 to100% of sensing element range

Performance

Repeatability(1): 0.5% of sensing element rangeDeadband(1) (Except Differential GapControllers(4): 0.1% of output spanTypical Frequency Response at 100%Proportional BandOutput to Actuator: 0.7 Hz and 110 degree phaseshift with 1850 cm3 (113 inches3) volume,actuator at mid-strokeOutput to Positioner Bellows: 9 Hz and 130degree phase shift with 0.2 to 1.0 bar (3 to 15psig) output to 33 cm3 (2 inches3) bellows

Ambient Operating Temperature Limits(2)

� Standard Construction: −40 to 93�C (−40 to200�F)� 4160KF (w/Reset Relief): −40 to 71�C (−40 to160�F)

Typical Ambient Temperature OperatingInfluence

Proportional Control only: Output pressurechanges �3.0% of sensing element range foreach 28�C (50�F) change in temperaturebetween −40 and 71�C (−40 and 160�F) for acontroller set at 100% proportional bandReset Control only: Output pressure changes�2.0% of sensing element range for each 28�C(50�F) change in temperature between −40 and71�C (−40 and 160�F) for a controller set at 100%proportional band

−Continued−


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Table 1. Specifications (continued)

Typical Ambient Temperature OperatingInfluence (continued)

Transmitters only: Output pressure changes�3.0% of sensing element range for each 28�C(50�F) change in temperature between −40 and71�C (−40 and 160�F) for a transmitter set at100% span

Hazardous Area Classification

Complies with the requirements of ATEX Group IICategory 2 Gas and Dust

Refer to figure 22 for location of ATEX label

Approximate Weight

8.2 kg (18 pounds)

Options

Case pressure tested to 0.14 bar (2 psig)

Declaration of SEP

Fisher Controls International LLC declares thisproduct to be in compliance with Article 3paragraph 3 of the Pressure Equipment Directive(PED) 97 / 23 / EC. It was designed andmanufactured in accordance with SoundEngineering Practice (SEP) and cannot bear theCE marking related to PED compliance.

However, the product may bear the CE markingto indicate compliance with other applicable ECDirectives.

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 H2S.4. An adjustable differential gap (differential gap controllers) is equivalent to an adjustable deadband.

Table 2. Available ConfigurationsTYPE NUMBER(1)

DESCRIPTION Bourdon TubeSensing Element(Gauge Pressure

Only)

Bellows Sensing Element

GaugePressure

DifferentialPressure

Proportional-only controller 4150K 4152K 4154K

Proportional-plus-reset controllerWithout anti-reset windup 4160K 4162K 4164K

With anti-reset windup 4160KF 4162KF - - -

Differential gap controller 4150KS 4152KS - - -

Transmitter 4157K 4158K 4155K1. The suffix R is added to the type number of a construction specified for reverse action.

Table 3. Bourdon Tube Pressure Ranges and Materials

PRESSURE RANGES(1)MAXIMUM ALLOWABLE STATIC PRESSURE(2) LIMITS(3)

MATERIALStandard With Optional Travel Stop(4)

Bar Psig Bar Psig Bar Psig

0 to 2.00 to 4.00 to 7.0

0 to 300 to 600 to 100

2.04.07.0

3060

100

3.36.611

4896

160

316 stainless steel

0 to 140 to 200 to 400 to 70

0 to 2000 to 3000 to 600(5)

0 to 1000(5)

14204070

200300600

1000

19295083

280420720

1200

0 to 1000 to 2000 to 350

0 to 1500(5)

0 to 30000 to 5000

100200350

150030005000

115230380

165033005500

0 to 5500 to 700

0 to 80000 to 10.000

550700

800010,000

550700

800010,000

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.


5

Table 4. Bellows Pressure Ranges and Materials

PRESSURE RANGES MAXIMUM ALLOWABLE STATICPRESSURE(1) LIMITS(2)

BrassConstruction

Stainless SteelConstruction

Bar Psig Bar Psig

Gauge Pressure

Vacuum0 to 150 mbar (0 to 60 inch wc)0 to 340 mbar (0 to 10 inch Hg)0 to 1.0 bar (0 to 30 inch Hg)

1.62.82.8

204040

------6.9

------

100

Compound Pressure75 mbar vac. to 75 mbar (30 inch wc vac. to 30 inch wc)500 mbar vac. to 500 mbar (15 inch Hg vac. to 7.5 psig)1.0 bar vac. to 1.0 bar (30 inch Hg vac. to 15 psig)

1.42.82.8

204040

---6.96.9

---100100

Positive pressure

0 to 150 mbar (0 to 60 inch wc)0 to 250 mbar(3) (0 to 100 inch wc)0 to 350 mbar(4) (0 to 140 inch wc)0 to 0.35 bar (0 to 5 psig)0 to 0.5 bar (0 to 7.5 psig)

1.41.42.82.82.8

2020404040

---------------

---------------

0 to 0.7 bar (0 to 10 psig)0 to 1.0 bar (0 to 15 psig)0 to 1.4 bar (0 to 20 psig)0 to 2.0 bar (0 to 30 psig)

2.82.82.82.8

40404040

---6.9---6.9

---100---

100

Differential Pressure(5)

0 to 300 mbar (0 to 80 inch wc)0 to 0.7 bar (0 to 10 psi)0 to 1.4 bar (0 to 20 psi)0 to 2.0 bar (0 to 30 psi)

1.42.82.8---

204040---

---------6.9

---------

1001. 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.

SU

PP

LY

AIR

FL

OW

, SC

FH

PROPORTIONALBAND SETTING OF 0OR 10

PROPORTIONAL BANDSETTING OF 5

OUTPUT, PSIG

3 TO 15 PSIG (0.2 TO 1.0 BAR) OUTPUT SIGNAL RANGE

SU

PP

LY

AIR

FL

OW

, SC

FH

OUTPUT, PSIG

6 TO 30 (0.4 TO 2.0 BAR) OUTPUT SIGNAL RANGE

PROPORTIONALBAND SETTING OF 5

PROPORTIONAL BANDSETTING OF 0 OR 10

NOTESTO CONVERT PSIG TO BAR, MULTIPLY BY 0.06895.SCFH—STANDARD CUBIC FEET PER HOUR (60�F AND 14.7 PSIA).

TO CONVERT TO NORMAL M3/HR—NORMAL CUBIC METERS PER HOUR (0�C AND 1.01325 BAR, ABSOLUTE), MULTIPLY BY 0.0268

1

1

1

2

2

2

A7242 / IL

Figure 2. Steady-State Air Consumption

WARNING

(Installation Warning, continued frompage 2)

� If installing into an existingapplication, also refer to the WARNINGat the beginning of the Maintenancesection in this instruction manual.

� Check with your process or safetyengineer for any additional measuresthat must be taken to protect againstprocess media.

Standard InstallationThe instruments are normally mounted vertical withthe case/cover as shown in figure 1. If installing theinstrument in any other position, be sure that thevent opening shown in figure 3 is facing downward.

Panel MountingRefer to figure 3.

Cut a hole in the panel surface according to thedimensions shown in figure 3. Remove the capscrews (key 252), brackets (key 251), and ventassembly (key 15). Slide the controller or transmitter


Form 5177March 2006

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into the cutout and reattach the brackets. Tighten thecap screw located in the center of each bracket todraw the case snugly and evenly against the panel.Reinstall the vent unless a remote vent will be used.

Wall MountingRefer to figure 3.

Drill four holes in the wall using the dimensionsshown in figure 3. In the bracket (key 251) are 8.7mm (0.3438 inch) diameter holes. Back out the capscrew located in the center of each bracket. (Thescrews are used for panel mounting but are notrequired for wall mounting.) If tubing runs throughthe wall, drill holes in the wall to accommodate thetubings. Figure 3 shows the pressure connectionlocations in the back of the case.

Mount the controller to the bracket using the four capscrews (key 252) provided. Attach the bracket to thewall, using suitable screws or bolts.

Pipestand MountingRefer to figure 3.

Attach the spacer spools (key 228) and the mountingplate (key 213) to the controller with cap screws,lock washers, and nuts (keys 215, 221, and 216).Attach the controller to a 2-inch (nominal) pipe withpipe clamps (key 250).

Actuator MountingRefer to figure 4.

Controllers specified for mounting on a control valveactuator are mounted at the factory. If the instrumentis ordered separately for installation on a controlvalve actuator, mount the instrument according tothe following instructions.

Mounting parts for the different actuator types andsizes vary. Two typical actuator-mountinginstallations are shown in figure 4; see the parts listfor parts required for the specific actuator type andsize involved. Attach the spacer spools (key 228)and the mounting plate (key 213) to the controllerwith machine screws, lock washers, and nuts (keys215, 221, and 216).

Attach the mounting bracket to the actuator yokewith cap screws (key 222) and, if needed, spacerspools. On some designs, the mounting bracket isattached to the actuator diaphragm casing ratherthan to the yoke.

Pressure Connections

WARNING

To avoid personal injury or propertydamage resulting from the suddenrelease of pressure, do not install anysystem component where serviceconditions could exceed the limitsgiven in this manual. Usepressure-relieving devices as requiredby government or accepted industrycodes and good engineering practices.

All pressure connections on 4150K and 4160KSeries instruments are 1/4-inch NPT female. Use 6mm (1/4-inch) or 10 mm (3/8-inch) pipe or tubing forsupply and output piping. The pressure connectionlocations are shown in figure 3.

Supply Pressure

WARNING

Severe personal injury or propertydamage may occur from anuncontrolled process if the instrumentsupply medium is not clean, dry,oil-free and noncorrosive. While useand regular maintenance of a filter thatremoves particles larger than 40microns in diameter will suffice inmost applications, check with anEmerson Process Management fieldoffice and industry instrument supplymedium quality standards for use withhazardous gas or if you are unsureabout the proper amount or method ofair filtration or filter maintenance.

Supply pressure must be clean, dry air ornoncorrosive gas that meets the requirements of ISAStandard S7.3. Use a suitable supply pressureregulator to reduce the supply pressure source tothe normal operating supply pressure shown in table5. Connect supply pressure to the SUPPLYconnection at the back of the case.

If operating the controller or transmitter from a highpressure source [up to 138 bar (2000 psig)], use ahigh pressure regulator system, such as the Type1367 High Pressure Instrument Supply System. ForType 1367 system installation, adjustment, andmaintenance information, see the separateinstruction manual.


7

2 INCH(NOMINAL)PIPE

VENT ASSEMBLY(KEY 15)

FOUR HOLESFOR WALLMOUNTING

CUTOUT FORPANEL MOUNTING

8.7(11/32)MOUNTINGHOLES

PANEL MOUNTING WALL MOUNTING

BACK VIEWPIPESTAND MOUNTING

mm(INCH)

NOTES: 1. ALL CONNECTIONS ARE 1/4-INCH NPT FEMALE.

HIGH-PRESSURE CONNECTION FOR DIFFERENTIAL-PRESSURE UNITS.23

B1563-2 / ILGE07082-A

LOW-PRESSURE CONNECTION FOR DIFFERENTIAL-PRESSURE UNITS.

Figure 3. Panel, Wall, and Pipestand Mounting

Process Pressure

WARNING

To avoid personal injury or propertydamage resulting from the suddenrelease of pressure when usingcorrosive media, make sure the tubingand instrument components thatcontact the corrosive medium are ofsuitable noncorrosive material.

Also refer to the Installation Warningat the beginning of this section.

The pressure connections to the controller dependupon the type of pressure sensing, gauge ordifferential. Gauge pressure controllers use either aBourdon tube or bellows as the sensing element, asindicated in table 2. Differential pressure controllersuse two bellows to sense differential pressure.

For gauge pressure instruments: The controlpressure block (key 8 in figure 18) has twoconnections. Process pressure can be connectedeither to the CONTROL connection on the back ofthe case, or to the connection on the left side of thecase, shown in figure 3, depending on theinstrument application. Plug the unused connection.


