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Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
Table 1. Specifications
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
Table 4. Bellows Pressure Ranges and Materials
MAXIMUM ALLOWABLE STATIC
PRESSURE RANGES
PRESSURE(1) LIMITS(2)
Brass Stainless Steel
Construction Construction
Bar Psig Bar Psig
0 to 150 mbar (0 to 60 inch wc) 1.6 20 --- ---
Vacuum 0 to 340 mbar (0 to 10 inch Hg) 2.8 40 --- ---
0 to 1.0 bar (0 to 30 inch Hg) 2.8 40 6.9 100
75 mbar vac. to 75 mbar (30 inch wc vac. to 30 inch wc) 1.4 20 --- ---
Compound Pressure 500 mbar vac. to 500 mbar (15 inch Hg vac. to 7.5 psig) 2.8 40 6.9 100
1.0 bar vac. to 1.0 bar (30 inch Hg vac. to 15 psig) 2.8 40 6.9 100
0 to 150 mbar (0 to 60 inch wc) 1.4 20 --- ---
Gauge Pressure 0 to 250 mbar(3) (0 to 100 inch wc) 1.4 20 --- ---
0 to 350 mbar(4) (0 to 140 inch wc) 2.8 40 --- ---
0 to 0.35 bar (0 to 5 psig) 2.8 40 --- ---
Positive pressure 0 to 0.5 bar (0 to 7.5 psig) 2.8 40 --- ---
0 to 0.7 bar (0 to 10 psig) 2.8 40 --- ---
0 to 1.0 bar (0 to 15 psig) 2.8 40 6.9 100
0 to 1.4 bar (0 to 20 psig) 2.8 40 --- ---
0 to 2.0 bar (0 to 30 psig) 2.8 40 6.9 100
0 to 300 mbar (0 to 80 inch wc) 1.4 20 --- ---
0 to 0.7 bar (0 to 10 psi) 2.8 40 --- ---
Differential Pressure(5)
0 to 1.4 bar (0 to 20 psi) 2.8 40 --- ---
0 to 2.0 bar (0 to 30 psi) --- --- 6.9 100
1. This term is defined in ISA Standard S51.1.
2. Bellows may be pressured to limit shown without permanent zero shift.
3. Type 4158K transmitter only.
4. Except Type 4158K transmitter.
5. The overrange limit for these sensing elements is a differential pressure equal to the maximum allowable static pressure limit.
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
2 PROPORTIONAL BAND
for supply and output piping. The pressure
SETTING OF 5 connection locations are shown in figure 3.
SUPPLY AIR FLOW, SCFH
Supply Pressure
PROPORTIONAL WARNING
BAND SETTING OF 0
OR 10
BAND SETTING OF 5
microns in diameter will suffice in
most applications, check with a Fisher
Field office and Industry Instrument air
PROPORTIONAL BAND quality standards for use with
SETTING OF 0 OR 10
corrosive gas or if you are unsure
about the proper amount or method of
air filtration or filter maintenance.
Supply pressure must be clean, dry air or
OUTPUT, PSIG 1
noncorrosive gas that meets the requirements of ISA
6 TO 30 (0.4 TO 2.0 BAR) OUTPUT SIGNAL RANGE
Standard S7.3. Use a suitable supply pressure
NOTES
1 TO CONVERT PSIG TO BAR, MULTIPLY BY 0.06895. regulator to reduce the supply pressure source to
2 SCFH—STANDARD CUBIC FEET PER HOUR (60_F AND 14.7 PSIA). the normal operating supply pressure shown in table
TO CONVERT TO NORMAL M3/HR—NORMAL CUBIC METERS PER HOUR (0_C AND 5. Connect supply pressure to the SUPPLY
1.01325 BAR, ABSOLUTE), MULTIPLY BY 0.0268
A7242 / IL
connection at the back of the case.
Figure 2. Steady-State Air Consumption
If operating the controller or transmitter from a high
pressure source [up to 138 bar (2000 psig)], use a
high pressure regulator system, such as the Type
Pressure Connections 1367 High Pressure Instrument Supply System. For
Type 1367 system installation, adjustment, and
maintenance information, see the separate
WARNING instruction manual.
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
2 INCH
(NOMINAL)
PIPE
VENT ASSEMBLY
(KEY 15)
8.7
(11/32)
MOUNTING
HOLES
The pressure connections to the controller depend For differential pressure instruments: Connect
upon the type of pressure sensing, gauge or the low pressure line to the CONTROL connection
differential. Gauge pressure controllers use either a on the side of the case and the high pressure line to
Bourdon tube or bellows as the sensing element, as the CONTROL connection on the back of the case
indicated in table 2. Differential pressure controllers as shown in figure 3.
use two bellows to sense differential pressure. When installing process piping, follow accepted
practices to ensure accurate transmission of the
For gauge pressure instruments: The control process pressure to the controller or transmitter.
pressure block (key 8 in figure 18) has two Install shutoff valves, vents, drains, or seal systems
connections. Process pressure can be connected as needed in the process pressure lines. If the
either to the CONTROL connection on the back of instrument is located such that the adjacent process
the case, or to the connection on the left side of the pressure lines will be approximately horizontal, the
case, shown in figure 3, depending on the lines should slope downward to the instrument for
instrument application. Plug the unused connection. liquid-filled lines and upward to instruments for
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
Vent Assembly specified. All adjustments must be made with the
cover open. When the adjustments and calibration
procedures are complete, close and latch the cover.
