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Emerson Fisher 4196 Instruction Manual

1. and S Controllers Instruction Manual March 2012 D200299X012 Figure 48 Controller Assembly Drawing cont d EN km RH VIEW E VIEW E 4196B CONTROLLERS CONTROLLERS WITH ANTI RESET WINDUP SUFFIX LETTER F VIEW C C VIEW C C 4196B CONTROLLERS 4196B CONTROLLERS WITH ANTI RESET WINDUP s6n0752 1SHT2 SUFFIX LETTER F 104 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 48 Controller Assembly Drawing cont d 56A9752 T SHT 2 6 9752 1 5 2 56A9752 T SHT 3 56A9752 T SHT 2 SECTION B B SECTION B B SECTION B B SECTION B B 4196A CONTROLLERS 4196A CONTROLLERS 4196A CONTROLLERS 4196A CONTROLLERS 56A9752 T SHT 4 VIEW L CONTROLLERS WITH AUTO MANUAL STATION SUFFIX LETTER E 105 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 48 Controller Assembly Drawing cont d i H Bis 56A9752 T SHT 2 VIEW C C 4196S CONTROLLERS 56A9752 T SHT 4 56A9752 T SHT 3 VI EW CONTROLLERS WITH EXTERNAL FEEDBACK OPTION 106 Instruction Manual D200299X012 4196A C and S Controllers March 2012 Key g 8 38A2279 A Description Process and Set Point Indicator Assembly key 56 figure 49 101 113 Indicator ass y Individual parts are listed in the indicator assembly subsection of this parts list Key numbers for individual assembly parts also appear in figure 50 For use w o
2. A 9 D LINEARITY RN VS ADJUSTMENT 9 ASSEMBLY B TIE BAR SCREW CAPSULES i py REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW 36A6988 C SIDE VIEW FRONT VIEW Replacing Pivot Assembly A Key 114 CAUTION Avoid bending or kinking the drive flexure during the following procedure Bending or kinking the drive flexure can result in product damage and impaired performance 1 Decrease the remote set point pressure to 0 bar 0 psig 88 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Remove the two screws key 103 and the tie bar key 106 3 Note where link A is connected Disconnect link A key 116 from the lever arm on pivot assembly A key 114 10 Disconnect the drive flexure key 79 from the adjustment arm of pivot assembly A Be careful not to bend or kink the drive flexure Remove the screw key 122 washer key 123 and nut key 124 that attach the quide flexure key 119 to the top of the pivot assembly Remove the pivot screw and spring washer keys 109 and 112 and the mounting screw key 102 attaching the pivot assembly to the mounting plate key 111 Lift out pivot assembly A Loosen the adjustment screw key 118 on the adjustment arm of the replacement pivot assembly and set the arm to the same length as the arm on the pivot assembly being replaced Tighten the screw Toreplace the pivot ass
3. SUPPLY PRESSURE ES OUTPUT PRESSURE WH POSITIVE FEEDBACK PRESSURE T oe OO p 9954 20 4 NOZZLE PRESSURE e ko Mt SUPPLY PRESSURE d 7 d ELEMENT RELAY B1546 2 As the process temperature decreases approaching the lower switching point the flapper moves away from the nozzle in a direct acting controller reducing nozzle pressure Through relay action pressure to the positive feedback bellows is reduced moving the flapper further away from the nozzle Thus the nozzle pressure falls even further Output pressure to the final control element switches to zero Moving the set point indicator changes the distance between the nozzle and flapper as does a change in process temperature except that when the set point is changed the nozzle moves with respect to the flapper Adjusting the set point moves both the upper and lower switching points The proportional band adjustment positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle away from the input connection When the proportional band adjustment moves the nozzle across the feedback connection the controller action changes between direct and reverse On a direct acting controller changing the proportional band adjustment widens or narrows the differential gap between the two switching points This is accomplished by changing the position of the lower switching point On a reverse acting con
4. ZONU 5 INCREASE MANUAL lif T LOADER KNOB AUTO MANUAL SWITCH PROCESS POINTER AUTO PROPORTIONAL BAND ADJUSTMENT PROPORTIONAL BAND ah INDICATOR COVER AUTO MANUAL STATION SUFFIX LETTER E OUTPUT PRESSURE GAUGE ANTI RESET WINDUP DIFFERENTIAL RELIEF VALVE SUFFIX LETTER F SUPPLY PRESSURE RESET RATE RESET GAUGE ADJUSTMENT ADJUSTMENT ADJUSTMENT TYPICAL ADJUSTMENTS 4196B SHOWN 4196C RESET AND RATE ADJUSTMENTS Manual Set Point Adjustment Adjust the set point by moving the set point indicator until the line on the set point indicator is over the desired value on the process temperature scale Move the indicator to the right to increase the set point and to the left to decrease it Adjusting the set point does not affect the proportional band setting If the controller is equipped with the optional internal or external set point adjustment turn the adjustment knob clockwise to increase the process set point and counterclockwise to decrease the process set point 29 4196 and S Controllers Instruction Manual March 2012 D200299X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point Manually moving the set point indicator could damage the controller If the controller is equipped with remote set point suffix letter M vary the remote set point pressure to change