Form 5177March 2006

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Table 5. Supply Pressure RequirementsOUTPUT

SIGNAL RANGE NORMAL OPERATING SUPPLYPRESSURE(1)

MAXIMUM ALLOWABLE SUPPLYPRESSURE TO PREVENT INTERNAL

PART DAMAGE

Bar0.2 to 1.0 or 0 and 1.4 (differential gap) 1.4 2.8

0.4 to 2.0 or 0 and 2.4 (differential gap) 2.4 2.8

Psig3 to 15 or 0 and 20 (differential gap) 20 40

6 to 30 or 0 and 35 (differential gap) 35 401. If this pressure is exceeded, control may be impaired.

Table 6. Common Signal Pressure ConversionsMps kg/cm2 bar kPa Psi

0.020.030.040.050.06

0.20.30.40.50.6

0.2(2)

0.30.40.50.6

20(1)

3540(1)

5060

35679

0.070.080.090.100.12

0.80.81.0

1.0(3)

1.3

0.80.81.0

1.0(2)

1.2

758095

100(1)

125

1112141518

0.140.150.170.180.20

1.41.51.81.92.0

1.41.51.71.9

2.0(3)

140150170185

200(1)

2022252730

0.220.230.240.340.55

2.22.32.53.55.6

2.22.32.43.45.5

220230240345550

3233355080

0.691.03

7.010.5

6.910.3

6901035

100150

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: Connectthe low pressure line to the CONTROL connectionon the side of the case and the high pressure line tothe CONTROL connection on the back of the caseas shown in figure 3.

When installing process piping, follow acceptedpractices to ensure accurate transmission of theprocess pressure to the controller or transmitter.Install shutoff valves, vents, drains, or seal systemsas needed in the process pressure lines. If theinstrument is located such that the adjacent processpressure lines will be approximately horizontal, thelines should slope downward to the instrument forliquid-filled lines and upward to instruments forgas-filled lines. This will minimize the possibility ofair becoming trapped in the sensor with liquid-filledlines or of condensation becoming trapped withgas-filled lines. The recommended slope is 83 mmper meter (1 inch per foot).

48B6020-A / DOC

SUPPLY PRESSUREREGULATOR

SUPPLY PRESSUREREGULATOR

TYPICAL ROTARY ACTUATOR

TYPICAL SLIDING STEM ACTUATOR

38B6021-A / DOC

Figure 4. Actuator Mounting


9

If a controller is being used in conjunction with acontrol valve to control pipeline pressure, connectthe process pressure line in a straight section of pipeapproximately 10 pipe diameters from the valve butaway from bends, elbows, and areas of abnormalfluid velocities. For pressure-reducing service, theprocess line must be connected downstream of thevalve. For pressure-relief service, the processpressure line must be connected upstream of thecontrol valve. Install a needle valve in the processpressure line to dampen pulsations.

Vent Assembly

WARNING

Personal injury or property damagecould result from fire or explosion ofaccumulated gas, or from contact withhazardous gas, if a flammable orhazardous gas is used as the supplypressure medium. Because theinstrument case and cover assemblydo not form a gas-tight seal when theassembly is enclosed, a remote ventline, adequate ventilation, andnecessary safety measures should beused to prevent the accumulation offlammable or hazardous gas. However,a remote vent pipe alone cannot berelied upon to remove all flammableand hazardous gas. Vent line pipingshould comply with local and regionalcodes, and should be be as short aspossible with adequate inside diameterand few bends to reduce casepressure buildup.

CAUTION

When installing a remote vent pipe,take care not to overtighten the pipe inthe vent connection. Excessive torquewill damage the threads in theconnection.

The vent assembly (key 15, figure 3) or the end of aremote vent pipe must be protected against theentrance of all foreign matter that could plug thevent. Use 13 mm (1/2-inch) pipe for the remote ventpipe, if one is required. Check the vent periodicallyto be certain it has not become plugged.

Controller Operation

Proportional-Only ControllersThis section describes the adjustments andprocedures for calibration and startup. Adjustmentlocations are shown in figure 5 unless otherwisespecified. All adjustments must be made with thecover open. When the adjustments and calibrationprocedures are complete, close and latch the cover.

To better understand the adjustments and overalloperation of the controller, refer to the Principle ofOperation section in this manual forproportional-only controllers. Refer also to theschematic diagram in figure 14.

Adjustments

Adjustment: Set Point

Adjust the pressure-setting knob by turning the knobclockwise to increase the set point andcounterclockwise to decrease the set point. Note:The dial setting and actual process pressure mayvary significantly, especially with a wide proportionalband setting.

Adjustment: Proportional Band

To adjust the proportional band, rotate theproportional band knob to the desired value.

The proportional band adjustment determines theamount of change in controlled pressure required tocause the control valve to stroke fully. It may beadjusted from 3-100 percent of the nominal sensingelement pressure rating.

Calibration: Proportional-OnlyControllersUnless otherwise indicated, key number locationsare shown in figure 5.

Provide a process pressure source capable ofsimulating the process pressure range of thecontroller. If an output pressure gauge is notprovided, install a suitable pressure gauge forcalibration purposes.

Connect a pressure source to the supply pressureregulator and be sure the regulator is delivering thecorrect supply pressure to the controller. Thecontroller must be connected open loop (Open loop:The controller output pressure changes must be


Form 5177March 2006

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PROPORTIONAL BANDADJUSTMENT KNOB

PRESSURE-SETTING KNOB(KEY 36)

PRESSURE-SETTINGDIAL (KEY 38)

FLAPPER (KEY 45)

NOZZLE (KEY 57)

CALIBRATION ADJUSTER (KEY 41)

ADJUSTER SCREWS (KEY 43)48B6003-AA6038-1 / IL

Figure 5. Proportional-Only Controller Adjustment Locations

dead ended into a pressure gauge). The followingprocedures use a 0.2 to 1.0 bar (3 to 15 psig) outputpressure range as an example. For a 0.4 to 2.0 bar(6 to 30 psig) output range, adjust the values asappropriate.

1. Complete the above connections and provide aprocess pressure equal to the sensing elementrange.

2. Rotate the proportional band knob, shown infigure 5, to 1.5 (15 percent proportional band).

3. Verify that the calibration adjuster screws (key 43) are at mid-position in the calibrationadjuster (key 41) slots.

Depending upon the controller action, perform oneor the other of the following procedures.

For direct-acting controllers:

4. Apply an input pressure equal to the sensingelement lower range value.

5. Rotate the pressure setting knob to the minimumvalue.

6. Adjust the nozzle (key 57) until the controlleroutput pressure is between 0.6 and 0.7 bar (8 and 10 psig.)

7. Apply an input pressure equal to the sensingelement upper range value.

8. Rotate the pressure-setting knob to the maximumvalue.

Note

When performing the span adjustmentin step 9, do not watch the outputgauge while changing the calibrationadjuster. The change in output is not agood indication of the change in span.While moving the calibration adjuster,the output pressure may change in theopposite direction than expected. Forexample, while moving the calibrationadjuster to increase span, the outputpressure may decrease. This shouldbe disregarded since even though theoutput pressure decreases, the span isincreasing.


11

IF OUTPUT IS:

BELOW8 TO 10 PSIG(0.6 TO 0.7 BAR)

ABOVE8 TO 10 PSIG(0.6 TO 0.7 BAR)

MOVE ADJUSTERLEFT

MOVE ADJUSTERRIGHT

FLAPPER

NOZZLE

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, ADJUSTVALUES AS APPROPRIATE.A6154 / IL

Figure 6. Direct-Acting Controller SpanAdjustment—Proportional-Only Controllers

Proper controller response dependson nozzle-to-flapper alignment.

When performing span adjustments,carefully loosen both calibrationadjuster screws while holding thecalibration adjuster in place. Thenmove the calibration adjuster slightlyin the required direction by hand orusing a screwdriver. Verify propernozzle-to-flapper alignment and holdthe calibration adjuster in place whiletightening both adjustment screws.

9. If the output is not between 0.6 and 0.7 bar (8and 10 psig), adjust the controller span by looseningthe two adjusting screws (key 43) and moving thecalibration adjuster (key 41) a small distance asindicated in figure 6.

10. Repeat steps 4 through 9 until no furtheradjustment is necessary.

11. Proceed to the startup procedure forproportional controllers.

For reverse-acting controllers:


5. Rotate the pressure setting knob to the maximumvalue.

6. Adjust the nozzle (key 57) until the controlleroutput pressure is between 0.6 and 0.7 bar (8 and 10 psig).


8. Rotate the pressure-setting knob to the minimumvalue.

Note




9. If the output is not between 0.6 and 0.7 bar (8and 10 psig), adjust the controller span by looseningthe two adjusting screws (key 43) and moving thecalibration adjuster (key 41) a small distance asindicated in figure 7.


11. Proceed to the startup procedure forproportional controllers.


Form 5177March 2006

12

IF OUTPUT IS:



MOVE ADJUSTERLEFT

MOVE ADJUSTERRIGHT

FLAPPER

NOZZLE

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, ADJUSTVALUES AS APPROPRIATE.A6155-1 / IL

Figure 7. Reverse-Acting Controller Span Adjustment —Proportional-Only Controllers

Startup: Proportional-Only Controllers(General Tuning Guidelines)Calibrate the controller prior to this procedure.

1. Be sure that the supply pressure regulator isdelivering the proper supply pressure to thecontroller.

2. Rotate the pressure-setting knob to the desiredset point.

3. Set the proportional band adjustment to 100percent for fast processes (example: liquid pressureor liquid flow). For slow processes (example:temperature), calculate the percentage from theequation below:

For a slow process, determine the initial proportionalband setting in percent from the following equation:

200 � Allowable OvershootPressure Span

� P.B.

For example:

200 � 1.4 bar2.1 bar

� 13% 200 � 2 psig30 psig

� 13%( )(1.3 proportional band setting)

4. Proportional Action

Disturb the system by tapping the flapper lightly orchange the set point a small amount and check forsystem cycling. If the system does not cycle thenlower the proportional band (raising the gain) anddisturb the system again. Continue this procedureuntil the system cycles. At that point, double theproportional band setting.

Note

Proportional band adjustment affectsthe set point. Proportional-onlycontrollers will show some offset fromset point depending upon proportionalband setting and process demand.After adjusting the proportional band,re-zero by carefully rotating the nozzle(key 57) until the steady-state processpressure equals the process pressureknob reading.

This tuning procedure may be too conservative forsome systems. The recommended proportional bandsetting should be checked for stability by introducinga disturbance and monitoring the process.

Proportional-Plus-Reset ControllersThis section describes the adjustments andprocedures for calibration and startup. Theadjustment locations are shown in figure 8 unlessotherwise specified. All adjustments must be madewith the cover open. When the adjustments andcalibration procedures are complete, close and latchthe cover. To better understand the adjustments andoverall operation of the controller, refer to thePrinciple of Operation section in this manual forproportional-plus-reset controllers. Refer also to theschematic diagram in figure 14.

Adjustments

Adjustment: Set Point

Adjust the pressure-setting knob by turning the knobclockwise to increase the set point andcounterclockwise to decrease the set point.

Rotate the knob until the indicator points to thedesired set point pressure value. The pressuresetting dial will reflect the desired set point if thecontroller is accurately calibrated.


13

RESET ADJUSTMENT KNOB

PROPORTIONAL BANDADJUSTMENT KNOB

PRESSURE SETTING KNOB(KEY 36)

PRESSURE SETTINGDIAL (KEY 38)

ADJUSTER SCREWS (KEY 43)

CALIBRATION ADJUSTER (KEY 41)FLAPPER (KEY 45)

NOZZLE (KEY 57)48B6002-AA5433-3 / IL

Figure 8. Proportional-Plus-Reset Controller Adjustment Locations


To adjust the proportional band, rotate theproportional band knob to the desired value.

The proportional band adjustment determines theamount of change in controlled pressure required tocause the control valve to stroke fully. It may beadjusted from 3-100 percent of the nominal sensingelement pressure rating.

Adjustment: Reset

To adjust reset action turn the knob clockwise todecrease the minutes per repeat. Turn the knobcounterclockwise to increase the minutes per repeat.Increasing the minutes per repeat provides a slowerreset action.