WARNING To better understand the adjustments and overall
operation of the controller, refer to the Principle of
Operation section in this manual for
If a flammable or hazardous gas is to proportional-only controllers. Refer also to the
be used as the supply pressure schematic diagram in figure 14.
medium, personal injury or property
damage could result from fire or
explosion of accumulated gas or from
contact with hazardous gas. The Adjustments
instrument case and cover assembly
does not form a gas-tight seal, and Adjustment: Set Point
when the assembly is enclosed, a
remote vent line, adequate ventilation, Adjust the pressure-setting knob by turning the knob
and necessary safety measures should clockwise to increase the set point and
be used. A remote vent pipe alone counterclockwise to decrease the set point. Note:
cannot be relied upon to remove all The dial setting and actual process pressure may
hazardous gas. Vent line piping should vary significantly, especially with a wide proportional
comply with local and regional codes band setting.
and should be as short as possible
with adequate inside diameter and few Adjustment: Proportional Band
bends to reduce case pressure
buildup.
To adjust the proportional band, rotate the
proportional band knob to the desired value.
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
PROPORTIONAL BAND
ADJUSTMENT KNOB
PRESSURE-SETTING KNOB
(KEY 36)
PRESSURE-SETTING
DIAL (KEY 38)
48B6003-A
A6038-1 / IL
ADJUSTER SCREWS (KEY 43) NOZZLE (KEY 57)
1. Complete the above connections and provide a 7. Apply an input pressure equal to the sensing
process pressure equal to the sensing element element upper range value.
range.
8. Rotate the pressure-setting knob to the maximum
2. Rotate the proportional band knob, shown in value.
figure 5, to 1.5 (15 percent proportional band).
3. Verify that the calibration adjuster screws (key Note
43) are at mid-position in the calibration adjuster
(key 41) slots. When performing the span adjustment
in step 9, do not watch the output
Depending upon the controller action, perform one gauge while changing the calibration
or the other of the following procedures. adjuster. The change in output is not a
For direct-acting controllers: good indication of the change in span.
While moving the calibration adjuster,
4. Apply an input pressure equal to the sensing the output pressure may change in the
element lower range value. opposite direction than expected. For
5. Rotate the pressure setting knob to the minimum example, while moving the calibration
value. adjuster to increase span, the output
pressure may decrease. This should
6. Adjust the nozzle (key 57) until the controller be disregarded since even though the
output pressure is between 0.6 and 0.7 bar (8 and output pressure decreases, the span is
10 psig.) increasing .
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
IF OUTPUT IS: 6. Adjust the nozzle (key 57) until the controller
output pressure is between 0.6 and 0.7 bar (8 and
10 psig).
FLAPPER
NOZZLE
Note
NOTE:
3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN. When performing the span adjustment
FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST
VALUES AS APPROPRIATE.
in step 9, do not watch the output
A6154 / IL gauge while changing the calibration
adjuster. The change in output is not a
good indication of the change in span.
Figure 6. Direct-Acting Controller Span While moving the calibration adjuster,
Adjustment—Proportional-Only Controllers the output pressure may change in the
opposite direction than expected. For
example, while moving the calibration
Loosen one screw only on the adjuster to increase span, the output
calibration adjuster and move the pressure may decrease. This should
calibration adjuster a small amount be disregarded since even though the
using the tight screw as a pivot and output pressure decreases, the span is
retighten the screw. If the adjustment increasing.
is repeated several times, alternate the
loosening of the two screws to prevent Loosen one screw only on the
the nozzle from being misaligned with calibration adjuster and move the
the flapper. During calibration, always calibration adjuster a small amount
be sure the nozzle remains using the tight screw as a pivot and
perpendicular to the flapper. retighten the screw. If the adjustment
is repeated several times, alternate the
9. If the output is not between 0.6 and 0.7 bar (8 loosening of the two screws to prevent
and 10 psig), adjust the controller span by loosening the nozzle from being misaligned with
one of the two adjusting screws (key 43) and move the flapper. During calibration, always
the calibration adjuster (key 41) a small distance as be sure the nozzle remains
indicated in figure 6. perpendicular to the flapper.
10. Repeat steps 4 through 9 until no further
adjustment is necessary. 9. If the output is not between 0.6 and 0.7 bar (8
and 10 psig), adjust the controller span by loosening
11. Proceed to the startup procedure for one of the two adjusting screws (key 43) and move
proportional controllers. the calibration adjuster (key 41) a small distance as
indicated in figure 7.
For reverse-acting controllers:
4. Apply an input pressure equal to the sensing 10. Repeat steps 4 through 9 until no further
element upper range value. adjustment is necessary.
5. Rotate the pressure setting knob to the 11. Proceed to the startup procedure for
maximum value. proportional controllers.
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
PROPORTIONAL BAND
ADJUSTMENT KNOB
PRESSURE SETTING
DIAL (KEY 38)
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
1. For controllers with anti-reset windup (Type MOVE ADJUSTER MOVE ADJUSTER
4160KF and 4162KF), record the direction of the LEFT RIGHT
arrow on the anti-reset windup assembly (key 186, in
figure 19). Remove the assembly and install the two FLAPPER
O-rings (key 367, not shown), and cover (key 369, NOZZLE
not shown) supplied with the controller. Secure the
cover with the two machine screws (key 368, not
NOTE:
shown) provided. 3 TO 15 PSIG (0.1 TO 1.0 BAR) OUTPUT SHOWN.