5. E 58 m aul Eo ma HO MONIS dd e 9 TAN 120 8 8 f 8 5 09 QS Cu LI B Cmk i Pea 318 B D EXC 2 EYE w7 a eee aed ABER Em L il x 1 E AB 2 29 AAGA 6AE 318 SECTIONE A 6 stt viEW 311 SEE VIEW M E OA iy DH 411 W 48 9 5 1 at Sa 19 i ye Y pes kt iS n LI s o tass n SEE VIEW E 562 re 310 Mz 49 afl 24 28 317 MID T SECTION D D K DEC D E a a LT zt E E NC SECTION C C TYPICAL REMOTE SET POINT 4196A CONTROLLERS ASSEMBLY MOUNTING APPLY LUB SEALANT 4190 CONTROLLERS 102 Instruction Manual D200299X012 Key 46 Pressure Gauge RANGE 4196A C and S Controllers March 2012 GAUGE MATERIAL Dual Scale Gauge 0 to 2 kg cm2 0 to 30 psig 0 to 4 kg cm2 0 to 60 psig 11B8577X042 11B8577X052 11B8583X032 Triple Scale Gauge 0 to 2 bar 0 to 200 kPa 0 to 30 psig 0 to 4 bar 0 to 400 kPa 0 to 60 psig 11B8577X012 11B8577X022 11B8583X012 11B8583X022 1 One type of pressure gauge is used for both output pressure and supply pressure indication Key 58 61 62 64 65 7 1 72 120 129 131 135 136 137 138 Description
6. Ensure that the nozzle is still centered on the flapper 28 Insert the pivot of the adjustable set point pivot assembly key 17 into the hole in the set point beam assembly key 23 29 Insert the screw with washer keys 19 and 20 through the frame key 3 and start it into the adjustable set point pivot assembly key 17 but do not tighten 30 Squeeze the adjustable set point pivot assembly against the set point beam assembly Check to be sure the nozzle is still centered on the flapper and tighten the machine screw key 19 If necessary loosen both machine screws key 19 to allow slightly moving the adjustable set point pivot assembly set point beam assembly and the relay nozzle tubing assembly as a unit to center the nozzle on the flapper After centering the nozzle tighten the two machine screws 31 Turn the proportional band adjustment knob to 5 percent DIRECT Refer to figure 34 to locate the locking nut on the adjustable set point pivot assembly Loosen the locking nut and back out the set screw slightly so that the set point beam assembly falls under its own weight when pivoted upward Also maintain a minimum side play between the adjustable set point pivot assembly and the nozzle tubing assembly Tighten the locking nut 32 Atthe frame manifold key 135 tighten the nut that secures the tubing from the relay nozzle tubing assembly key 18 Apply full supply pressure with the nozzle capped to obtain maximum output pressu
7. 19 20 21 Attach link 3 to the set point beam shoe as shown in figure 31 For controllers with reset or rate adjustment 4196B and 4196C controllers turn the reset adjustment to the CLOSED 4196 or OFF 4196C position Set the rate adjustment to the OFF position The controller output must be 0 bar 0 psig To be sure the controller output is 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4196B or OFF 4196C position Apply the correct supply pressure refer to table 3 to the controller and provide an accurate means of measuring the controller output pressure Perform the appropriate process indicator zero and span calibration procedure and if necessary the remote set point zero and span calibration procedure in Section 3 4 or 5 When calibration is complete continue with step 22 below Note Th CO 22 23 24 25 26 27 28 29 30 31 32 33 70 following procedure steps 22 through 28 matches the process pointer motion to the set point indicator motion so the ntroller will control at set point at all positions on the process scale Set the proportional band to 40 percent REVERSE or DIRECT depending on the desired controller action Adjust the set point to the lower limit on the process scale Disconnect link 1 from the temperature element noting the hole from which
8. 53 4196 and S Controllers Instruction Manual March 2012 D200299X012 Example The sensing element has a range of 38 C 100 F The lower switching point is to be set at 1 C 30 F and the upper switching point is to be set at 27 C 80 F Proceed as follows e Divide the differential gap the difference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap dag 509F 109C Sensing Element Range FOOSE 100 50 Locate the 50 percent line on figure 26 Move along this line until you intersect the curve Read the proportional band setting on the left hand axis For this example the setting is approximately 35 percent Figure 26 Curve for Determining the Proportional Band Setting PROPORTIONAL BAND SETTING SENSOR RANGE BETWEEN SWITCHING POINTS A2853 1 1 Using the curve in figure 26 determine the correct proportional band setting for the desired gap expressed as a percent of the input span between the switching points Set the proportional band to the desired setting determined in step 1 Adjust the set point to the desired upper switching point Increase the process temperature until the controller output switches from zero pressure to full supply pressure BR UJ N Decrease the process temperature to the desired switching point at which the controller output switches from full