The reset adjustment dial is calibrated in minutes perrepeat. By definition, this is the time in minutesrequired for the reset action to produce an outputchange which is equal to the change produced byproportional control action. This is in effect, the timein minutes required for the controller to increase (ordecrease) its output pressure by an amount equal to

a proportional increase (or decrease) caused by achange in set point or process pressure.

Adjustment: Anti-Reset Windup

The externally mounted differential relief valve canbe mounted to relieve on increasing or decreasingoutput pressure.

CalibrationCalibration: Proportional-Plus-Reset Controllers

Unless otherwise indicated, key number locationsare shown in figure 8.

Before starting this procedure:

� Provide a process pressure source capable ofsimulating the process pressure range of thecontroller.

� If an output pressure gauge is not provided,install a suitable pressure gauge for calibrationpurposes. The controller must be connected openloop (Open loop: The controller output pressurechanges must be dead ended into a pressuregauge).


Form 5177March 2006

14

Note

Type 4160KF and 4162KF (anti-resetwindup) controllers are supplied withtwo O-rings (key 367, not shown), ananti-reset windup cover (key 369, notshown), and two machine screws (key368, not shown). Use these parts in thenext step.

1. For controllers with anti-reset windup (Type4160KF and 4162KF), record the direction of thearrow on the anti-reset windup assembly (key 186, infigure 19). Remove the assembly and install the twoO-rings (key 367, not shown), and cover (key 369,not shown) supplied with the controller. Secure thecover with the two machine screws (key 368, notshown) provided.

2. Connect regulated supply pressure to thecontroller. Do not exceed the normal operatingpressure in table 5.

3. Rotate the reset knob to 0.01 minutes per repeat(fastest setting).

4. Rotate the proportional band knob to 1.5 (15percent proportional band).


Depending upon the controller action, perform oneor the other of the following procedures.

For direct-acting controllers:


7. Rotate the pressure setting knob to the minimumvalue.



10. Rotate the pressure-setting knob to themaximum value.

Note

When performing the span adjustmentin step 11, do not watch the outputgauge while changing the calibrationadjuster. The change in output is not agood indication of the change in span.While moving the calibration adjuster,

IF OUTPUT IS:



MOVE ADJUSTERLEFT

MOVE ADJUSTERRIGHT

FLAPPER

NOZZLE


Figure 9. Direct-Acting Controller Span Adjustment—Proportional-Plus-Reset Controllers

the output pressure may change in theopposite direction than expected. Forexample, while moving the calibrationadjuster to increase span, the outputpressure may decrease. This shouldbe disregarded since even though theoutput pressure decreases, the span isincreasing.



11. If the output pressure is not between 0.6 and 0.7bar (8 and 10 psig), adjust the controller span byloosening the two adjusting screws (key 43) andmoving the calibration adjuster (key 41) a smalldistance as indicated in figure 9.


13. For controllers with anti-reset windup (Type4160KF and 4162KF), remove the two machinescrews, anti-reset windup cover, and two O-ringsinstalled in step 1 of this procedure. Install theanti-reset windup assembly (key 186) with the arrowpointing in the direction recorded in step 1.


15

14. Proceed to the Startup procedures forproportional-plus-reset controllers.

For reverse-acting controllers:


7. Rotate the pressure setting knob to the maximumvalue.



10. Rotate the pressure-setting knob to the minimumvalue.

Note




11. If the output pressure is not between 0.6 and 0.7bar (8 and 10 psig), adjust the controller span byloosening the two adjusting screws (key 43) and

IF OUTPUT IS:



MOVE ADJUSTERLEFT

MOVE ADJUSTERRIGHT

FLAPPER

NOZZLE

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, ADJUSTVALUES AS APPROPRIATE.A6155-1 / IL

Figure 10. Reverse-Acting Controller Span Adjustment—Proportional-Plus-Reset Controllers

moving the calibration adjuster (key 41) a smalldistance as indicated in figure 10.


13. For controllers with anti-reset windup (Type4160KF and 4162KF), remove the two machinescrews, anti-reset windup cover, and two O-ringsinstalled in step 1 of this procedure. Install theanti-reset windup assembly (key 186) with the arrowpointing in the direction recorded in step 1.

14. Proceed to the Startup procedures forproportional-plus-reset controllers.

Calibration: Anti-Reset Windup

Controllers with anti-reset windup have a differentialrelief valve assembly (figure 19). This relief valve isset at the factory to relieve at a 0.3 bar (5 psi)pressure difference between the reset bellowspressure and the proportional bellows pressure. Thevalve can be adjusted to relieve from 0.14 to 0.4 bar(2 to 7 psig).

The relief valve can relieve on either rising controlleroutput pressure or falling controller output pressure.If the arrow on the relief valve points toward thebottom of the controller case as shown in figure 19,the valve will relieve on falling output pressure. If thearrow points in the opposite direction, the valve willrelieve on rising output pressure. The valve can beremoved and reinstalled with the arrow pointing inthe opposite direction to change the relief action.


Form 5177March 2006

16

Startup: Proportional-Plus-ResetControllers (General Tuning Guidelines)Calibrate the controller prior to this procedure.


2. Rotate the pressure-setting knob to the desiredset point.

3. Start with a reset setting of 0.05 minutes perrepeat (m/r) for fast processes, and 0.5 m/r for slowprocesses.

4. Set the proportional band adjustment to 100percent for fast processes (example: liquid pressureor liquid flow). For a slow process (example:temperature), calculate the percentage from theequation below:

For a slow process, determine the initial proportionalband setting in percent from the following equation:

200 � Allowable OvershootPressure Span

� P.B.

For example:

200 � 1.4 bar2.1 bar

� 13% 200 � 2 psig30 psig

� 13%( )(1.3 proportional band setting)

5. Proportional Action:

Disturb the system by tapping the flapper lightly orchange the set point a small amount and check forsystem cycling. If the system does not cycle thenlower the proportional band (raising the gain) anddisturb the system again. Continue this procedureuntil the system cycles. At that point, double theproportional band setting and begin tuning the reset.

6. Reset Action:

Disturb the system. If the system does not cycle thenspeed up the reset and disturb the system again.Continue this procedure until the system cycles.When the system cycles multiply the reset timesetting by a factor of three (3) and slow the resetdown to the new value. The reset is now tuned.

This tuning procedure may be too conservative forsome systems. The recommended proportional bandand reset setting should be checked for stability byintroducing a disturbance and monitoring theprocess as previously described. For someapplications, tighter control may be desirable.

Differential Gap ControllersThis section describes the adjustments andprocedures for calibration and startup. Theadjustment locations are shown in figure 5 unlessotherwise specified. The output of each controller ischecked at the factory before the instrument isshipped.

To convert a differential gap controller to aproportional-only controller or vice versa, refer to theappropriate procedure in the Maintenance section.

If the process pressure can be varied through all orpart of the sensing element range or through the twodesired switching points, use the process pressurefor calibration. If not, provide a pressure source tosimulate the process pressure range for calibrationprocedures.

To better understand the adjustments and overalloperation of the controller, refer to the Principle ofOperation section in this manual for differential gapcontrollers and the schematic diagram in figure 14.

AdjustmentsAdjustment: Set Point

The position of the pressure-setting knob determinesthe location of the differential gap within the range ofthe pressure sensing element. Move the pointer tothe desired pressure where the output of thecontroller should switch from zero to full supplypressure with rising process pressure (direct-actingcontrollers) or with falling process pressure(reverse-acting controllers).


The proportional band adjustment shown in figure 5determines the width of the differential gap. Thewidth of the gap is the difference between theprocess pressures at which the controller output willswitch from zero to full supply pressure, or from fullsupply pressure to zero. The relationship betweenthe proportional band dial setting and the differentialgap is shown in figure 11.

Calibration: Differential Gap ControllersThe output of each controller is checked at thefactory before the unit is shipped. Before placing thecontroller in control of a process loop, check to verifythat the controller is calibrated correctly for theapplication. The controller must be connected openloop (Open loop: The controller output pressurechanges must be dead ended into a pressuregauge).


17

A2202-3 / IL

PR

OP

OR

TIO

NA

L B

AN

D K

NO

B S

ET

TIN

G

DIFFERENTIAL GAP (PERCENT OF ELEMENT RANGE)

Figure 11. Differential Gap Adjustment for Differential GapControllers

1. Temporarily convert the differential gap controllerto a proportional-only controller by disconnecting theproportional tubing (key 104, figure 16) from themounting base. Reinstall the tubing into the otherconnection in the mounting base as shown infigure 16. Do not invert the reversing block (key 59,figure 16).

2. Use the calibration procedures forproportional-only controllers.

3. Upon completion of the calibration procedures,reinstall the tubing (key 104) in its original location,and continue with the following procedures.

Note

After reinstalling the tubing (key 104)in step 3 a slight offset of the outputpressure will be noticed due toswitching from the proportionalbellows to the reset bellows. This isbecause the effective area and springrate of the two bellows may not match.Performing step 5b below adjusts forthis offset.

4. Refer to figure 11 to determine the proportionalband dial setting required for the desired differentialgap.

For example, assume that a 0 to 100 psig sensingelement is being used and the controller is to switchfrom zero to full supply pressure at a processpressure of 80 psig with rising process pressure andfrom full supply pressure to zero at 20 psig with

falling pressure. (This is for a direct-actingcontroller.) The differential gap is:

5.5 bar � 1.3 bar6.9 bar

� 100 � 60%

80 psig � 20 psig100 psig

� 100 � 60%( )From figure 11, the proportional band dial settingshould be approximately 4.5; rotate the proportionalband knob to 4.5.

5. Setting the process pressure

For a Direct-Acting Controller:

a. Rotate the pressure-setting knob to thepressure at which the controller output is toswitch to the upper switching point (zero to fullsupply pressure) with rising process pressure. Inthe above example, this pressure is 5.5 bar (80psig).

b. Increase pressure to the sensing elementwhile monitoring the output pressure gauge. Thecontroller output pressure should switch fromzero to full supply pressure when the upperswitching point is reached with rising inputpressure.

Note

If the upper switching point is notcorrect, adjust the nozzle to correctthe error. Repeat step 5b until theinput pressure and upper switchingpoint are at the desired setting.

c. With falling input pressure, the output shouldswitch from full supply pressure back to zerowhen the lower switching point is reached.

Reverse-acting controllers produce the oppositeresponse.

6. Vary the process pressure and observe theswitching points. Widen or narrow the differentialgap by rotating the proportional band knob, thenrepeat the above steps.

If the output is within the limits stated, refer to thestartup procedures in this section. If the outputpressure cannot be adjusted within the limits stated,refer to the maintenance procedures.


Form 5177March 2006

18

PRESSURE SETTINGDIAL (KEY 38)

ADJUSTER SCREWS (KEY 43)

CALIBRATION ADJUSTER (KEY 41)

FLAPPER (KEY 45)

NOZZLE (KEY 57)

SPANADJUSTMENT KNOB

ZERO ADJUSTMENT KNOB(KEY 36)

48B6004-BA6039-3 / IL

Figure 12. Transmitter Adjustment Locations

Startup: Differential Gap ControllersCalibrate the controller prior to this procedure.


2. Adjust the proportional band knob for the properdifferential gap (see figure 11).

3. If the controller is used in conjunction with acontrol valve, slowly open the upstream anddownstream manual shutoff valves, and close thebypass valves.

4. To change the differential gap, perform steps 1through 4 of the calibration for differential gapcontrollers procedure.

Transmitter OperationThis section describes the adjustments andprocedures for calibration and startup. Refer tofigure 12 for the adjustment locations. Alladjustments must be made with the cover open.

When the adjustments and calibration proceduresare complete, close and latch the cover.

To better understand the adjustments and overalloperation of the transmitter, refer to the Principle ofOperation section in this manual for transmitters.Refer also to the schematic diagram in figure 14.

Adjustments

Adjustment: ZeroThe pressure-setting dial is marked ZEROADJUSTMENT PRESSURE SETTING. Zero is in thecenter of the dial, and the pressure values increaseto the right and left of the center as shown in figure12. To set the zero, rotate the pointer around thepressure setting dial. Rotate the pointer clockwise toincrease or counterclockwise to decrease the outputdepending on transmitter action and desired setting.