FOR 6 TO 30 PSIG (0.2 TO 2.0 BAR) OUTPUT, ADJUST
2. Connect regulated supply pressure to the VALUES AS APPROPRIATE.
controller. Do not exceed the normal operating A6154 / IL
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
14. Proceed to the Startup procedures for IF OUTPUT IS:
proportional-plus-reset controllers.
For reverse-acting controllers:
10 psig). NOZZLE
Note
12. Repeat steps 6 through 11 until no further
When performing the span adjustment adjustment is necessary.
in step 11, do not watch the output
gauge while changing the calibration 13. For controllers with anti-reset windup (Type
adjuster. The change in output is not a 4160KF and 4162KF), remove the two machine
good indication of the change in span. screws, anti-reset windup cover, and two O-rings
While moving the calibration adjuster, installed in step 1 of this procedure. Install the
the output pressure may change in the anti-reset windup assembly (key 186) with the arrow
opposite direction than expected. For
pointing in the direction recorded in step 1.
example, while moving the calibration
adjuster to increase span, the output
pressure may decrease. This should 14. Proceed to the Startup procedures for
be disregarded since even though the proportional-plus-reset controllers.
output pressure decreases, the span is
increasing. Calibration: Anti-Reset Windup
Loosen one screw only on the
calibration adjuster and move the Controllers with anti-reset windup have a differential
calibration adjuster a small amount relief valve assembly (figure 19). This relief valve is
using the tight screw as a pivot and set at the factory to relieve at a 0.3 bar (5 psi)
retighten the screw. If the adjustment pressure difference between the reset bellows
is repeated several times, alternate the pressure and the proportional bellows pressure. The
loosening of the two screws to prevent valve can be adjusted to relieve from 0.14 to 0.4 bar
the nozzle from being misaligned with (2 to 7 psig).
the flapper. During calibration, always The relief valve can relieve on either rising controller
be sure the nozzle remains output pressure or falling controller output pressure.
perpendicular to the flapper. If the arrow on the relief valve points toward the
bottom of the controller case as shown in figure 19,
11. If the output pressure is not between 0.6 and 0.7 the valve will relieve on falling output pressure. If the
bar (8 and 10 psig), adjust the controller span by arrow points in the opposite direction, the valve will
loosening one of the two adjusting screws (key 43) relieve on rising output pressure. The valve can be
and move the calibration adjuster (key 41) a small removed and reinstalled with the arrow pointing in
distance as indicated in figure 10. the opposite direction to change the relief action.
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
Disturb the system by tapping the flapper lightly or Adjustment: Proportional Band
change the set point a small amount and check for The proportional band adjustment shown in figure 5
system cycling. If the system does not cycle then determines the width of the differential gap. The
lower the proportional band (raising the gain) and width of the gap is the difference between the
disturb the system again. Continue this procedure process pressures at which the controller output will
until the system cycles. At that point, double the switch from zero to full supply pressure, or from full
proportional band setting and begin tuning the reset. supply pressure to zero. The relationship between
6. Reset Action: the proportional band dial setting and the differential
gap is shown in figure 11.
Disturb the system. If the system does not cycle then
speed up the reset and disturb the system again. Calibration: Differential Gap Controllers
Continue this procedure until the system cycles. The output of each controller is checked at the
When the system cycles multiply the reset time factory before the unit is shipped. Before placing the
setting by a factor of three (3) and slow the reset controller in control of a process loop, check to verify
down to the new value. The reset is now tuned. that the controller is calibrated correctly for the
This tuning procedure may be too conservative for application. The controller must be connected open
some systems. The recommended proportional band loop (Open loop: The controller output pressure
and reset setting should be checked for stability by changes must be dead ended into a pressure
introducing a disturbance and monitoring the gauge).
process as previously described. For some 1. Temporarily convert the differential gap controller
applications, tighter control may be desirable. to a proportional-only controller by disconnecting the
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
( 80 psig * 20 psig
100 psig
100 + 60% )
PROPORTIONAL BAND KNOB SETTING
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
SPAN
ADJUSTMENT KNOB
PRESSURE SETTING
DIAL (KEY 38)
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
range. The transmitter achieves the highest 7. Apply an input pressure equal to the sensing
accuracy when the span is 100 percent. element upper range value.
The transmitter span adjustment shown in figure 12
is the same as the controller proportional band Note
adjustment.
When performing the span adjustment
in step 8, loosen one screw only on
Calibration: Transmitters the calibration adjuster and move the
calibration adjuster a small amount
The output of each transmitter is checked at the
using the tight screw as a pivot and
factory before the unit is shipped. The transmitter
retighten the screw. If the adjustment
provides an output signal that is proportional to the
is repeated several times, alternate the
pressure applied to the sensing element. The output
loosening of the two screws to prevent
pressure has no direct effect on the process
the nozzle from being misaligned with
pressure.
the flapper. During calibration, always
The transmitter is calibrated at the factory and be sure the nozzle remains
should not need additional adjustment. Use the perpendicular to the flapper.
following calibration procedures when the sensing 8. If the output pressure is not 15 psig, adjust the
element has been changed or other maintenance span by loosening one of the two adjusting screws
procedures have altered the calibration of the (key 43) and move the calibration adjuster (key 41) a
transmitter. The following procedures use a 0.1 to small distance as indicated in figure 13.