9. 55 extension A92011 aluminum 139 Machine screw fill hd 18 8 SST 3 req d 141 Adj arm 530400 304 SST 311 Anti seize sealant not furnished with controller Auto Manual Station suffix letter E figure 52 274 Lower loader ass y aluminum 275 Spring seat screw pl steel 276 Valve plug spring A228 music wire alt desgntn K08500 pl steel 277 Valve plug 18 8 SST 278 Tube plastic 279 Ball SST Recommended spare parts 8 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 4196 and S Controllers March 2012 dt zan HA a Description Ball seat nitrile 2 req d Diaphragm 55 nitrile aluminum Upper loader ass y aluminum plastic Range spring SST Range spring cup pl steel Spring adj screw pl steel Retaining ring pl steel Loader knob plastic Machine screw rd hd 18 8 SST 2 req d Machine screw fill hd 18 8 SST 4 req d Machine screw fill hd 530200 302 SST 2 req d Switch body ass y aluminum nitrile O ring nitrile O ring nitrile O ring nitrile Switch body spring A228 music wire alt desgntn 08500 pl steel 2 req d Ball SST 2 req d Lever ass y SST O ring nitrile S 8 S Part Number 1C853806992 11A8741X052 13A1584X012 1E2226X0
10. Actuator Mounting 4196A C and S Controllers March 2012 Figure 5 Wall Mounting LOCKWASHER KEY 67 260 HEX HEAD CAP SCREW KEY 66 2 43 BRACKET KEY 68 REAR VIEW mm ug INCH Refer to figure 2 A controller specified for mounting on a control valve actuator is mounted at the factory If the controller is ordered separately for installation on a control valve actuator mount the unit as described in this section Mounting parts vary for different actuator types Attach the mounting bracket to the actuator yoke with cap screws lock washers and spacer spools Attach the controller to the bracket with cap screws lock washers and spacer spools On some designs the mounting bracket is attached to the actuator casing rather than to the yoke Temperature Sensing Bulb Bushings and Thermowells WARNING Failure of the thermowell may result in personal injury or equipment damage due to escaping process fluid To avoid such injury or damage be sure the process fluid velocity and pressure are within the thermowell limits in tables 5 and 6 Process temperature is sensed by a temperature element consisting of a bulb immersed in the process fluid a bendable extension and an armored capillary tube see figure 6 When the temperature bulb is to be placed within a closed vessel bushings are available to attach the bulb to the vessel The bushing dimensions are shown in figure 7 penetrates the vessel and
11. wm RIGHT HAND EDGE MER LEFT HAND EDGE 20 If the controller does not perform as indicated in steps 14 through 19 the flapper is not correctly aligned This may occur because the output was not sufficiently stabilized in steps 9 through 13 Repeat steps 9 through 19 21 Setthe proportional band to 400 percent in the desired controller action Replace the proportional band indicator cover key 36 and tighten the two screws key 6 Reconnect link number 1 if disconnected to the same hole in the temperature element noted in step 8 22 For controllers with anti reset windup suffix letter F remove the two machine screws valve cover and two O rings installed in step 1 of this procedure Install the anti reset windup relief valve key 55 with the arrow pointing in the direction recorded in step 1 23 If the controller has the external feedback option available with the 4196B controllers only remove the connection between the controller output and the external feedback connection Anti Reset Windup Suffix Letter F Differential Relief Valve Calibration Calibration for the differential relief valve to relieve on rising controller output pressure 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Do not apply supply pressure at this time 2 Setthe reset adjustment to 0 01 minutes per repeat wide open and the rate adjustment 4196C
12. 2 req d 362 Capscrew hex hd pl steel 2 req d 363 Lock washer pl steel 2 req d 364 Hexnut A563 pl steel 2 req d 365 Tubing fittings 2 req d See fittings subsection 111 4196 B C and S Controllers March 2012 Instruction Manual D200299X012 Key Description Panel Mounting figure 4 66 Capscrew hex hd pl steel 3 req d 67 Lock washer pl steel 3 req d 68 Bracket A569 pl steel 70 Machine Screw rd hd pl steel 4 req d Wall Mounting figure 5 66 Capscrew pl steel 3 req d 67 Lock washer pl steel 3 req d 68 Bracket pl steel Controller Mounting Parts for Actuator with Casing Mounted Controller Spacer Spool steel 3 req d Cap screw hex hd pl steel 3 req d Lock washer pl steel 5 req d Mounting bracket G10100 pl steel Cap screw hex hd pl steel 2 req d Mounting bracket pl steel Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Washer pl steel 2 req d Washer G10100 pl steel 2 req d Controller Mounting Parts for Actuator With Yoke Mounted Controller figure 2 Spacer spool steel 3 req d Cap screw hex hd pl steel 3 req d Lock washer pl steel 5 req d Mounting bracket steel For 1061 w switches or manual operator For all other types Spacer spool steel 2 req d Cap screw pl steel 2 req d Key Description Regulator Mounting Parts Regulator Mounting Parts for Casing Mounted Regulator Cap screw hex hd pl steel