For direct-acting transmitters, zero adjustmentdetermines the process pressure at which thetransmitter output signal will be at its lower rangelimit.

The dial (key 38) graduations are approximateindications of the transmitter zero setting. Whenmaking adjustments, do not rely solely on the dial


19

setting. Monitor the process pressure and outputpressure to be sure the desired settings are attained.

Adjustment: SpanThe span adjustment dial is graduated from 0 to 10.A setting of 10 on the dial represents a span settingof 100 percent of the process sensing elementrange. The transmitter achieves the highestaccuracy when the span is 100 percent.

The transmitter span adjustment shown in figure 12is the same as the controller proportional bandadjustment.

Calibration: TransmittersThe output of each transmitter is checked at thefactory before the unit is shipped. The transmitterprovides an output signal that is proportional to thepressure applied to the sensing element. The outputpressure has no direct effect on the processpressure.

The transmitter is calibrated at the factory andshould not need additional adjustment. Use thefollowing calibration procedures when the sensingelement has been changed or other maintenanceprocedures have altered the calibration of thetransmitter. The following procedures use a 0.1 to1.0 bar (3 to 15 psig) output pressure range as anexample. For other output pressure ranges [such as0.2 to 2.0 bar (6 to 30 psig)] adjust the values tomatch the application.

Provide a process pressure source capable ofsimulating the process pressure range of thetransmitter. If an output pressure gauge is notprovided, install a suitable pressure gauge forcalibration purposes(1). Connect a pressure sourceto the supply pressure regulator and be sure theregulator is delivering the correct supply pressure tothe transmitter.

Unless otherwise indicated, key number locationsare shown in figure 12.

1. Complete the above connections and provide aprocess pressure equal to the sensing elementrange.

2. Rotate the span adjustment knob to 10 on thedial (100 percent span).


Depending upon the transmitter action, perform oneor the other of the following procedures.

For direct-acting transmitters:

4. Rotate the zero adjustment knob to zero.

5. Set the input pressure to zero.

6. Adjust the nozzle (key 57) until the transmitteroutput pressure is at 0.1 bar (3 psig).


Note

Proper transmitter response dependson nozzle-to-flapper alignment.

When performing the span adjustmentin step 8, carefully loosen bothcalibration adjuster screws whileholding the calibration adjuster inplace. Then move the calibrationadjuster slightly in the requireddirection by hand or using ascrewdriver. Verify propernozzle-to-flapper alignment and holdthe calibration adjuster in place whiletightening both adjustment screws.

8. If the output pressure is not 15 psig, adjust thespan by loosening the two adjusting screws (key 43)and moving the calibration adjuster (key 41) a smalldistance as indicated in figure 13.


10. Proceed to the startup procedure fortransmitters.

For reverse-acting transmitters:

4. Rotate the zero adjustment knob to zero.

5. Apply an input pressure equal to the sensingelement upper range limit.

6. Adjust the nozzle (key 57) until the transmitteroutput pressure is at 0.1 bar (3 psig).

7. Set the input pressure equal to zero.

Note

Proper transmitter response dependson nozzle-to-flapper alignment.

When performing the span adjustmentin step 8, carefully loosen bothcalibration adjuster screws while

1. For stability, some transmitter applications will require additional volume than just thegauge. Provide a minimum volume of approximately 25 cm3 (1.5 in3) or greater if stabilityis a problem.


Form 5177March 2006

20

IF OUTPUT IS:

MOVE ADJUSTERLEFT

MOVE ADJUSTERRIGHT


ABOVE15 PSIG(1.0 BAR)

BELOW15 PSIG(1.0 BAR)

Figure 13. Transmitter Span Adjustment

holding the calibration adjuster inplace. Then move the calibrationadjuster slightly in the requireddirection by hand or using ascrewdriver. Verify propernozzle-to-flapper alignment and holdthe calibration adjuster in place whiletightening both adjustment screws.

8. If the output pressure is not 15 psig, adjust thespan by loosening the two adjusting screws (key 43)and moving the calibration adjuster (key 41) a smalldistance as indicated in figure 13.


10. Proceed to the startup procedure fortransmitters.

Startup: Transmitters1. Be sure that the supply pressure regulator isdelivering the proper supply pressure to thetransmitter.

2. Refer to the calibration procedures for thetransmitter initial settings.

3. If the transmitter is used in conjunction with acontrol valve, slowly open the upstream and

downstream manual shutoff valves, and close thebypass valves.

Principle of OperationThe following sections describe the operation of acontroller or transmitter using a Bourdon tubesensing element. The operation is the same for aninstrument using a bellows sensing element (key 71,figure 21) except that movement of the beam iscaused by expansion or contraction of the bellows ordifferential bellows.

Proportional-Only ControllersAs shown in figure 14, supply pressure enters therelay and bleeds through the fixed orifice beforeescaping through the nozzle. Nozzle pressure alsoregisters on the large relay diaphragm, and loadingpressure (controller output pressure) registers on thesmall relay diaphragm.

A change in the process pressure moves the beamand flapper with respect to the nozzle by eitherexpanding or contracting the Bourdon tube arc. Anincreasing process pressure with direct action (ordecreasing pressure with reverse action) produces anozzle-flapper restriction that increases the loadingon the large relay diaphragm and opens the relayvalve. Additional supply pressure flows through therelay chamber to increase the loading pressure onthe control valve actuator. A decreasing processpressure with direct action (or increasing pressurewith reverse action) produces a nozzle-flapperopening that bleeds off pressure on the large relaydiaphragm and opens the relay valve to exhaustcontroller output pressure from the actuator.

This controller output pressure change feeds back tothe proportional bellows, countering the pressurechange in the nozzle and equalizes the relaydiaphragm pressure differential. The relay valvemaintains a new loading pressure according to thechange in sensed pressure.

If the proportional valve is wide open, all of thecontroller output pressure change feeds back to theproportional bellows. The more the proportionalvalve is closed, the more the controller outputpressure change bleeds out through the proportionalvalve exhaust and the less there is to feed back tothe proportional bellows. A fully open proportionalvalve results in a proportional band of 100 percent;closing the proportional valve reduces theproportional band.


21

CONSTANT SUPPLY PRESSURE

EXHAUST

EXHAUST END OF RELAY VALVE

BOURDON TUBE

FIXEDPIVOT

BEAM ANDFLAPPER

NOZZLE

VENT

INLET END OFRELAY VALVESMALL DIAPHRAGM

LARGE DIAPHRAGM

FIXED ORIFICE

PROPORTIONAL BELLOWSPIVOTING CROSS SPRINGS

RESET BELLOWS

RESETVALVE

PROPORTIONAL VALVEPROPORTIONAL VALVE

EXHAUST

SENSEDPRESSURE

LOADINGPRESSURE

NOZZLEPRESSURE

PROPORTIONALPRESSURE

RESETPRESSURE

PROPORTIONAL-PLUS-RESET

CONTROLLERPROPORTIONAL-ONLY CONTROLLER

28A2970-A28A2971-AB1561-3 / IL

Figure 14. Schematic of Direct-Acting Proportional-Only and Proportional-Plus-Reset Controllers

Proportional-Plus-Reset ControllersAction of a proportional-plus-reset controller issimilar to that of a proportional-only controller exceptthat feedback from the controller output pressure ispiped to a reset bellows as well as to theproportional bellows as shown at the right in figure14.

With an increasing controller output pressure,pressure in the reset bellows increases. Increases inreset bellows pressure moves the beam and flappercloser to the nozzle, starting another increase ofpressure throughout the system. Pressure buildupcontinues until the controlled pressure is broughtback to the set point. The reset valve is adjustable tovary the amount of delay in the reset action. Closingthe reset valve increases the delay in reset action.

Controllers with Anti-Reset WindupDuring a prolonged difference between set point andthe controlled variable, such as encountered withintermittent control applications (e.g., batchtemperature control or wide open monitors onpressure control), reset ramps the controller outputto either zero or full supply pressure; this condition isreset windup. When the controlled variable crossesthe set point, there will be a delay before thecontroller output responds to the change in

controlled variable. Anti-reset windup minimizes thisdelay and permits returning the controlled variable toset point more quickly with minimal overshoot.

As shown in figure 15 a proportional-plus-resetcontroller with anti-reset windup includes adifferential relief valve. The valve consists of twopressure chambers separated by a spring-loadeddiaphragm.

For the controller shown in figure 15, proportionalpressure registers rapidly on the spring side of therelief valve diaphragm as well as in the proportionalbellows, and reset pressure registers on theopposite side of the relief valve diaphragm. As longas controlled pressure changes are slow enough fornormal proportional and reset action, the relief valvespring will keep the relief valve diaphragm fromopening. However, a large or rapid decrease incontroller pressure will cause the relay to exhaustloading pressure from the control device rapidly, andalso from the proportional system and spring side ofthe relief diaphragm. If this decrease on the springside of the diaphragm is greater than the relief valvespring setting, the diaphragm will move off the reliefvalve orifice and permit the proportional pressure onthe opposite side of the relief valve diaphragm tobleed rapidly into the reset bellows. The anti-resetwindup action also can be reversed to relieve withan increasing proportional pressure.


Form 5177March 2006

22

CONSTANT SUPPLYPRESSURE

TO FINALCONTROLELEMENT

EXHAUST

RESETBELLOWS

ADJUSTINGSCREW

ORIFICE RELIEF VALVEDIAPHRAGM

WITH ARROW DOWN-RELIEVES ONDECREASING OUTPUT(OUTPUT AT SUPPLY DURING SHUTDOWN)

SENSEDPRESSURE

PROPORTIONALBELLOWS

RESETVALVE

LOADINGPRESSURE

NOZZLEPRESSURE

PROPORTIONALPRESSURE

RESETPRESSURE

38B6006-CB1562-5 / IL

SENSEDPRESSURE

RELIEF VALVESPRING

PROPORTIONAL VALVE

Figure 15. Schematic of Reverse-Acting Proportional-Plus-Reset Controller with Anti-Reset Windup

Differential Gap ControllersWith a differential gap controller, feedback pressuredoes not counteract the change in flapper positionas it does in a proportional-only controller. Instead,feedback pressure is piped through the proportionalvalve to the bellows located on the side of the beamand flapper opposite the nozzle (the lower bellows infigure 14 for direct-acting controllers). Then, ascontroller output pressure increases, feedbackpressure moves the flapper closer to the nozzle toagain increase controller output pressure. Thisprocess continues rapidly until the controller outputpressure is at the upper range limit. The action of adifferential gap controller is so rapid that outputpressure changes from zero to maximum as soon asthe switching point is reached. The action is similarwith falling output pressure. Lower feedbackpressure lowers the bellows pressure, which movesthe flapper away from the nozzle. This againreduces the output pressure and continues until theoutput pressure is zero.

TransmittersAction of a pneumatic transmitter is similar to that ofa proportional-only controller. Since the outputpressure of the transmitter has no effect on theprocess pressure, transmitter output pressure is aproportional measure of the process pressure. Theproportional valve determines the span of thetransmitter, and the pressure setting mechanismdetermines the zero of the transmitter.

MaintenanceIf the installation includes a 67 Series filter regulator,periodically open the drain on the filter regulator todrain accumulated moisture. Also, push the cleanerwire on the relay orifice (key 88, not shown). Checkthe opening of the vent assembly (key 15, figure 3)or the opening of the remote vent pipe, if one isused. If necessary, clean the openings.

Parts are subject to normal wear and must beinspected and replaced as necessary. Thefrequency of inspection and parts replacementdepends upon the severity of the service conditions.

WARNING

The following maintenance proceduresrequire taking the controller out ofservice. To avoid personal injury andproperty damage caused by therelease of pressure or process fluid,observe the following before startingmaintenance:

� Always wear protective clothing,gloves, and eyewear.

� Provide some temporary meansof control for the process beforetaking the controller out of service.

� Provide a means of containing theprocess fluid before removing anymeasurement devices from theprocess.


23

� Use lock-out procedures to besure that the above measures stay ineffect while you work on theequipment.