1.0 bar (3 to 15 psig) output pressure range as an
example. For other output pressure ranges [such as 9. Repeat steps 4 through 8 until no further
0.2 to 2.0 bar (6 to 30 psig)] adjust the values to adjustment is necessary.
match the application. 10. Proceed to the startup procedure for
Provide a process pressure source capable of transmitters.
simulating the process pressure range of the For reverse-acting transmitters:
transmitter. If an output pressure gauge is not
provided, install a suitable pressure gauge for 4. Rotate the zero adjustment knob to zero.
calibration purposes(1). Connect a pressure source
to the supply pressure regulator and be sure the 5. Apply an input pressure equal to the sensing
regulator is delivering the correct supply pressure to element upper range limit.
the transmitter.
Unless otherwise indicated, key number locations 6. Adjust the nozzle (key 57) until the transmitter
are shown in figure 12. output pressure is at 0.1 bar (3 psig).
1. Complete the above connections and provide a 7. Set the input pressure equal to zero.
process pressure equal to the sensing element
range.
2. Rotate the span adjustment knob to 10 on the Note
dial (100 percent span). When performing the span adjustment
3. Verify that the calibration adjuster screws (key in step 8, loosen one screw only on
43) are at mid-position in the calibration adjuster the calibration adjuster and move the
(key 41) slots. calibration adjuster a small amount
using the tight screw as a pivot and
Depending upon the transmitter action, perform one retighten the screw. If the adjustment
or the other of the following procedures. is repeated several times, alternate the
loosening of the two screws to prevent
For direct-acting transmitters: the nozzle from being misaligned with
the flapper. During calibration, always
4. Rotate the zero adjustment knob to zero. be sure the nozzle remains
5. Set the input pressure to zero. perpendicular to the flapper.
6. Adjust the nozzle (key 57) until the transmitter 8. If the output pressure is not 15 psig, adjust the
output pressure is at 0.1 bar (3 psig). span by loosening one of the two adjusting screws
1. For stability, some transmitter applications will require additional volume than just the
gauge. Provide a minimum volume of approximately 25 cm3 (1.5 in3) or greater if stability
is a problem.
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
BELOW ABOVE
15 PSIG 15 PSIG
(1.0 BAR) (1.0 BAR)
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
INLET END OF
CONSTANT SUPPLY PRESSURE RELAY VALVE
SMALL DIAPHRAGM
LARGE DIAPHRAGM
EXHAUST
FIXED ORIFICE
EXHAUST END OF RELAY VALVE PROPORTIONAL BELLOWS
PIVOTING CROSS SPRINGS
BOURDON TUBE
FIXED
PIVOT
NOZZLE
RESET
BEAM AND VALVE
FLAPPER
RESET BELLOWS
VENT
EXHAUST
PROPORTIONAL−PLUS−RESET
CONTROLLER
PROPORTIONAL−ONLY CONTROLLER
28A2970-A
28A2971-A
B1561-3 / IL SENSED LOADING NOZZLE PROPORTIONAL RESET
PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
EXHAUST
RESET
BELLOWS
TO FINAL
CONTROL RESET
ELEMENT VALVE
PROPORTIONAL
BELLOWS
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
Use lock-out procedures to be Note
sure that the above measures stay in
effect while you work on the One gauge type (key 13) is used for
equipment. either supply pressure indication or
output pressure indication when both
Check with your process or safety gauges are installed inside the
engineer for any additional measures controller case.
that must be taken to protect against
1. Shut off the supply pressure and process lines to
process media.
the controller or transmitter.
2. Remove the gauge to be replaced:
Replacing Gauges
Unscrew the output or supply gauge (key 13)
from the relay base.
WARNING
Unscrew the process pressure gauge (key 106)
from the process connection (key 107).
Refer to the WARNING at the
beginning of the Maintenance Section. Unscrew the supply gauge (key 14) from the
Refer to figures 18 and 19 for key number locations supply pressure regulator.
unless otherwise directed. 3. Coat the threads of the replacement gauge with a
Three gauge configurations are available for 4150K sealant.
and 4160K units. 4. Screw the replacement gauge into the relay base,
process connection, or supply pressure regulator.
Output and supply pressure indications
5. Check for leaks by applying the correct supply
pressure with the nozzle capped to produce full
Output and process pressure indications output pressure.
Output, process, and supply pressure
indications Replacing Bourdon Tube
One gauge type (key 13) is used for both output and
supply pressure indications when the gauges are WARNING
installed inside the controller case. Key 13 features a
1/8-inch connecting stem that matches the threaded Refer to the WARNING at the
gauge boss extending from the relay base. beginning of the Maintenance Section.
In some cases, a process pressure gauge (key 106) Refer to figure 20 for key number locations unless
covers the position of the internal supply pressure otherwise directed.
gauge. The supply pressure gauge has been
removed and replaced with a pipe plug (key 108). 1. Shut off the supply pressure and process lines to
The pressure control block (key 8) is different to the controller or transmitter.
accommodate a different control tubing assembly 2. Unscrew the machine screw (key 63) to
(key 132) with a pressure connection (key 107) for a disconnect the link (key 64) and bearing (key 65)
process pressure gauge. If a supply pressure gauge from the beam (key 44). Be careful to avoid losing
is required, a gauge with a 1/4-inch connecting stem the bearing (key 65). Washer(s) (key 370) for the
(key 14) must be mounted on the supply pressure machine screw (key 63) are at times furnished for
regulator. insertion at the beam (key 44) connection to ensure
alignment of the connecting link (key 64).