13. 2 req d Lock washer pl steel 2 req d Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Mounting bracket G10100 pl steel For 657 667 size 80 amp 100 For all other types Regulator Mounting Parts for Yoke Mounted Regulator Mounting Bracket Not Required Cap screw hex hd pl steel 2 req d Lock washer pl steel 2 req d Regulator Mounting Parts for Yoke Mounted Regulator With Mounting Bracket Cap screw hex hd pl steel 2 req d Lock washer pl steel 4 req d Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Mounting bracket G10100 pl steel For 1061 size 30 all shaft sizes For all other types Fittings Fittings for 3 8 inch tubing casing or yoke mounted controller with regulator Connector brass 2 req d Elbow brass 2 req d Fittings for 3 8 inch copper tubing pipestand mounted controller with regulator Elbow brass 2 req d Fittings for 3 8 inch copper tubing all controllers without regulator Connector brass 1 req d Elbow brass 1 req d Fittings for 1 2 inch synthetic rubber hose all controllers with or w o regulator Connector 316 SST Elbow 316 SST Swivel 316 SST 2 req d Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher
14. 26 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 13 Fisher 4196A Auto Manual Station Schematic MANUAL LOADER AUTOMATIC POSITION 7 AUTO MANUAL WITCH S MANUAL off LOADER E KNOB AA PLASTIC TUBE OUTPUTPRESSURE 4 Ex gore METAL FINAL CONTROL ELEMENT MANUAL La POSITION N AUTO MANUAL RELAY OUTPUT PRESSURE SWITCH SUPPLY PRESSURE PRESSURE OUTPUT PRESSURE MANUAL LOADER OUTPUT PRESSURE ELEMENT A2999 1 27 4196 B C and S Controllers March 2012 28 Instruction Manual D200299X012 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Section 4 4196B Proportional Plus Reset Controllers and 4196C Proportional Plus Reset Plus Rate Controllers Adjustments for 4196B and C Controllers This section includes descriptions of adjustments and procedures for prestartup startup and calibration Adjustment locations are shown in figures 14 and 16 To better understand the adjustments and overall controller operation refer to the principle of operation section and to the schematic diagrams in figures 18 through 22 Unless otherwise noted key numbers refer to figure 48 Figure 14 Fisher 4196B and C Controller Adjustment Locations SET POINT INDICATOR METAL BALL SWITCHING ZONE INDICATOR i WITHIN
15. 51 Temperature Baths 51 Process Indicator Zero and Span CAlIDIAlOMN exe S E ORE PES ES 52 Remote Set Point suffix letter M Zero and Span Calibration 53 Setting Switching Points 53 Direct Acting Controllers 53 Reverse Acting Controllers 54 Principle of Operation for 4196S Controllers 55 Overall Operation 55 Remote Set Point suffix letter M Operaio ama ee E ERREUR ORE PT PEG 56 Auto Manual Station suffix letter E OPeldlOl ios osculo adeat ome 5 6 Maintenance PES da 59 Inspection Maintenance 59 60 Replacing Common ControllerParts 63 Replacing the Process Temperature Scale 63 Replacing the Relay 64 Replacing the Case and Cover 65 Replacing the Gauges 65 Replacing the Supply Gauge Proportional Reset and Reset Valve Tubing Assemblies 65 Replacing the Proportional Band Adjustment Knob Nozzle Assembly and Set Point Beam Assembly 66 Replacing the Flapper Assembly and Flapper Flexure Pivot Assembly 71 Replacing the Proportional or Reset 25 aaa pus aan eO SR ee aas 75 Replacing the Reset Restriction Valve E 96B axes 78 Replacing the Rate Reset Valve A
16. General Calibration Instructions Temperature Baths Process Indicator Zero and Span Calibration Deere Rees Remote Set Point suffix letter M Zero and Span Calibration Flapper Alignment Principle of Operation for 4196A Controllers Overall Operation www Fisher com gt a Y March 2012 Remote Set Point suffix letter M ODeratlOL Do ss 26 Auto Manual Station suffix letter E 25 bid LIU 26 4 4196B Proportional Plus Reset Controllers and 4196C Proportional Plus Reset Plus Rate Controllers de beta doe 29 Adjustments for 4196B and C Controllers 29 Manual Set Point Adjustment 29 Remote Set Point suffix letter M 30 Proportional Band Adjustment ADJ 30 Changing Controller Action 30 Reset Adjustment 31 Rate 31 Anti Reset Windup suffix letter F 31 Switching the Auto Manual Station suffix letter E 31 Prestartup Checks for 4196B and C CODEFOllets 31 Startup for 4196B and C Controllers 32 Calibration of 4196B and C Controllers 33 General Calibration Instructions 34 Temperature Bath