� Personal injury or propertydamage may result from fire orexplosion if natural gas is used as thesupply medium and preventativemeasures are not taken. Preventativemeasures may include: Remoteventing of the unit, re-evaluating thehazardous area classification,ensuring adequate ventilation, and theremoval of any nearby ignitionsources. For information on remoteventing of this controller/transmitter,refer to page 9.

� Check with your process or safetyengineer for any additional measuresthat must be taken to protect againstprocess media.

Replacing Gauges

WARNING

Refer to the WARNING at thebeginning of the Maintenance Section.

Refer to figures 18 and 19 for key number locationsunless otherwise directed.

Three gauge configurations are available for 4150Kand 4160K units.

� Output and supply pressure indications

� Output and process pressure indications

� Output, process, and supply pressureindications

One gauge type (key 13) is used for both output andsupply pressure indications when the gauges areinstalled inside the controller case. Key 13 features a1/8-inch connecting stem that matches the threadedgauge boss extending from the relay base.

In some cases, a process pressure gauge (key 106)covers the position of the internal supply pressuregauge. The supply pressure gauge has beenremoved and replaced with a pipe plug (key 108).

The pressure control block (key 8) is different toaccommodate a different control tubing assembly(key 132) with a pressure connection (key 107) for aprocess pressure gauge. If a supply pressure gaugeis required, a gauge with a 1/4-inch connecting stem(key 14) must be mounted on the supply pressureregulator.

CAUTION

Before performing this procedure, besure the replacement gauges are thecorrect range so they are not damagedby overpressure.

Note

Key 13 is used as both a supply gaugeand an output gauge on units withouta process pressure gauge. A quantityof 2 is required for these units. Onunits with a process pressure gauge(key 106), key 13 is used for the outputgauge. A quantity of 1 is required forthese units.

Use key 14 for supply pressureindication when a process pressuregauge is installed. Key 14 installs onthe supply pressure regulator.

1. Shut off the supply pressure and process lines tothe controller or transmitter.

2. Remove the gauge to be replaced:

� Unscrew the output or supply gauge (key 13)from the relay base.

� Unscrew the process pressure gauge (key 106)from the process connection (key 107).

� Unscrew the supply gauge (key 14) from thesupply pressure regulator.

3. Coat the threads of the replacement gauge with asealant.

4. Screw the replacement gauge into the relay base,process connection, or supply pressure regulator.

5. Check for leaks by applying the correct supplypressure with the nozzle capped to produce fulloutput pressure.


Form 5177March 2006

24

Replacing Bourdon Tube

WARNING


Refer to figure 20 for key number locations unlessotherwise directed.


2. Unscrew the machine screw (key 63) todisconnect the link (key 64) and bearing (key 65)from the beam (key 44). Be careful to avoid losingthe bearing (key 65). Washer(s) (key 370) for themachine screw (key 63) are at times furnished forinsertion at the beam (key 44) connection to ensurealignment of the connecting link (key 64).

3. Disconnect the control tubing (key 132). Unscrewtwo screws (key 77) and washers (key 76), andremove the Bourdon tube (key 62).

4. Unscrew the machine screw (key 63), andremove the link and bearing (keys 64 and 65) fromthe Bourdon tube. Be careful to avoid losing thebearing (key 65).

5. Attach the link and bearing to the replacementBourdon tube.

6. Attach the Bourdon tube with two machinescrews and washers (keys 77 and 76).

7. Connect the link and bearing to the beam(key 44).

8. After connecting the link to the beam, make surethe nozzle is centered in the slot in the beam. If not,carefully loosen the machine screw (key 63) enoughso that you can slip a washer (key 370) between thebearing (key 65) and beam (key 44). Retighten themachine screw and check the nozzle and beamalignment.

9. Check to be sure that the beam is parallel withthe bottom of the case and that the link (key 64) is intension. If the beam is not parallel with the case,loosen the machine screws (key 77), reposition theBourdon tube to get the beam parallel, and retightenthe screws.

10. If a Bourdon tube with a different range wasinstalled, remove the machine screw and washer(keys 40 and 39) and dial (key 38). Install a new dialhaving an adjustment range corresponding to therange of the Bourdon tube. If an optional processpressure gauge (key 106, figure 18) is being used,

install a new gauge with the appropriatemeasurement capability.

11. Check all tubing connections for leaks and theBourdon tube machine screws, tighten asnecessary. Perform the appropriate calibrationprocedures.

Replacing Bellows Sensing Element

WARNING


Refer to figure 21 for key number locations unlessotherwise directed.


2. Disconnect the tubing from the mounting base(key 30) and calibration adjuster (key 41).Disconnect the tubing that connects the pressureblock (key 8, figure 18) to the bellows assembly (key 71), at the pressure block end.

3. Unscrew the four machine screws (key 28, figure 18 or 19), and remove the pressure sensingsubassembly from the case.

4. Remove the bellows yoke machine screws andwashers (keys 75 and 76), and move the bellowsyoke to the right to permit access to the link screw.

5. Disconnect the link (key 71M) and bearing (key 71L) from the beam. Be careful to avoid losingthe bearing.

6. Loosen the nuts that secure the bellowsassembly (key 71), and remove this assembly fromthe bellows yoke (key 70).

7. For a gauge-pressure sensing element (only onebellows in the assembly), install the proper bellowsspring (key 80) into the bellows assembly if the inputsignal range is being changed. See the parts list forthe correct part number.

8. Install the new bellows assembly into the bellowsyoke.

9. Attach the link and bearing to the bellowsassembly. Position the bellows yoke (key 70) on themounting base (key 30), and attach the link andbearing to the beam. Start but do not tighten the fourmachine screws (key 75) with washers (key 76) thatattach the yoke to the mounting base. Slide the yokeup or down as necessary to position the beamhorizontally, as shown in figure 21. Tighten themachine screws.


25

PROPORTIONALTUBING (KEY 104)

RELAY TUBING (KEY 103)

REVERSINGBLOCK (KEY 59)

DIRECTACTING POSITION

BEAM (KEY 44)BELLOWS(KEY 52)

REVERSEACTING POSITION


PROPORTIONAL TUBING(KEY 104)

REVERSEPOSITION

RESET VALVE

RELAY TUBING(KEY 103)



BEAM (KEY 44)

PROPORTIONALTUBING(KEY 104)

RESET TUBING(KEY 117)

REVERSE ACTINGPOSITION


PROPORTIONALTUBING

RESETTUBING

NOTES:P = PROPORTIONAL BELLOWSR = RESET BELLOWSX = NO PRESSURE

DIRECT ACTING REVERSE ACTING


PROPORTIONAL-ONLY CONTROLLER OR TRANSMITTER

PROPORTIONAL-PLUS-RESET CONTROLLERB1564-5 / IL10C2008-B

FLAPPER/SCREW(KEY 45)

FLAPPER/SCREW(KEY45)

FLAPPER/SCREW(KEY 45) FLAPPER/SCREW

(KEY 45)

Figure 16. Direct/Reverse Acting Tubing Connections

10. Replace the subassembly in the case andsecure with the four machine screws (key 28,figure 18 or 19). Reconnect all tubing.

11. If a bellows assembly with a different range isinstalled, remove the machine screws and washer(keys 40 and 39) and dial (key 38), and install a newdial having an adjustment range corresponding tothe range of the bellows. If an optional processpressure gauge (key 106, figure 18) is being used,install a new gauge with the appropriatemeasurement capability.

12. Check all tubing connections for leaks and thebellows yoke machine screws, tighten as necessary.Perform the appropriate calibration procedures.

Changing Proportional or Reset Valve

WARNING


1. Disconnect the appropriate tubing and removethe proportional band valve assembly (figure 18or 19) or the reset restriction valve assembly(figure 19) by unscrewing it from the relay base(key 4, figure 18 or 19). Install the desiredreplacement assembly.

2. Connect the tubing, check all connections forleaks and perform the appropriate calibrationprocedures.


Form 5177March 2006

26

PROPORTIONALTUBING (KEY 104)

REVERSE ACTINGPOSITION


REVERSEPOSITION


NOTES:P = PROPORTIONAL BELLOWSX = NO PRESSURE

DIFFERENTIAL GAP CONTROLLERB2671 / IL10C2008-B

FLAPPER/SCREW(KEY45)

RELAY TUBING (KEY 103)



BEAM (KEY 44)

FLAPPER/SCREW(KEY 45)

Figure 16. Direct/Reverse Acting Tubing Connections (Continued)

Changing Anti-Reset WindupDifferential Relief Valve (4160KF)

WARNING


Refer to figure 19 for key number locations.

1. Note the controller output pressure (zero orsupply) when the process is shut down.

2. Remove the differential relief valve assembly.

3. Refer to figure 19. Install the replacement reliefvalve with the arrow positioned so that the controlleroutput will be as noted in step 1 when the process isshut down.

Changing Action

WARNING


Proportional-Only to a Differential GapControllerA proportional-only controller may be changed to adifferential gap controller, or vice versa, by changingthe position of the proportional tubing (key 104,figure 16). Refer to figure 16 for key numberlocations.

1. Isolate the controller from process, control, andsupply pressure. Vent any trapped pressure from thecontroller before proceeding with the following steps.

2. Disconnect the proportional tubing (key 104) fromthe mounting base (key 30, figure 20 or 21) andreinstall it in the other connection in the mountingbase.

3. Do not invert the reversing block unless alsochanging the controller action.

4. Check all connections for leaks with asoap-and-water solution. Perform the appropriatecalibration procedure.

Direct to Reverse ActionUse the numbered steps below to change fromdirect action (increasing pressure producesincreasing output pressure) to reverse action(increasing pressure produces decreasing outputpressure), or vice versa. Changing the action isaccomplished by reversing the positions of thereversing block and bellows tubing(s). Refer to figure16 for key number locations unless otherwisedirected.

1. Isolate the controller or transmitter from process,control, and supply pressure. Vent any trappedpressure from the controller or transmitter beforeproceeding with the following steps.

2. Locate the new tubing and reversing blockpositions for the action desired.

3. Locate the two bellows and the reversing block(key 59, figure 16).

4. Disconnect the tubing:

a. For a proportional-only controller or for atransmitter, disconnect the proportional tubing


27

(key 104) from the mounting base (key 30, figure20 or 21) and reconnect it in the opposite hole.

b. For a proportional-plus-reset controller,disconnect the proportional tubing (key 104) andreset tubing (key 117) from the mounting base(key 30, figure 20 or 21), and reconnect them inthe opposite hole.

5. Change the reversing block assembly (key 59):

a. Remove the sealing screw (key 56, figure 20or 21). Inspect the O-ring (key 55, figure 20 or 21)located in the recessed area under the sealingscrew head. Replace the O-ring if necessary.

b. Remove the reversing block screw (key 61,figure 20 or 21) and reversing block assembly(key 59). Inspect the O-rings (key 55) located inthe recessed area under the reversing blockscrew head and between the reversing blockassembly and the calibration adjuster (key 41,figure 20 or 21). Replace these O-rings, ifnecessary.

c. Position the reversing block assembly, withO-ring, on the calibration adjuster (key 41) so thatthe nozzle is on the opposite side of the beam(key 44, figure 20 or 21) from which it wasremoved. Properly position the reversing blockassembly so that the alignment pin engages thehole in the calibration adjuster. Install thereversing block screw (key 61) with O-ring (key 55).

d. Install the sealing screw (key 56) with O-ringin the hole previously covered by the reversingblock assembly.

6. Check all connections for leaks with asoap-and-water solution. Perform the appropriatecalibration procedures.

Relay Replacement

WARNING


Key numbers used in this procedure are shown infigure 18 or 19 except where indicated.

1. Shut off the supply pressure and processpressure line(s) to the controller or transmitter.

2. Disconnect the tubing (key 103) from the relay.

3. Unscrew the output or supply pressure gauge(key 13).

4. To remove the relay assembly, unscrew twoPhillips-head machine screws (key 81, not shown)located behind the relay on the back of the case.

5. Remove the relay gasket (key 7, figure 18).

6. A new relay can be installed as a replacement. Ifa new relay is being installed, continue with the nextstep.

7. Attach the replacement relay and new relaygasket with machine screws inserted through theback of the case. Reinstall the output or supplygauge.

