4150K and 4160K Series Wizard II Pressure …

1 And 4160K Series Wizardr II PressureControllers and TransmittersContentsIntroduction2.. Scope of Manual2.. Description2.. Specifications2.. Educational Services2.. Installation2.. Standard Installation5.. Panel Mounting5.. Wall Mounting6.. Pipestand Mounting6.. Actuator Mounting6.. Pressure Connections6.. Supply Pressure6.. Process Pressure7.. Vent Assembly9.. Controller Operation9.. Proportional-Only Controllers9.. Adjustments9.. Adjustment: Set Point9.. Adjustment: Proportional Band9.. Calibration: Proportional-Only Controllers9.. Startup: Proportional-Only Controllers12.. Proportional-Plus-Reset Controller12.. Adjustments12.. Adjustment: Set Point12.. Adjustment: Proportional Band13.. Adjustment: Reset13.. Adjustment: Anti-Reset Windup13.

2 Calibration13.. Calibration: Proportional-Plus-ResetControllers13.. Calibration: Anti-Reset Windup15.. Startup: Proportional-Plus-Reset Controllers 16 Differential Gap Controllers16.. Adjustments16.. Adjustment: Set Point16.. Adjustment: Proportional Band16.. Calibration: Differential Gap Controllers16.. Startup: Differential Gap Controllers18.. Transmitter Operation18.. Adjustments18.. Adjustment: Zero18.. Adjustment: Span19.. Calibration: Transmitters19.. W3525-1 / ILFigure 1. Wizard II Controller Yoke-Mounted on ControlValve ActuatorStartup: Transmitters20.. Principle of Operation20.. Proportional-Only Controllers20.. Proportional-Plus-Reset Controllers21.. Controllers with Anti-Reset Windup21.. Differential Gap Controllers22.

3 Transmitters22.. Maintenance22.. Replacing Gauges23.. Replacing Bourdon Tube24.. Replacing Bellows Sensing Element24.. Changing Proportional or Reset Valve25.. Changing Anti-Reset Windup DifferentialRelief Valve (4160KF)26.. Changing Action26.. Proportional-Only to a DifferentialGap Controller26.. Direct to Reverse Action26.. Relay Replacement27.. Changing Output Signal Range27.. Parts Ordering28.. Instruction ManualForm 5177 March 20064150K and 4160K Controllers and Transmitters4150K and 4160K Controllers and TransmittersInstruction ManualForm 5177 March 20062 Contents (Continued)Parts Kits29.. Controller Repair Kits29.. Relay Replacement Kits29.. Parts List29.. Assemblies29.. Common Parts29.. Mounting Parts for Panel, Wall, Pipestandor Actuator Mounting36.

4 IntroductionScope 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, person may install, operate, or maintain 4150 Kand 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 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.

5 The controlleror transmitter output is a pneumatic Pressure signalthat can be used to operate a final control element,indicating device, or recording otherwise noted, all NACE references are toNACE for the 4150K and 4160K Seriescontrollers and transmitters are listed in table 2 explains available configurations ServicesFor information on available courses for 1450K and4160K Series controllers and transmitters, as well asa variety of other products, contact:Emerson Process ManagementEducational Services, Box 190; 301 S. 1st , IA 50158-2823 Phone: 800-338-8158 orPhone: 641-754-3771 FAX: 641-754-3431e-mail: EmersonR, Emerson ProcessManagement, FisherR, nor any of theiraffiliated entities assumesresponsibility for the selection, use,and maintenance of any for the selection, use,and maintenance of any productremains with the purchaser avoid personal injury or propertydamage resulting from the suddenrelease of Pressure : Always wear protective clothing,gloves, and eyewear when performingany installation operations.

6 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 5177 March 20063 Table 1. SpecificationsAvailable ConfigurationsSee 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: to bar (3 to 15 psig) or to bar (6 to 30 psig) pneumaticpressure signalDifferential Gap Controllers: 0 and bar (0 and 20 psig) or 0 and 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).

7 The suffix R is added to the typenumber of a construction specified for Pressure Requirements(2)See table 5 Supply Pressure MediumAir or natural gas(3)Steady-State Air Consumption(1)See figure 2 Supply and Output Connections1/4-inch NPT femaleCommon Signal Pressure ConversionsSee table 6 Proportional Band(1) AdjustmentFor Proportional-Only andProportional-Plus-Reset Controllers: Fulloutput Pressure change adjustable from 3 to100% for a to bar (3 to 15 psig), or 6 to100% for a to bar (6 to 30 psig) of thesensing element Gap AdjustmentFor Differential Gap Controllers: Full outputpressure change adjustable from 15% to 100% ofsensing element rangeReset(1) AdjustmentFor Proportional-Plus-Reset Controllers:Adjustable from to 74 minutes per repeat(100 to repeats per minute)Zero(1) Adjustment (Transmitters Only)Continuously adjustable to position span of lessthan 100% anywhere within the sensing elementrangeSpan(1) Adjustment (Transmitters Only)Full output Pressure change adjustable from 6 to100% of sensing element rangePerformanceRepeatability(1): of sensing element rangeDeadband(1) (Except Differential GapControllers(4): of output spanTypical Frequency Response at 100%Proportional BandOutput to Actuator: Hz and 110 degree phaseshift with 1850 cm3 (113 inches3) volume,actuator at mid-strokeOutput to Positioner Bellows.)

8 9 Hz and 130degree phase shift with to bar (3 to 15psig) output to 33 cm3 (2 inches3) bellowsAmbient 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 OperatingInfluenceProportional Control only: Output pressurechanges 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 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 4150K and 4160K Controllers and TransmittersInstruction ManualForm 5177 March 20064 Table 1.

9 Specifications (continued)Typical Ambient Temperature OperatingInfluence (continued)Transmitters only: Output Pressure changes 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% spanHazardous Area ClassificationComplies with the requirements of ATEX Group IICategory 2 Gas and DustRefer to figure 22 for location of ATEX labelApproximate kg (18 pounds)OptionsCase Pressure tested to bar (2 psig)Declaration of SEPF isher 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 , the product may bear the CE markingto indicate compliance with other applicable This term is defined in ISA Standard The Pressure /temperature limits in this document and any applicable standard or code limitation should not be This product can be used with natural gas.

10 Natural gas should not contain more than 20 ppm of An adjustable differential gap (differential gap controllers) is equivalent to an adjustable 2. Available ConfigurationsTYPE NUMBER(1)DESCRIPTIONB ourdon TubeSensing Element(Gauge PressureOnly)Bellows Sensing ElementGaugePressureDifferentialPressure Proportional-only controller4150K4152K4154 KProportional-plus-reset controllerWithout anti-reset windup4160K4162K4164 KWith anti-reset windup4160KF4162KF- - -Differential gap controller4150KS4152KS- - -Transmitter4157K4158K4155K1. The suffix R is added to the type number of a construction specified for reverse 3. Bourdon Tube Pressure Ranges and MaterialsPRESSURE RANGES(1)MAXIMUM ALLOWABLE STATIC Pressure (2) LIMITS(3)MATERIALS tandardWith Optional Travel Stop(4)BarPsigBarPsigBarPsig0 to to to to 300 to 600 to stainless steel0 to 140 to 200 to 400 to 700 to 2000 to 3000 to 600(5)0 to 1000(5)142040702003006001000192950832804 2072012000 to 1000 to 2000 to 3500 to 1500(5)0 to 30000 to 5000100200350150030005000115230380165033 0055000 to 5500 to 7000 to 80000 to ,000550700800010,0001.