17. Inspect the input element and linkage for damage 7 4 Mechanical alignment 7 4 Move the set point and verify 7 4 Repair or replace parts as necessary that the nozzle is uncapped by the flapper If not inspect linkages and flexures for damage 7 5 Relay failure or restriction in 7 5 Manually move flapper 1 6 mm 7 5 If the output pressure remains at the nozzle passage 1 16 inch from the nozzle supply pressure remove the controller case and cover assembly and test again with the relay nozzle tubing nut key 18 loose If the output is O psig clean or replace the nozzle assembly If the output remains at supply pressure replace the relay 7 6 Flapper misaligned 7 6 Manually push the flapper away 7 6 Perform the flapper alignment from the nozzle Controller output procedure in Section 3 4 or 5 should go to 0 psig 8 Controller remains at zero output 8 1 Gauge not functioning 8 1 Verify that the supply pressure is 8 1 Replace gauges as necessary at its correct value and that the controller output is zero 8 2 Input element or linkage 8 2 Vary the process temperature 8 2 Repair or replace parts as necessary failure and observe the flapper for movement Inspect the input element and linkage for damage 8 3 Mechanical alignment 8 3 Move the set point and verify 8 3 Repair or replace parts as necessary that the nozzle is capped by the flapper If not inspect linkages and flexures for damage Continued 62 Ins
18. inside the bearings and do not rest against the end of either bearing d Hold the pivot assembly A shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing e Tighten the screws that hold the drive flexure in place Setting the Travel Stops 1 Loosen the set screw key 87 in the travel stop nut key 86 CAUTION Make sure the loose travel stop nut does not bind on the diaphragm capsule extension key 134 when pressurizing the capsules key 80 Damage to the capsules may result 2 Full span stop Adjust the remote set point pressure to 2 1 2 percent of span greater than the remote set point input range upper limit Loosen the two screws keys 139 and 140 that secure the travel stop key 83 to the mounting plate key 111 Slide the travel stop until it is just touching the end of the capsule stack Tighten the travel stop mounting screws to lock it into position 3 Zero stop Adjust the remote set point pressure input to 2 1 2 percent of span less than the remote set point input range lower limit Slide the travel stop nut key 86 along the diaphragm capsule extension key 134 until it is just touching the travel stop key 83 Tighten the set screw key 87 to lock the travel stop nut in position Aligning the Linkage 1 Adjust the remote set point pressure to 50 percent of the remote set point input range 92 Instruction Manual 4196A B C and S
19. m gt AN 73 W4199 Before installing the replacement bellows coat the threads with a suitable lubricant such as key 310 Screw in the replacement bellows until it is finger tight against the frame key 3 Reinstall the bellows beam key 49 and tighten the four machine screws key 71 Position the bellows bracket key 31 over the bellows Insert a machine screw key 35 through the bellows bracket key 31 into the proportional bellows Do not tighten Place the washer key 362 on the second machine screw key 35 and start the screw through the bellows bracket key 31 into the reset bellows Do not tighten Compress the bellows and start the four machine screws key 6 through the bellows bracket key 31 into the bellows beam key 49 but do not tighten Be sure that the bellows bracket is aligned such that it does not rub on the frame at any point and tighten the screws keys 6 and 35 Install the proportional or reset tubing assembly on the bellows base For a4196B or C controller set the reset adjustment for 0 01 minutes per repeat For a4196C controller set the rate adjustment to OFF Apply the correct supply pressure with the nozzle capped and check for leaks Remove the supply pressure Reconnect link 4 key 65 to the bellows bracket Be sure that the link does not contact the frame If it does loosen the four screws key 6 which attach the bellows bracket to the bellows beam a
20. or from manual to automatic you must first balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output To switch from automatic to manual mode carefully adjust the loader knob until the metal ball inside the plastic tube moves into the switching zone Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counterclockwise to decrease it To switch from manual to automatic mode adjust the set point to move the ball into the switching zone Turn the switch to AUTO and adjust the set point to control the output When the automatic manual switch is in AUTO adjusting the loader knob has no effect on the controller output When the automatic manual switch is in MANUAL changing the set point has no effect on the controller output Prestartup Checks for 4196B and C Controllers Refer to figure 14 for adjustment locations and refer to figure 48 for key number locations 31 4196 and S Controllers Instruction Manual March 2012 D200299X012 When performing the checks open loop conditions must exist An open loop exists when the controller output does not affect the input pressure or other control signal to the controller Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing prestartup checks