8. Connect the tubing, and check all connections forleaks. Perform the appropriate calibrationprocedures.

Changing Output Signal Range

WARNING

Refer to the WARNING at thebeginning of the Maintenance Section..

Use the following information and subsequentprocedures when changing the output signal rangeof the controller or transmitter. Use the followingprocedure:

� For a controller or transmitter, use thisprocedure to change from a 0.2 to 1.0 bar (3 to 15psig) to a 0.4 to 2.0 bar (6 to 30 psig) output signalrange or vice versa.

� For a differential gap controller, use thisprocedure to change from a 0 and 1.0 bar (0 and 20psig) to a 0 and 2.4 bar (0 and 35 psig) output signalrange or vice versa.

� When changing the supply pressure source toa new range, refer to table 5 for supply pressurerequirements for the output signal range selected.


Form 5177March 2006

28

0-RING(KEY 55)

A6281-1 / IL

Figure 17. Bellows Screw Detail

Also, make appropriate changes to the nameplate ofthe controller or transmitter, reflecting the new rangeselections. Refer to figure 20 or 21 for key numberlocations unless otherwise directed.


2. Disconnect the tubing from the mounting base(key 30) and calibration adjuster (key 41).Disconnect the tubing that connects the pressureblock (key 8, figure 18 or 19) to the Bourdon tube orbellows assembly (key 62 or 71), at the pressureblock end.

3. Unscrew the machine screws (key 28, figure 18or 19), and remove the subassembly from the case.

4. If the controller or transmitter uses a Bourdontube sensing element, disconnect the Bourdon tubefrom the beam (key 44) by removing the screw(key 63). Be careful to avoid losing the bearing (key 65). Unscrew the machine screws (key 77), andremove the washers and Bourdon tube (keys 76 and 62).

5. Unscrew the bellows screws (key 54) from eachend of the mounting base (key 30). [Note: Thebellows screws (key 54) have an O-ring (key 55,figure 17) installed beneath the bellows screw head.Remove the O-ring and obtain a replacement whenre-assembling the bellows.]

6. Compress the bellows so that the end of thebellows and beam can be removed from the end ofthe mounting base (key 30) and unscrewed from thestud (key 51, not shown) that connects the bellows.

7. With the stud that connects the two bellows inplace in the spacer (key 50), screw the new bellowsonto the stud. Install new gaskets (key 53) on eachbellows.

Note

The bellows screw (key 54) has anO-ring (key 55) installed beneath thebellows screw head as shown in figure17. Be sure this O-ring is in placebefore installing the screw into themounting base.

8. Compress the bellows, and install them into themounting base (key 30). With the beam parallel withthe mounting base, secure the bellows with thebellows screws (key 54).

9. After tightening the bellows screws, make surethat the nozzle (key 57) is centered on the flapper(key 45).

10. Replace the subassembly in the case andsecure with the machine screws (key 28, figure 18 or 19). Install the Bourdon tube if it was removed;refer to the Replacing Bourdon Tube section ifneeded. Reconnect all tubing.

11. Unscrew the supply and output gauges (key 13,figure 18 or 19) and install new gauges with correctranges.

12. Check all tubing connections and the bellowsmachine screws for leaks, tighten as necessary.Perform the appropriate calibration procedures.

Parts OrderingWhenever corresponding with your EmersonProcess Management sales office about thisequipment, mention the serial number of the unit.The serial number can be found on the nameplate(key 22, figure 18). When ordering replacementparts, also state the complete 11-character partnumber of each part required as found in thefollowing parts list.

Note

Use only genuine Fisher replacementparts. Components that are notsupplied by Emerson ProcessManagement should not, under anycircumstances, be used in any Fisherinstrument. Use of components notsupplied by Emerson ProcessManagement will void your warranty,might adversely affect theperformance of the instrument, andmight jeopardize worker andworkplace safety.


29

Note

Neither Emerson, Emerson ProcessManagement, Fisher, nor any of theiraffiliated entities assumesresponsibility for the selection, use,and maintenance of any product.Responsibility for the selection, use,and maintenance of any productremains with the purchaser andend-user.

Parts KitsKey Description Part Number

Controller Repair KitsKit contains keys 5, 9, 10, 21, 24, 45, 46, 53,55, 56, 57, 58, 59, 60, 61, 63, 64, and 65Standard Temperature R4150X00L12High Temperature R4150X00H22

Relay Replacement KitsKit contains key 7 and 43 and the replacement relay

Standard Temperature RRELAYX0L22High Temperature RRELAYX0H22

Case Assembly Seal KitKit contains 3 Manifold Seals, 1 Manifold Seal Cover, and 10 Mounting Screws R4150KX0012

Parts ListKey Description Part Number

Assemblies (Figures 18 and 19)Case & Cover Std. Ass’y GE09600X012Case & Cover Ass’y w/ Anti-Reset, −40 to 71�C (−40 to 160�F) GE09601X012

Case & Cover Std. Ass’y,2 Psig Pressure tested GE09600X022

Case & Cover Std. Ass’y,2 Psig Pressure tested, w/ Anti-Reset,−40 to 71�C (−40 to 160�F) GE09601X032

Proportional Band Valve or Span Adjustment AssemblyStd and High Temperature, aluminum 10A9122X032Stainless steel construction 10A9122X082

Reset Restriction Valve AssemblyStandard TemperatureFor all except Type 4160KF and 62KF 19A4361X012

Reset Restriction Valve AssemblyStandard TemperatureFor Type 4160KF and 62KF 19A4363X012

Relay AssemblyStandard Temperature 22B0463X012High Temp, Type 4150K, 50KS, 52K, 52KS,57K, 60K, 62K, and 64K 22B0462X012

w/sst instrument constructionStandard Temp 22B0463X032High Temp, Type 4150K, 50KS, 57K, 60K 22B0462X022w/process pressure gauge 1J251035072

For differential pressure instruments, sst 1H673035072

Common Parts (Figures 18, 19, 20,and 21)Key Description Part Number

1 Case and Cover Assembly, aluminum

Note

Refer to Assemblies for Case and CoverAssembly part numbers.

7* Relay Gasket, for all seriesStd Temp, chloroprene 1C897403012High Temp, silicone 1N873804142

8 Control Pressure BlockFor gauge pressure instruments, sstw/o process pressure gauge 16A0979X012

9* O-Ring, nitrile, for all series 1C37620699210* Gasket, chloroprene, for all series (not shown) 1C32860301211* Sealing Washer (not shown) Use w/0.14 bar (2 psi)

pressure-tested case and cover (2 req’d) 1J186999012

Note

Key 13 is used as both a supply gauge andan output gauge on units without a processpressure gauge. A quantity of 2 is requiredfor these units. On units with a processpressure gauge (key 106), key 13 is used forthe output gauge. A quantity of 1 is requiredfor these units.

Use key 14 for supply pressure indicationwhen a process pressure gauge is installed.Key 14 installs on the supply pressureregulator.

13* Supply and Output Pressure Gauge, w/o processpressure gauge (1/8-inch connecting stem),ABS plastic, black enamel/polycarbonate/nitrile (2 req’d)Dual scale0-2.0 kg/cm20 and 0-30 psig 11B8577X0420-4.0 kg/cm20 and 0-60 psig 11B8577X052

Triple scale0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8577X0120-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8577X022

13* Output Pressure Gauge, w/process pressuregauge (1/8-inch connecting stem) (1 req’d)Triple scale0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8577X0120-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8577X022

14* Supply Pressure Gauge, w/process pressuregauge (1/4-inch connecting stem), ABS plastic, blackenamel/polycarbonate/nitrileTriple scale0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8579X0220-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8579X032

15 Vent Ass’y 27A5516X01222 Plate, Instruction, aluminum 12B6338X0A228 Machine Screw, steel pl (4 req’d) 1E98542898230 Mounting Base, aluminum 26A7668X01231 Flexure Strip, sst 1C897836012

*Recommended spare parts


Form 5177March 2006

30

RELAY ASSEMBLY SPAN ADJUSTMENTASSEMBLY

SUBASSEMBLY(KEY NOS. SHOWNIN FIGURE 20 OR 21)

NOTE:KEYS 10, 81, 105 AND 108ARE NOT SHOWN

TRANSMITTER

OPTIONAL PROCESS PRESSURE INDICATION

48B6004-B / DOC

48B6005-A

B2651-1 / IL

Figure 18. Typical Direct-Acting 4150K Series Assembly(Refer to figure 22 for the Front View of the Case & Cover Assembly)

Key Description Part Number32 Flexure Strip Washer, steel pl (2 req’d) 16A7671X01233 Machine Screw, steel pl (4 req’d) 14B4995X01234 Pressure Set Arm, steel pl 36A7669X01235 Rotary Spring, sst 1J42343702236 Knob, PPS 36A7670X01237 Knob Spring, steel pl 1C22152702238 Dial, aluminum

For Bourdon tube controllers0-30 psig 16A7662X0120-60 psig 16A7662X0220-100 psig 16A7662X0320-150 psig 16A7662X4120-200 psig 16A7662X0420-300 psig 16A7662X0520-600 psig 16A7662X0620-1000 psig 16A7662X0720-1500 psig 16A7662X0820-3000 psig 16A7662X0920-5000 psig 16A7662X1020-8000 psig 16A7662X1120-10,000 psig 16A7662X1220-200 kPa 16A7662X1420-400 kPa 16A7662X1520-700 kPa 16A7662X1620-1400 kPa 16A7662X1720-2000 kPa 16A7662X1820-4000 kPa 16A7662X1920-7000 kPa 16A7662X2020-10,000 kPa 16A7662X2120-20,000 kPa 16A7662X222

Key Description Part Number

38 Dial, aluminumFor Bourdon tube controllers (continued)0-35,000 kPa 16A7662X2320-55,000 kPa 16A7662X2420-70,000 kPa 16A7662X2520-100% 16A7662X2720-2 bar 16A7662X4820-4 bar 16A7662X4420-7 bar 16A7662X4720-14 bar 16A7662X4620-20 bar 16A7662X4920-40 bar 16A7662X4520-70 bar 16A7662X5020-100 bar 16A7662X5120-200 bar 16A7662X5220-350 bar 16A7662X5320-550 bar 16A7662X5420-700 bar 16A7662X552

For bellows sensing element controllersGauge pressure0-60 inches wc 16A7662X2820-140 inches wc 16A7662X2920-5 psig 16A7662X3020-10 psig 16A7662X3120-15 psig 16A7662X3220-20 psig 16A7662X3320-30 psig 16A7662X0120-200 kPa 16A7662X1420-10 inches Hg vacuum 16A7662X342


31

PROPORTIONAL-ONLY CONTROLLER

NOTE:KEYS: 10, 81, 105 NOT SHOWN

48B6003-AB2652 / IL

PILOT RELAY

PROPORTIONALBANDADJUSTMENT

SUBASSEMBLY (KEY NOS.SHOWN IN FIGURE 19 OR 20)

222 PSIG LABEL (USEDWITH 2 PSIG CASE &COVER ASSEMBLY

CHANGE ACTION LABEL

Figure 18.Typical Direct-Acting 4150K Series Assembly (continued)


38 Dial, aluminumFor bellows sensing element controllersGauge pressure (continued)0-30 inches Hg vacuum 16A7662X35230-0-30 inches wc compound 16A7662X36215 in. Hg vacuum-0-7.5 psig compound 16A7662X37230 in. Hg vacuum-0-15 psig compound 16A7662X3820-60 inches wc vacuum 16A7662X392

Differential pressure0-80 inches wc 16A7662X4020-10 psig 16A7662X3120-20 psig 16A7662X3320-30 psig 16A7662X0120-200 kPa 16A7662X1420-2 bar 16A7662X482

For all Type 4155K, 57K, and 58K transmitters 16A7664X01239 Washer, steel pl 1R98202507240 Machine Screw, steel pl 1E17582898241 Calibration Adjuster, steel pl 2H26624401242 Washer, steel (2 req’d) 1E87302899243 Machine Screw, steel pl (2 req’d) 1A5733X001244 Beam, steel 1H26682507245 Flapper, K93602 nickel alloy 1H26694113246 Machine Screw, steel pl 1B27512899247 Cross Spring, sst (2 req’d) 1H26603703248 Washer, steel pl (4 req’d) 1H26712898249 Machine Screw, steel pl (4 req’d) 1A34612898250 Spacer, zinc 1H26594401251 Bellows Stud, brass (not shown) 1H265814012

Key Description Part Number52* Feedback Bellows Ass’y

Brass0.2-1.0 bar (3-15 psig) (2 req’d) 14A5726X0120.4-2.0 bar (6-30 psig) (2 req’d) 14A5726X032

Stainless steel0.2-1.0 bar (3-15 psig) (2 req’d) 14A5726X0220.4-2.0 bar (6-30 psig) (2 req’d) 14A5726X042

53* GasketStd Temp, chloroprene (2 req’d) 1D397003012High Temp, silicone (2 req’d) 1N873604142

54 Bellows Screw (2 req’d)Brass 22B8036X012Stainless steel 22B8036X022

Note

A total of 5 O-rings (key 55) are used. 1O-ring is used under the sealing screw (key56), 1 O-ring is used under the reversingblockscrew (key 61), 1 O-ring is usedbetween the reversing block ass’y (key 59)and the calibration adjuster (key 41), and 1O-ring is used in the recessed area under thehead of each of the bellows screws (key 54).