3. Disconnect the control tubing (key 132). Unscrew
CAUTION two screws (key 77) and washers (key 76), and
remove the Bourdon tube (key 62).
Before performing this procedure, be 4. Unscrew the machine screw (key 63), and
sure the replacement gauges are the remove the link and bearing (keys 64 and 65) from
correct range so they are not damaged the Bourdon tube. Be careful to avoid losing the
by overpressure. bearing (key 65).
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Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
5. Attach the link and bearing to the replacement 3. Unscrew the four machine screws (key 28, figure
Bourdon tube. 18 or 19), and remove the pressure sensing
6. Attach the Bourdon tube with two machine subassembly from the case.
screws and washers (keys 77 and 76).
4. Remove the bellows yoke machine screws and
7. Connect the link and bearing to the beam (key washers (keys 75 and 76), and move the bellows
44). yoke to the right to permit access to the link screw.
8. After connecting the link to the beam, make sure
the nozzle is centered in the slot in the beam. If not, 5. Disconnect the link (key 71M) and bearing (key
carefully loosen the machine screw (key 63) enough 71L) from the beam. Be careful to avoid losing the
so that you can slip a washer (key 370) between the bearing.
bearing (key 65) and beam (key 44). Retighten the
machine screw and check the nozzle and beam 6. Loosen the nuts that secure the bellows
alignment. assembly (key 71), and remove this assembly from
9. Check to be sure that the beam is parallel with the bellows yoke (key 70).
the bottom of the case and that the link (key 64) is in
tension. If the beam is not parallel with the case, 7. For a gauge-pressure sensing element (only one
loosen the machine screws (key 77), reposition the bellows in the assembly), install the proper bellows
Bourdon tube to get the beam parallel, and retighten spring (key 80) into the bellows assembly if the input
the screws. signal range is being changed. See the parts list for
10. If a Bourdon tube with a different range was the correct part number.
installed, remove the machine screw and washer
(keys 40 and 39) and dial (key 38). Install a new dial 8. Install the new bellows assembly into the bellows
having an adjustment range corresponding to the yoke.
range of the Bourdon tube. If an optional process
pressure gauge (key 106, figure 18) is being used, 9. Attach the link and bearing to the bellows
install a new gauge with the appropriate assembly. Position the bellows yoke (key 70) on the
measurement capability. mounting base (key 30), and attach the link and
11. Check all tubing connections for leaks and the bearing to the beam. Start but do not tighten the four
Bourdon tube machine screws, tighten as machine screws (key 75) with washers (key 76) that
necessary. Perform the appropriate calibration attach the yoke to the mounting base. Slide the yoke
procedures. up or down as necessary to position the beam
horizontally, as shown in figure 21. Tighten the
machine screws.
Replacing Bellows Sensing Element
10. Replace the subassembly in the case and
secure with the four machine screws (key 28, figure
WARNING 18 or 19). Reconnect all tubing.
Refer to the WARNING at the 11. If a bellows assembly with a different range is
beginning of the Maintenance Section. installed, remove the machine screws and washer
Refer to figure 21 for key number locations unless (keys 40 and 39) and dial (key 38), and install a new
otherwise directed. dial having an adjustment range corresponding to
the range of the bellows. If an optional process
1. Shut off the supply pressure and process lines to pressure gauge (key 106, figure 18) is being used,
the controller or transmitter. install a new gauge with the appropriate
2. Disconnect the tubing from the mounting base measurement capability.
(key 30) and calibration adjuster (key 41).
Disconnect the tubing that connects the pressure 12. Check all tubing connections for leaks and the
block (key 8, figure 18) to the bellows assembly (key bellows yoke machine screws, tighten as necessary.
71), at the pressure block end. Perform the appropriate calibration procedures.
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Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
RELAY TUBING (KEY 103) PROPORTIONAL PROPORTIONAL TUBING
TUBING (KEY 104) (KEY 104)
REVERSING
BLOCK (KEY 59)
DIRECT
ACTING POSITION REVERSE
BELLOWS POSITION
BEAM (KEY 44) (KEY 52)
FLAPPER/SCREW
(KEY45)
FLAPPER/SCREW REVERSE
(KEY 45) ACTING POSITION
REVERSING
DIRECT ACTING BLOCK (KEY 59) REVERSE ACTING
DIRECT
ACTING POSITION RESET TUBING
(KEY 117) RESET
BEAM (KEY 44) TUBING
FLAPPER/SCREW
(KEY 45) FLAPPER/SCREW
(KEY 45)
REVERSE ACTING
NOTES:
POSITION
P = PROPORTIONAL REVERSING
BELLOWS DIRECT ACTING BLOCK (KEY 59) REVERSE ACTING
R = RESET BELLOWS
X = NO PRESSURE
B1564-5 / IL
10C2008-B
PROPORTIONAL−PLUS−RESET CONTROLLER
Changing Proportional or Reset Valve 1. Disconnect the appropriate tubing and remove
the proportional band valve assembly (figure 18 or
19) or the reset restriction valve assembly (figure 19)
25
Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
PROPORTIONAL
RELAY TUBING (KEY 103) TUBING (KEY 104)
REVERSE
REVERSING POSITION
BLOCK (KEY 59)
DIRECT
ACTING POSITION
BEAM (KEY 44)
FLAPPER/SCREW
FLAPPER/SCREW (KEY45)
(KEY 45)
REVERSE ACTING
POSITION
NOTES: REVERSING
P = PROPORTIONAL
BELLOWS DIRECT ACTING BLOCK (KEY 59)
REVERSE ACTING
X = NO PRESSURE
B2671 / IL
10C2008-B DIFFERENTIAL GAP CONTROLLER
Figure 16. Direct/Reverse Acting Tubing Connections (Continued)
Changing Anti-Reset Windup 1. Isolate the controller from process, control, and
Differential Relief Valve (4160KF) supply pressure. Vent any trapped pressure from the
controller before proceeding with the following steps.