21. shown in table 3 Connect supply pressure to the SUPPLY connection on the bottom of the case as shown in figure 8 Remote Set Point suffix letter M Pressure Connection If the controller has remote set point suffix letter M connect the remote set point pressure to the top of the controller case at the location shown in figure 8 Use clean dry air or a non corrosive gas Use a 0 2 to 1 0 bar 3 to 15 psig remote set point pressure range for a 0 2 to 1 0 bar 3 to 15 psig controller output pressure range Use a 0 4 to 2 0 bar 6 to 30 psig remote set point pressure range for a 0 4 to 2 0 bar 6 to 30 psig controller output pressure range If pressure is supplied to the remote set point connection with a regulator a small bleed orifice should be placed between the regulator and remote set point connection to prevent pressure variations due to regulator lock up External Feedback Pressure Connection 4196B Controllers Only When a secondary controller in an override application has this option reset windup is minimized in the secondary controller Connect the external feedback connection shown in figure 8 of the secondary controller to the customer supplied high or low select relay 4196 and S Controllers Instruction Manual March 2012 D200299X012 Vent Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the
22. the screw nearest the nozzle until the nozzle just touches the flapper Adjust the proportional band to 5 percent REVERSE Turn flapper leveling screw 1 the screw nearest the nozzle until the nozzle just touches the flapper Flapper leveling screws 1 and 3 should protrude the same distance from the clinch nuts see figure 43 If leveling screw 1 protrudes further than leveling screw 3 turn the link 3 adjusting screw counterclockwise If leveling screw 3 protrudes further than leveling screw 1 turn the link 3 adjusting screw clockwise Repeat steps 8 through 11 until leveling screws 1 and 3 protrude an equal distance from the clinch nuts Remove the tape and reconnect link number 1 to the same hole in the temperature element assembly Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 4196 B C and S Controllers Instruction Manual March 2012 D200299X012 Figure 43 Flapper Leveling Screw and Clinch Nut FLAPPER LEVELING CLINCH NUT SCREW W4191 1 Replacing Link 4 1 Remove the screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 4 from the bellows bracket key 31 and the flapper assembly key 11 3 Connect the replacement link to the flapper assembly so that the two adjusting screws on the link are nearest to the bellows bracket key 31 and so that the screw heads are facing
23. 0 2 to 1 0 Bar 3 to 15 psig Output 5 9 normal m h 240 scth 0 4 to 2 0 Bar 6 to 30 psig Output 10 4 normal m h 350 scfh 4196 B C and S Controllers March 2012 Table 1 Specifications continued Instruction Manual D200299X012 Exhaust Capacity All 4196 Controllers 3 0 2 to 1 0 Bar 3 to 15 psig Output 4 6 normal m h 186 scfh 0 4 to 2 0 Bar 6 to 30 psig Output 7 0 normal m h 295 scfh Operative Ambient Temperature Limits 40 to 70 C 40 to 160 F Housing Designed to NEMA 3 weatherproof and IEC 529 IP54 specifications Hazardous Area Classification Complies with the requirements of ATEX Group II Category 2 Gas and Dust Mounting Controller can be mounted on actuator panel wall or pipestand Approximate Weight 4 5 kg 10 pounds Declaration of SEP Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph of the Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot bear the CE marking related to PED compliance However the product may bear the CE marking to indicate compliance with other EC Directives Note Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 Consult your Emerson Process Management sales d for additional information 2 At 40 C 100 F 3 N
24. 10 04 1 4 18 NPT KEN CONTROLLER OUTPUT APPLICABLE CONNECTION 4196B ONLY 1 4 18 NPT VENT CONNECTION CAPILLARY TUBE REAR VIEW BOTTOM VIEW FRONT VIEW mm INCH 239 2 14 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Supply Pressure Connection A WARNING Severe personal injury or property damage may occur if the instrument supply medium is not clean dry air or oil free or noncorrosive gas While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications check with an Emerson Process Management field office and industry instrument air quality standards for use with 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 noncorrosive gas that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Alternatively natural gas may be used as the supply pressure medium Gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 ppm Use a suitable supply pressure regulator to reduce the supply pressure source to the normal operating supply pressure