55* O-Ring,Std Temp, nitrile (5 req’d) 1D687506992High Temp, fluoroelastomer (5 req’d) 1N430406382

56 Sealing Screw, sst 14A5721X01257* Nozzle, sst 1U639135132



Form 5177March 2006

32

NOTE:KEYS: 10, 81, 105, 115 NOT SHOWN

48B6002-AB2653-1 / IL

PILOT RELAY

PROPORTIONALBANDADJUSTMENT

SUBASSEMBLY (KEY NOS.SHOWN IN FIGURE 20 OR 21)

PROPORTIONAL-PLUS-RESET CONTROLLER

WITHOUT ANTI-RESET WINDUP

RESET RESTRICTIONVALVE ASSEMBLY

222 PSIG LABEL (USEDWITH 2 PSIG CASE &COVER ASSEMBLY

CHANGE ACTION LABEL

Figure 19. Typical Direct-Acting 4160K Series Assembly(Refer to figure 22 for the Front View of the Case & Cover Assembly)


58* Nozzle O-Ring,Std Temp, nitrile 1E222606992High Temp, fluoroelastomer 1N838706382

59 Reversing Block, steel pl 26A0975X01260 Sleeve, POM 16A0976X01261 Reversing Block Screw, sst 24A5720X01262* Bourdon Tube See table 763 Machine Screw, steel pl

Bourdon tube instruments only (2 req’d) 1A33192898264* Connecting Link, Bourdon tube instruments only

Std., N04400 1L379641012Bourdon tube w/optional travel stop,Stainless steel 1L611235022

65* Link bushing, sstBourdon tube instruments only (2 req’d) 1L379546202

66 Travel Stop Assembly, steeloptional w/Bourdon tube 1H7793000A2

67 Lockwasher, steel pl (2 req’d)Use w/optional Bourdon tube travel stop 1H267228982

68 Machine Screw, steel pl (2 req’d)Use w/optional Bourdon tube travel stop 1H267628982

69 Cap Screw, steel plUse w/optional Bourdon tube travel stop 1H779232982

70 Bellows Yoke, zincUse w/gauge and differential pressure bellows 2H453844012


71* Gauge Pressure Bellows (input)(1)

Brass0-150 mbar (0-60 inches wc) positive, 0-150 mbar(6-60 inches wc) vacuum, and 75-0-75 mbar(30-0-30 inches wc) compound 1L3780000A2

0-250 mbar (0-100 inches wc) positive,Type 4158K only 1L3788000A2

0-0.35 mbar (0-5 psig) positive and for0-350 mbar (0-10 inches Hg) vacuum 1L3781000A2

0-0.5 bar (0-7.5 psig) positive, 4158K only 1L3789000A20-0.7 bar (0-10 psig) positive 1L3782000A20-1.0 bar (0-15 psig) positive, 0-1.0 bar(0-30 inches Hg) vacuum, and 500-0-500 mbar(15-0-7.5 psig) compound 1L3783000A2

0-1.4 bar (0-20 psig) positive 1L3784000A20-2.0 bar (0-30 psig) positive and 1.0-0-1.0 bar(30-0-15 psig) compound 1L3785000A2

Stainless steel,0-1.0 bar (0-15 psig) positive, 0-1.0 bar(0-30 inches Hg) vacuum, and 500-0-500 mbar(15-0-7.5 psig) compound 1L3786000A2

0-2.0 bar (0-30 psig) positive, 1.0-0-1.0 bar(30-0-15 psig) compound 1L3787000A2

*Recommended spare parts1. If ordering the bellows (key 71) to change the range of a gauge pressurecontroller, also order the appropriate bellows spring (key 80). Also order keys 72,73, and 74, if you do not have them.


33

48B6001-B / DOC

NOTES:ARROW DOWN—RELIEVES ON DECREASING OUTPUT (OUTPUT @ SUPPLY DURING SHUTDOWN)ARROW UP—RELIEVES ON INCREASING OUTPUT (OUTPUT @ ZERO DURING SHUTDOWN)

KEYS 367, 368, AND 369 NOT SHOWN

PROPORTIONAL-PLUS-RESET CONTROLLER

WITH DIFFERENTIAL RELIEF VALVE ASSEMBLY FOR

ANTI-RESET WINDUP

1

1

2

2

Figure 19. Typical Direct-Acting 4160K Series Assembly (continued)


71* Differential-Pressure Bellows (input)Brass0-200 mbar (0-80 inches wc) 2L3790000A20-0.7 bar (0-10 psi) 2L3791000A20-1.4 bar (0-20 psi) 2L3792000A2

Stainless steel,0-2.0 bar (0-30 psi) 2L3793000A2

71K Machine Screw, steel pl(2)

bellows sensing instruments only (2 req’d) 1A33192898271L* Bearing(2)

bellows sensing instruments only (2 req’d) 1L37954620271M* Link(2) bellows sensing instruments only 1L37964101272 Jam Nut, steel pl

Gauge pressure bellows instruments only 1A94632412273 Washer, steel pl

Gauge pressure bellows instruments only 1B86592898274 Spring Seat, pl brass

Gauge pressure bellows instruments only 1H45321402275 Machine Screw, steel pl

Gauge and differential pressurebellows instruments (4 req’d) 1H267628982


76 Washer, steel plfor Bourdon tube instruments (2 req’d) 1H267228982for bellows sensing instruments (4 req’d) 1H267228982

77 Machine Screw, steel plBourdon tube instruments only (2 req’d) 1H267728982

79 Screw, nylon Transmitters only 1A3461X004280 Spring, gauge pressure bellows instruments only

Steel pl0-150 mbar (0-60 inches wc) positive,0-150 mbar (0-60 inches wc) vacuum,75-0-75 mbar, and(30-0-30 inches wc) compound 1J729227022

0-250 mbar (0-100 inches wc) positive,0-0.35 bar (0-5 psig) positive, and0-350 mbar (0-10 inches Hg) vacuum 1H448227022

0-0.5 bar (0-7.5 psig) positive 1K5257270220-0.7 bar (0-10 psig) positive 1K4934270220-1.0 bar (0-15 psig) positive,0-1.0 bar (0-30 inches Hg) vacuum,500-0-500 mbar (15-0-7.5 psig) compound 1H448327022

0-1.4 bar (0-20 psig) positive 1K525927022

*Recommended spare parts2. This part is part of the bellows assembly, key 71


Form 5177March 2006

34

BOURDON TUBE TRAVEL

STOP SUBASSEMBLY

SHOWNWITHCONTROLLERDIAL,KEY 38

NOTES:KEY 51, BELLOWS STUD NOT SHOWN: KEY 52 IS FEEDBACK BELLOWS1. THERE IS AN O-RING (KEY 55) BETWEEN THE REVERSING BLOCK(KEY 59) AND THE CALIBRATION ADJUSTER (KEY 41).2. THERE MAY BE AN O-RING (KEY 55) UNDER THE BELLOWS SCREW(KEY 54). SEE NOTE PRECEDING KEY 54 IN THE PARTS LIST.

A

A

B

B

A

A

C

C SECTION A-A

SECTION B-B

VIEW A-A

SECTION C-C

26A7677-B / DOC

26A7689-A / DOC

26A7681-A /DOC

Figure 20. Controller Subassembly with Bourdon Tube Sensing Element


80 Spring, gauge pressure bellows instruments only (continued)0-2.0 bar (0-30 psig) positive,1.0-0-1.0 bar (30-0-15 psig) compound 1H448427022

316 SST0-1.0 bar (0-15 psig) positive,0-1.0 bar (0-30 inches Hg) vacuum,500-0-500 mbar (15-0-7.5 psig) compound 1H641137012

0-2.0 bar (0-30 psig) positive,1.0-0-1.0 bar (30-0-15 psig) compound 1H641237012

81 Machine Screw, steel pl (not shown) (2 req’d) 1H52712898282 Machine Screw, steel pl (4 req’d) 1C333328982

101 Lockwasher, steel pl (4 req’d) 1C225628982103 Relay Tubing Assembly, sst 1H6861000A2104 Compensator Tubing Assembly, sst

Types 4150K, 50KS, 52K, 52KS,54K, 55K, 57K, and 58K 1H6864000A2

Types 4160K, 60KF, 62K, 62KF and 64K 1H6870000A2105 Plug, S31600 (316 SST), (not shown)

used with gauge pressure only 1A767535072


Note

Controllers with bellows sensing elementuse only the 2.0 bar, 0 to 0.2 MPa, and 0 to 0to 30 psig triple scale brass and stainlesssteel process pressure gauges. Differentialpressure controllers do not use a processpressure gauge.

106* Process Pressure Gauge (use only when specified)Triple scaleABS plastic/Brass0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8578X0120-4.0 bar, 0-0.4 MPa, and 0-60 psig 11B8578X0220-11 bar, 0-1.1 MPa, and 0-160 psig 11B8578X0320-20 bar, 0-2.0 MPa, and 0-300 psig 11B8578X0420-40 bar, 0-4.0 MPa, and 0-600 psig 11B8578X0520-69 bar, 0-6.9 MPa, and 0-1000 psig 11B8578X062

ABS plastic/Stainless steel0-2.0 bar, 0-0.2 MPa, and 0-30 psig 11B8584X0220-20 bar, 0-2.0 MPa, and 0-300 psig 11B8584X0120-69 bar, 0-6.9 MPa, and 0-1000 psig 11B8584X032



35

SECTION C-C

26A7681-A /DOC

SHOWN WITHTRANSMITTERDIAL & SCREW,KEY 38 & 79

SCREW(KEY 71K)

LINK (KEY 71M)

SCREW(KEY 71K)

BEARING(KEY 71L)

LINK (KEY 71M)

BEARING(KEY 71L)

SECTION A-A

A

A

SIDE VIEW OF SUBASSEMBLY

WITH GAUGE-PRESSURE

BELLOWS SENSING ELEMENT

SIDE VIEW OF SUBASSEMBLY

WITH DIFFERENTIAL PRESSURE

BELLOWS SENSING ELEMENT

NOTES:KEYS 46 AND 51 NOT SHOWN: KEY 52 IS FEEDBACK BELLOWS

KEYS 71K, 71L, & 71M ARE PART OF THEBELLOWS ASSEMBLY (KEY 71)

1

1 1

1

1

1

1

C

C

26A7683-B / DOC26A7675-B / DOC

Figure 21. Controller Subassembly with Either Gauge-Pressure Bellows or Differential-Pressure Bellows Sensing Element


107 Pressure Connection, sstUse w/process gauge 1J251235162

108 Pipe Plug, steel pl (not shown)Use w/process gauge,not used w/Bourdon tube protector 1E823128982

115 Mounting Screw for reset restriction valveType 4160K, 60KF, 62K, 62KF, and 64K1/4-20 UNC, steel pl (not shown) 1H527028982