2. Disconnect the proportional tubing (key 104) from
WARNING the mounting base (key 30, figure 20 or 21) and
reinstall it in the other connection in the mounting
base.
Refer to the WARNING at the
beginning of the Maintenance Section. 3. Do not invert the reversing block unless also
changing the controller action.
Refer to figure 19 for key number locations.
4. Check all connections for leaks with a
1. Note the controller output pressure (zero or soap-and-water solution. Perform the appropriate
supply) when the process is shut down. calibration procedure.
2. Remove the differential relief valve assembly.
Direct to Reverse Action
3. Refer to figure 19. Install the replacement relief Use the numbered steps below to change from
valve with the arrow positioned so that the controller
direct action (increasing pressure produces
output will be as noted in step 1 when the process is increasing output pressure) to reverse action
shut down. (increasing pressure produces decreasing output
pressure), or vice versa. Changing the action is
Changing Action accomplished by reversing the positions of the
reversing block and bellows tubing(s). Refer to figure
16 for key number locations unless otherwise
WARNING directed.
1. Isolate the controller or transmitter from process,
Refer to the WARNING at the control, and supply pressure. Vent any trapped
beginning of the Maintenance Section. pressure from the controller or transmitter before
proceeding with the following steps.
2. Locate the new tubing and reversing block
Proportional-Only to a Differential Gap positions for the action desired.
Controller 3. Locate the two bellows and the reversing block
A proportional-only controller may be changed to a (key 59, figure 16).
differential gap controller, or vice versa, by changing
4. Disconnect the tubing:
the position of the proportional tubing (key 104,
figure 16). Refer to figure 16 for key number a. For a proportional-only controller or for a
locations. transmitter, disconnect the proportional tubing
26
Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
(key 104) from the mounting base (key 30, figure 3. Unscrew the output or supply pressure gauge
20 or 21) and reconnect it in the opposite hole. (key 13).
27
Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
0 - RING Note
(KEY 55)
Also, make appropriate changes to the nameplate of 10. Replace the subassembly in the case and
the controller or transmitter, reflecting the new range secure with the machine screws (key 28, figure 18 or
selections. Refer to figure 20 or 21 for key number 19). Install the Bourdon tube if it was removed; refer
locations unless otherwise directed. to the Replacing Bourdon Tube section if needed.
Reconnect all tubing.
1. Shut off the supply pressure and process lines to
the controller or transmitter. 11. Unscrew the supply and output gauges (key 13,
figure 18 or 19) and install new gauges with correct
2. Disconnect the tubing from the mounting base ranges.
(key 30) and calibration adjuster (key 41). 12. Check all tubing connections and the bellows
Disconnect the tubing that connects the pressure machine screws for leaks, tighten as necessary.
block (key 8, figure 18 or 19) to the Bourdon tube or Perform the appropriate calibration procedures.
bellows assembly (key 62 or 71), at the pressure
block end.
3. Unscrew the machine screws (key 28, figure 18
or 19), and remove the subassembly from the case.
4. If the controller or transmitter uses a Bourdon Parts Ordering
tube sensing element, disconnect the Bourdon tube Whenever corresponding with your Fisher sales
from the beam (key 44) by removing the screw (key office about this equipment, mention the serial
63). Be careful to avoid losing the bearing (key 65). number of the unit. The serial number can be found
Unscrew the machine screws (key 77), and remove on the nameplate (key 22, figure 18). When ordering
the washers and Bourdon tube (keys 76 and 62). replacement parts, also state the complete
11-character part number of each part required as
5. Unscrew the bellows screws (key 54) from each
found in the following parts list.
end of the mounting base (key 30). [Note: The
bellows 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 when Note
re-assembling the bellows.]
Use only genuine Fisher replacement
6. Compress the bellows so that the end of the parts. Components that are not
bellows and beam can be removed from the end of supplied by Fisher should not, under
the mounting base (key 30) and unscrewed from the any circumstances, be used in any
stud (key 51, not shown) that connects the bellows. Fisher instrument. Use of components
not supplied by Fisher will void your
7. With the stud that connects the two bellows in warranty, might adversely affect the
place in the spacer (key 50), screw the new bellows performance of the instrument, and
onto the stud. Install new gaskets (key 53) on each might jeopardize worker and
bellows. workplace safety.