25. 4 Replacing the Anti Reset Windup suffix letter F Relief Valve Tubing Assembly Refer to the 4196 or 4196C suffix letter F portion of figure 48 for key number locations 1 Du gt Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures Loosen the nuts at both ends of the relief valve tubing key 44 and remove the tubing Install the replacement relief valve tubing and tighten the tubing nuts at both ends Apply the correct supply pressure to the controller cap the nozzle and check for leaks Remove the supply pressure Install the controller into the case by performing steps 6 through 9 of the case and cover replacement procedure Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid Replacing the Temperature Element 1 2 Note in which hole link 1 key 128 is connected and disconnect the link from the temperature element Remove the three screws key 127 from the temperature element assembly 79 4196A B C and S Controllers Instruction Manual March 2012 D200299X012 3 Remove the two screws key 129 at the bottom of the controller case 4 Lift off the temper
26. 8 INCH HEX FOR 3 8 INCH TEMPERATURE BULB 1 1 8 INCH HEX FOR 9 16 INCH TEMPERATURE BULB INCH A3240 2 13 4196 and S Controllers Instruction Manual March 2012 D200299X012 Table 6 Maximum Process Pressures for Thermowells Temperature Temperature C F Thermowell Bulb Diameter 21 70 93 200 204 400 316 600 427 800 538 1000 Size Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig 30 4 Carbon steel 200 1 1 2 NPT 304 SST 234 6 316 SST 265 7 04400 224 3 Carbon steel 3 4 304 SST 316 SST N04400 Carbon steel 304 SST 3 4 316 SST Pressure Connections A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install any system component where service conditions could exceed the limits given in this manual Use pressure relieving devices as required by government or accepted industry codes and good engineering practices Refer to figure 8 for pressure connection locations All pressure connections are 1 4 NPT internal Use 1 4 inch or 3 8 inch pipe or tubing for supply output and remote set point connections Figure 8 Location of Connections 1 4 18 102 REMOTE SET CONNECTION WHEN APPLICABLE 130 51 2 00 5 16 18UNC 2B L 3 HOLES 5 81 a os t 4 P 114 18 SUPPLY PRESSURE T EXTERNAL CONNECTION
27. 8 SST Used to attach the reset valve 4196B controllers or rate reset valve 4196C controllers to the frame For 4196B and C controllers only Rate reset valve 55 for 4196C controllers only Brass bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig SST bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig Auto manual station suffix letter E Individual assembly parts are listed in the Auto Manual Station subsection of the parts list Key numbers for individual ass y parts also appear in figure 52 Lithium grease not furnished with controller Anti seize sealant not furnished with controller O ring nitrile For all types w suffix letter E auto manual station 3 req d Auto Manual Scale plastic For all types w suffix letter E auto manual station Machine screw fill hd 530400 304 SST For all types w suffix letter E auto manual station Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station Silicone based lubricant not furnished with controller Lubricant silicone sealant not furnished with controller External feedback assembly SST Spring Retaining Washer SST Washer 18 8 SST 1P8453X0022 101 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 48 Controller Assembly Drawing SEE VIEW H SEE VIEW G B SEE VIEWL
28. If the controller has the external feedback option connect the controller output connection to the external feedback connection see figure 8 Adjust the controller for full output pressure and with the RESET knob adjusted to 0 01 minutes repeat verify the tubing connections do not leak Disconnect after completing the prestartup checks 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller Do not exceed the normal operating pressure in table 3 2 Fora controller with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 1 bar 6to 30 psig to the remote set point connection at the top of the controller case Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the set point a minimum of 20 percent of the scale span above the process pointer Setthe reset adjustment to 0 01 minutes per repeat Set the rate adjustment to OFF 4196C controllers Adjust the proportional band for 5 percent DIRECT controller output pressure should be 0 psig Rotate the proportional band to 5 percent REVERSE controller output should be within 0 14 bar 2 psig of the supply pressure O WON DD Hh UJ Ifthe controller ou