116 Reset Tubing Ass’y, sstType 4160K, 60KF, 62K, 62KF, and 64K 1H6866000A2

117 Compensator Tubing Ass’y, sst 1H6868000A2127 Tubing Assembly, sst

Type 4160KF and 4162KF only 27B9975X012129 Tubing Assembly, sst

Type 4160KF and 4162KF only 27B9976X012


132 Control Tubing AssemblyFor Bourdon tube instrumentsw/o process pressure gaugeStainless steel 1H3011000A2N05500 (not used on Type 4151K) 1H3011X0022

w/process pressure gauge, sst 1J2530000A2For gauge-pressure bellows instruments, sstw/o process pressure gauge 1H4526000A2w/process pressure gauge 1J2553000A2

For differential-pressurebellows instruments, sst 1H4526000A2

133 Control Tubing Assembly, sstFor differential-pressure instruments only 1H6732000A2

167 Label, Use w/2 psi (0.14 bar) pressure-testedcase and cover 12A9842X012


Form 5177March 2006

36


186 Anti-Reset Windup Ass’yFor Type 4160KF and 4162KF 21A6447X0A2

365 Label, bellows sensing instruments onlyGauge pressure instruments0-60 inches wc 11B5655X0620-100 inches wc 11B5655X2720-140 inches wc 11B5655X0820-5 psig 11B5655X0120-7.5 psig 11B5655X2620-10 psig 11B5655X0220-15 psig 11B5655X0320-20 psig 11B5655X0420-30 psig 11B5655X052

Differential pressure instruments0-80 inches wc 11B5655X2220-60 inches wc 11B5655X0620-10 psi 11B5655X2320-20 psi 11B5655X2420-30 psi 11B5655X252

366 Pipe Plug, Use w/0.14 bar (2 psi) pressure-testedcase and cover (2 req’d) 1P2796X0012

367* O-Ring (not shown)Type 4160KF and 4162KF only (2 req’d) 1C853806992

368 Machine Screw (not shown)Type 4160KF and 4162KF only (2 req’d) 1U8842X0012

369 Anti-Reset Windup Cover (not shown)Type 4160KF and 4162KF only (2 req’d) 2V597308012

370 Plain Washer, brass 1H339718992

Mounting Parts for Panel, Wall,Pipestand, or Actuator Mounting(Figures 3 and 4)213 Mounting Plate, steel

For yoke mounting onTypes 470, 472, 513, 656, 657 and 667 1C221825022

For yoke mounting on Type 480Vertical 3L276725092Horizontal 3J854725012

For yoke mounting on Types 1051 and 1052Size 40, positions 1 and 3 w/switch andSize 60, position 1 w/switch 23A8891X012

All others 1C221825022For yoke mounting on Type 1061Size 30, positions 1 and 3 w/switch and position 1 w/o

switch, Size 40, position 1 w/switch andSizes 80 and 100, position 3 w/o switch 23A8891X012

All others 1C221825022For pipe stand mounting 3N975725092For mounting on Type 115 3J779825012For mounting on Type 115C 2K654825022

215 Machine Screw, steel pl (specify quantity req’d)5/16 UNC X 1 inch 1C6391289825/16 UNC X 1-1/2 inches 1H3047289825/16 UNC X 2 inches 1B762424052

216 Hex Nut, steel pl (specify quantity req’d)For casing mounting on Types 126 and 127 andfor filter regulator mounting onTypes 1051, 1052 and 1061 1A352724122

All other types and mountings 1C332828982


220 Mounting Bracket, steel pl (not shown)For casing mounting on Types 126, 127, 657, 667,1051 and 1052 and for casing-mounted filterregulator on Types 1051 and 1052 1F401225072

221 Lockwasher, steel pl (specify quantity req’d) 1C225728982222 Cap Screw, steel pl (specify quantity req’d)

5/16 UNC X 3/4 inch 1A3816240525/16 UNC X 1 inch 1A3526240525/16 UNC X 1-1/8 inches 1C3791240525/16 UNC X 1-1/4 inches 1B7877240525/16 UNC X 1-3/4 inches 1A5534240525/16 UNC X 2-1/2 inches 1C8702240525/16 UNC X 3-5/8 inches 1C3988240523/8 UNF X 1-1/8 inches 1A582824052

223 Cap Screw, steel plTypes 1051 and 1052 with either case oryoke mounted regulator and Type 1061with yoke mounted regulator (2 req’d) T14109T0012

228 Spacer Spool, steel (specify quantity req’d)Types 470, 472, 480, 513, 656, 657, 667,pipe stand 1051, 1052 and 1061 1F906724092

Type 115W/o regulator or w/one regulator 1K153424092W/two regulators 1K414424092

Type 115C 1K654724092229 Cap Screw, steel pl (not shown) (specify quantity req’d)

Type 115w/o regulator or w/one regulator 1F960324052w/two regulators 1C870224052

Type 115C 1D770424052Types 126 and 127 1B227524052Types 1051 and 1052 casing-mounted controller 1A582824052

230 Cap Screw, steel pl (not shown)Types 126 and 127 1C595824052

231 Pipe Nipple, steel (not shown) (specify quantity req’d)For casing mounting on Types 126 and 127W/Types 67FR, 67R, 254, 254F and 1301 11A3740X012

232 Pipe Tee, steel (not shown)For casing mounting on Types 126 and 127W/Types 67R, 254 and 1301 1B8606X0012

238 Mounting Plate, steelFor yoke-mounted filter regulatorTypes 1051, 1052 and 1062 sizes 40 and 60 1C221825022Types 1061 size 30 23A8891X012

240 Cap Screw, steelFor yoke-mounted filter regulator onTypes 1051 and 1052 sizes 40 and

60 (2 req’d) 1A553424052241 Spacer Spool, steel

For yoke mounted filter regulators onTypes 1051 and 1052 sizes 40 and

60 (2 req’d) 1C559024092242 Spacer Spool, steel (not shown)

For yoke mounting onTypes 1051 and 1052 size 40 (2 req’d) 1V102624092Type 1061 sizes 30, 80 and 100 (2 req’d) 1J830724092

243 Street Elbow, pl galvanized malleable iron (not shown)For mounting on Types 470, 472, 480, 513, 656,657, 667, panel, pipe stand, 1051, 1052 and 1061w/nipple-mounted filter regulator 1A913221992



37

SECTION B-B

SECTION A-A

COMPRESSION PLUGS

ATEX LABEL CASE ASSEMBLY

COVER ASSEMBLY

2X ROLL PIN

A

A

B

B

GE09600 Rev. A

Figure 22. Front View of Case and Cover Assembly


244 Pipe Nipple, pl galvanized steel (not shown)For mounting on Types 470, 472, 480, 513, 656,657, panel, pipe stand, 1051, 1052 and 1061w/nipple-mounted filter regulator 1D239726232

250 Clamp, SteelFor pipe stand mounting (2 req’d) 1P427028982

251 Bracket Assembly, steelFor panel or wall mounting (2 req’d) 1H2892000A2

252 Cap Screw, steel plFor panel or wall mounting (4 req’d) 1B848024052


Note

Specify quantity of fittings.Connector, Brass

1/8-inch NPT X 1/4-inch od tubing 1A3959140121/4-inch NPT X 1/4-inch od tubing 1A6368140121/4-inch NPT X 3/8-inch od tubing 1B885618992

Elbow, Brass1/8-inch NPT X 1/4-inch od tubing 1A6850189921/4-inch NPT X 1/4-inch od tubing 1A3971189921/4-inch NPT X 3/8-inch od tubing 1B884618992

Table 7. Key 62* Bourdon Tube

PRESSURE RANGE MATERIAL

kPa Psig Stainless Steel N05500(1)

0-2000-4000-700

0-1400

0-300-600-1000-200

32B1243X01232B1243X02232B1243X03232B1243X042

------------

0-20000-40000-7000

0-10,0000-20,000

0-3000-600

0-10000-15000-3000

32B1244X05232B1244X06232B1244X07232B1245X08232B1245X092

---32B1244X20232B1244X21232B1245X222

---

0-35,0000-55,0000-70,000

0-50000-8000

0-10,000

32B1245X10232B1245X11232B1245X122

------

1. For NACE applications.



Form 5177March 2006

38

A subassembly with Bourdon tube sensing elementas shown in figure 20 contains the following keynumbers: 30 through 37, 39 through 61, 63, 65, 76,and 77. When ordering the subassembly as

indicated in table 8, one of each of the following keynumbered parts must also be ordered to completethe subassembly: dial, key 38; Bourdon tube, key62; and connecting link, key 64.

Table 8. Subassemblies with Bourdon Tube Sensing ElementOUTPUT PRESSURE RANGE FEEDBACK

BELLOWS MATERIAL STANDARDHIGH

TEMPERATUREBar Psig

0.2 to 1/0 or 0 and 1.4differential gap

3 to 15 or 0 and 20differential gap

Brass 26A7677X012 26A7677X022

Stainless steel 26A7677X052 26A7677X062

0.4 to 2.0 or 0 and 2.4differential gap


Brass 26A7677X032 26A7677X042


A subassembly with gauge pressure bellows sensingelement as shown in figure 21 contains the followingkey numbers: 30 through 37, 39 through 61, 71K,and 71L. The machine screws, key 77, quantity of 2,and washers, key 76, quantity of 2, also come withthe subassembly. The two washers, key 76, may beused with the machine screws, key 75, but fourwashers and machine screws are required so twomore washers must be ordered. The machinescrews, key 77, are not used on subassemblies withbellows input so they may be discarded. Althoughtwo machine screws, key 71K, and two bearings,key 71L, are included with the subassembly, they

are also included with the bellows assembly, key 71.When ordering the subassembly as indicated intable 9, one of each of the following key numberedparts, unless other quantities are indicated, mustalso be ordered to complete the subassembly: dial,key 38; bellows yoke, key 70; bellows assembly, key71; jam nut, key 72; washer, key 73; spring seat, key74; machine screw, key 75, quantity of 4; washer,key 76, quantity of 2; and spring, key 80. The link,key 71M, is included with the bellows assembly, key71. If ordering parts for a transmitter, a screw, key79, must also be ordered.

Table 9. Subassemblies with Gauge-Pressure Sensing ElementOUTPUT PRESSURE RANGE FEEDBACK


TEMPERATUREBar Psig



Brass 26A7677X012 26A7677X022




Brass 26A7677X032 26A7677X042



39

A subassembly with differential pressure bellowssensing element as shown in figure 21 contains thefollowing key numbers: 30 through 37, 39 through61, 71K, and 71L. The machine screws, key 77,quantity of 2, and washers, key 76, quantity of 2,also come with the subassembly. The two washers,key 76, may be used with the machine screws, key75, but four washers and machine screws arerequired so two more washers must be ordered. themachine screws, key 77, are not used onsubassemblies with bellows input so they may bediscarded. Although two machine screws, key 71K,

and two bearings, key 71L, are included with thesubassembly, they are also included with thebellows assembly, key 71. When ordering thesubassembly as indicated in table 10, one of each ofthe following key numbered parts, unless otherquantities are indicated, must also be ordered tocomplete the subassembly: dial, key 38; bellowsyoke, key 70; bellows assembly, key 71; machinescrew, key 75, quantity of 4; and washer, key 76,quantity of 2. The link, key 71M, is included with thebellows assembly, key 71. If ordering parts for atransmitter, a screw, key 79, must also be ordered.

Table 10. Subassemblies with Differential-Pressure Bellows Sensing ElementOUTPUT PRESSURE RANGE FEEDBACK


TEMPERATUREBar Psig



Brass 26A7677X012 26A7677X022




Brass 26A7677X032 26A7677X042



Form 5177March 2006

40

Fisher Marshalltown, Iowa 50158 USACernay 68700 France Sao Paulo 05424 BrazilSingapore 128461

Emerson Process Management

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot 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.

�Fisher Controls International LLC 1982, 2006; All Rights Reserved Printed in USA

Wizard and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division ofEmerson 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.

4160 pressure controller

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