28
Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
Note Common Parts (Figures 18 through 21)
Fisher does not assume responsibility Key Description Part Number
for the selection, use, or maintenance
of any product. Responsibility for the 1 Case and Cover Assembly, aluminum
selection, use, and maintenance of any
Fisher product remains solely with the
purchaser and end-user. Note
Parts Kits
7* Relay Gasket, for all series
Key Description Part Number
Std Temp, neoprene 1C897403012
Controller Repair Kits
High Temp, silicone 1N873804142
Kit contains keys 5, 9, 10, 21, 24, 45, 46, 53,
8 Control Pressure Block
55, 56, 57, 58, 59, 60, 61, 63, 64, and 65
For gauge pressure instruments, sst
Standard Temperature R4150X00L12
w/o process pressure gauge 16A0979X012
High Temperature R4150X00H22
9* O-Ring, nitrile, for all series 1C376206992
Relay Replacement Kits
10* Gasket, neoprene, for all series (not shown) 1C328603012
Kit contains key 7 and 43 and the replacement relay
11* Sealing Washer (not shown) Use w/0.14 bar (2 psi)
Standard Temperature RRELAYX0L22
pressure-tested case and cover (2 req’d) 1J186999012
High Temperature RRELAYX0H22
Case Assembly Seal Kit
Kit contains 3 Manifold Seals, 1 Manifold Seal Cover,
and 10 Mounting Screws R4150KX0012 Note
48B6005-A
SUBASSEMBLY
(KEY NOS. SHOWN
IN FIGURE 20 OR 21)
NOTE:
KEYS 10, 81, 105 AND 108 TRANSMITTER
ARE NOT SHOWN
Figure 18. Typical Direct-Acting 4150K Series Assembly
(Refer to figure 22 for the Front View of the Case & Cover Assembly)
B2651-1 / IL
30
Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
PILOT RELAY
NOTE:
KEYS: 10, 81, 105 NOT SHOWN
48B6003-A
PROPORTIONAL−ONLY CONTROLLER
B2652 / IL
NOTE:
KEYS: 10, 81, 105, 115 NOT SHOWN PROPORTIONAL−PLUS−RESET CONTROLLER
48B6002-A
B2653-1 / IL
WITHOUT ANTI−RESET WINDUP
NOTES:
1 ARROW DOWN—RELIEVES ON DECREASING OUTPUT (OUTPUT @ SUPPLY DURING SHUTDOWN)
2 ARROW UP—RELIEVES ON INCREASING OUTPUT (OUTPUT @ ZERO DURING SHUTDOWN)
KEYS 367, 368, AND 369 NOT SHOWN
48B6001-B / DOC 1
PROPORTIONAL−PLUS−RESET CONTROLLER
WITH DIFFERENTIAL RELIEF VALVE ASSEMBLY FOR
ANTI−RESET WINDUP
A A
B SHOWN
A C WITH SECTION A−A
CONTROLLER
DIAL,
KEY 38 SECTION B−B
C VIEW A−A
26A7689-A / DOC
NOTES:
KEY 51, BELLOWS STUD NOT SHOWN: KEY 52 IS FEEDBACK BELLOWS
1. THERE IS AN O-RING (KEY 55) BETWEEN THE REVERSING BLOCK
(KEY 59) AND THE CALIBRATION ADJUSTER (KEY 41).
26A7681-A /DOC
2. THERE MAY BE AN O-RING (KEY 55) UNDER THE BELLOWS SCREW
(KEY 54). SEE NOTE PRECEDING KEY 54 IN THE PARTS LIST.
SECTION C−C
Note
80 Spring, gauge pressure bellows instruments only (continued) Controllers with bellows sensing element
0 - 2.0 bar (0 - 30 psig) positive, use only the 2.0 bar, 0 to 0.2 MPa, and 0 to 0
1.0 - 0 - 1.0 bar (30 - 0 - 15 psig) compound 1H448427022 to 30 psig triple scale brass and stainless
316 SST steel process pressure gauges. Differential
0 - 1.0 bar (0 - 15 psig) positive, pressure controllers do not use a process
0 - 1.0 bar (0 - 30 inches Hg) vacuum, pressure gauge.
500 - 0 - 500 mbar (15 - 0 - 7.5 psig) compound1H641137012 106* Process Pressure Gauge (use only when specified)
0 - 2.0 bar (0 - 30 psig) positive, Triple scale
1.0 - 0 - 1.0 bar (30 - 0 - 15 psig) compound 1H641237012 ABS plastic/Brass
81 Machine Screw, steel pl (not shown) (2 req’d) 1H527128982 0 - 2.0 bar, 0 - 0.2 MPa, and 0 - 30 psig 11B8578X012
82 Machine Screw, steel pl (4 req’d) 1C333328982 0 - 4.0 bar, 0 - 0.4 MPa, and 0 - 60 psig 11B8578X022
101 Lockwasher, steel pl (4 req’d) 1C225628982 0 - 11 bar, 0 - 1.1 MPa, and 0 - 160 psig 11B8578X032
103 Relay Tubing Assembly, sst 1H6861000A2 0 - 20 bar, 0 - 2.0 MPa, and 0 - 300 psig 11B8578X042
104 Compensator Tubing Assembly, sst 0 - 40 bar, 0 - 4.0 MPa, and 0 - 600 psig 11B8578X052
Types 4150K, 50KS, 52K, 52KS, 0 - 69 bar, 0 - 6.9 MPa, and 0 - 1000 psig 11B8578X062
54K, 55K, 57K, and 58K 1H6864000A2 ABS plastic/Stainless steel
Types 4160K, 60KF, 62K, 62KF and 64K 1H6870000A2 0 - 2.0 bar, 0 - 0.2 MPa, and 0 - 30 psig 11B8584X022
105 Plug, S31600 (316 SST), (not shown) 0 - 20 bar, 0 - 2.0 MPa, and 0 - 300 psig 11B8584X012
used with gauge pressure only 1A767535072 0 - 69 bar, 0 - 6.9 MPa, and 0 - 1000 psig 11B8584X032
A
SHOWN WITH
TRANSMITTER SECTION A−A
DIAL & SCREW,
A KEY 38 & 79
C
C SCREW
(KEY 71K) 1
SCREW
(KEY 71K) 1
BEARING 1 BEARING
(KEY 71L) 1 (KEY 71L)
26A7675-B / DOC
26A7683-B / DOC
NOTES:
26A7681-A /DOC
KEYS 46 AND 51 NOT SHOWN: KEY 52 IS
FEEDBACK BELLOWS
1 KEYS 71K, 71L, & 71M ARE PART OF THE
SECTION C−C
BELLOWS ASSEMBLY (KEY 71)
Figure 21. Controller Subassembly with Either Gauge-Pressure Bellows or Differential-Pressure Bellows Sensing Element
35
Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
COMPRESSION PLUGS
SECTION B−B
A
2X ROLL PIN
B
COVER
ASSEMBLY
GE09600 Rev. A
Note
244 Pipe Nipple, pl galvanized steel (not shown)
For mounting on Types 470, 472, 480, 513, 656, Specify quantity of fittings.
657, panel, pipe stand, 1051, 1052 and 1061 Connector, Brass
w/nipple-mounted filter regulator 1D239726232 0.125 inch NPT X 0.25 inch od tubing 1A395914012
250 Clamp, Steel 0.25 inch NPT X 0.25 inch od tubing 1A636814012
For pipe stand mounting (2 req’d) 1P427028982 0.25 inch NPT X 0.375 inch od tubing 1B885618992
251 Bracket Assembly, steel Elbow, Brass
For panel or wall mounting (2 req’d) 1H2892000A2 0.125 inch NPT X 0.25 inch od tubing 1A685018992
252 Cap Screw, steel pl 0.25 inch NPT X 0.25 inch od tubing 1A397118992
For panel or wall mounting (4 req’d) 1B848024052 0.25 inch NPT X 0.375 inch od tubing 1B884618992
A subassembly with Bourdon tube sensing element indicated in table 7, one of each of the following key
as shown in figure 20 contains the following key numbered parts must also be ordered to complete
numbers: 30 through 37, 39 through 61, 63, 65, 76, the subassembly: dial, key 38; Bourdon tube, key
and 77. When ordering the subassembly as 62; and connecting link, key 64.
A subassembly with gauge pressure bellows sensing are also included with the bellows assembly, key 71.
element as shown in figure 21 contains the following When ordering the subassembly as indicated in
key numbers: 30 through 37, 39 through 61, 71K, table 8, one of each of the following key numbered
and 71L. The machine screws, key 77, quantity of 2, parts, unless other quantities are indicated, must
and washers, key 76, quantity of 2, also come with also be ordered to complete the subassembly: dial,
the subassembly. The two washers, key 76, may be key 38; bellows yoke, key 70; bellows assembly, key
used with the machine screws, key 75, but four 71; jam nut, key 72; washer, key 73; spring seat, key
washers and machine screws are required so two 74; machine screw, key 75, quantity of 4; washer,
more washers must be ordered. The machine key 76, quantity of 2; and spring, key 80. The link,
screws, key 77, are not used on subassemblies with key 71M, is included with the bellows assembly, key
bellows input so they may be discarded. Although 71. If ordering parts for a transmitter, a screw, key
two machine screws, key 71K, and two bearings, 79, must also be ordered.
key 71L, are included with the subassembly, they
38
Instruction Manual
Form 5177
August 2004 4150K and 4160K Controllers and Transmitters
A subassembly with differential pressure bellows and two bearings, key 71L, are included with the
sensing element as shown in figure 21 contains the subassembly, they are also included with the
following key numbers: 30 through 37, 39 through bellows assembly, key 71. When ordering the
61, 71K, and 71L. The machine screws, key 77, subassembly as indicated in table 9, one of each of
quantity of 2, and washers, key 76, quantity of 2, the following key numbered parts, unless other
also come with the subassembly. The two washers, quantities are indicated, must also be ordered to
key 76, may be used with the machine screws, key complete the subassembly: dial, key 38; bellows
75, but four washers and machine screws are yoke, key 70; bellows assembly, key 71; machine
required so two more washers must be ordered. the screw, key 75, quantity of 4; and washer, key 76,
machine screws, key 77, are not used on quantity of 2. The link, key 71M, is included with the
subassemblies with bellows input so they may be bellows assembly, key 71. If ordering parts for a
discarded. Although two machine screws, key 71K, transmitter, a screw, key 79, must also be ordered.
Table 9. Subassemblies with Differential-Pressure Bellows Sensing Element
OUTPUT PRESSURE RANGE FEEDBACK HIGH
STANDARD
Bar Psig BELLOWS MATERIAL TEMPERATURE
0.2 to 1/0 or 0 and 1.4 3 to 15 or 0 and 20 Brass 26A7677X012 26A7677X022
differential gap differential gap Stainless steel 26A7677X052 26A7677X062
0.4 to 2.0 or 0 and 2.4 6 to 30 or 0 and 35 Brass 26A7677X032 26A7677X042
differential gap differential gap Stainless steel 26A7677X072 26A7677X082
39
Instruction Manual
Form 5177
4150K and 4160K Controllers and Transmitters August 2004
Wizard and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of
Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their
respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are
not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.
We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Fisher does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and
maintenance of any Fisher product remains solely with the purchaser and end-user.
Emerson Process Management
Fisher
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461
www.Fisher.com
40
Fisher Controls International LLC 1982, 2004; All Rights Reserved Printed in USA