29. LETTER F ONLY W6395 S E 1 SCREW 1 SCREW 2 SCREW 3 T c REMOTE SET POINT 1 ADJUSTMENT SPAN ADJUSTMENT SUFFIX LETTER d 3d n SIDE VIEW OF 6731 SET POINT PROCESS INDICATOR ASSEMBLY 59A9752 S SHT 1 LB SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 85 4196 and S Controllers Instruction Manual March 2012 D200299X012 2 Setthe proportional band between DIRECT and REVERSE 3 Adjust the reset valve 4196B and C controllers only to 0 01 minutes per repeat 4 Adjust the rate valve 4196C controllers only to OFF Note Temperature baths are required for the following steps Please refer to the appropriate section of this manual for more information on temperature baths 5 Immerse the temperature bulb in the 50 percent bath Allow a minimum of 5 minutes for the controller to stabilize 6 The takeoff assembly should be vertical If not loosen the temperature element adjusting screw and reposition the assembly so it is vertical Tighten the adjusting screw 7 The process pointer should be aligned with the pointer subassembly as shown in figure 42 If not loosen the zero adjustment locking screw and adjust the zero adjustment screw to align the process pointer with the pointer subassembly Tighten the zero adjustment locking screw 8 The process pointer should indicate 50 3 percent of the process scale span If not
30. Loosen the two adjusting screws on link 4 shown in figure 38 and connect the link to the bellows bracket key 31 allowing the link to find its free length 40 Tighten the two adjusting screws on link 4 41 Lift link 4 out of the hole in the bellows bracket key 31 and ensure it drops back into the hole under its own weight If not repeat steps 39 and 40 42 Adjust the proportional band to 40 percent REVERSE or DIRECT depending on the desired controller action 43 Adjust the set point to the process scale lower limit 74 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 44 45 46 47 48 49 50 51 52 53 Tape the process pointer at the process scale lower limit The output pressure may be anywhere between 0 2 and 1 0 bar 3 and 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output signal range or between 0 4 and 2 0 bar 6 and 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output signal range If the output is not within the specified range adjust the flapper leveling screw nearest the nozzle until the output is within the range specified Record the output pressure Adjust the set point to the process scale upper limit Remove the tape and move the process pointer until the controller output equals the pressure recorded in step 44 Note the process temperature indication The process temperature indication should be within 2 percent of the process scale upper limit If the proce
31. Process Indicator Zero and Span Calibration Before starting this procedure e Provide a means of changing the process temperature to the controller and a means of measurement external to the controller e Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 Note Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment Refer to figures 23 and 25 for adjustment locations 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize 4 he process pointer should indicate the process scale lower limit If not adjust the process pointer to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw Ul Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize 6 The process pointer should indicate the process scale upper limit If not adjust the span screw to correct one half the error as follows clockwise to increase
32. Wall Mounting 112 Regulator Mounting Parts for Controller Mounting Parts for Actuator Yoke Mounted Regulator with Mounting with Casing Mounted Controller 112 Bracket Bt aes 112 Controller Mounting Parts for Actuator aie alee 112 with Yoke Mounted Controller 112 Section 1 Introduction Scope of Manual This instruction manual provides installation operating calibration maintenance and parts ordering information for Fisher 4196A 4196B 4196C and 41965 temperature indicating controllers Portions of this manual apply only to specific configurations in the 4196 controller configurations These configurations are indicated by letter suffixes in the type number that correspond to the mode and option designated in table 2 The specific controller type number with letter suffixes is on the nameplate shown in figure 1 Refer to table 2 for the definition of each 4196 type number 4196 and S Controllers Instruction Manual March 2012 D200299X012 Do not install operate or maintain a 4196 temperature indicating controller without being fully trained and qualified in field instrument and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions regardin
33. adjust the remote set point zero adjustment screw to correct for half the error at mid scale Tighten the zero adjustment locking screw 11 Apply remote set point pressure equal to the lower and upper range limits and make sure the set point indicator is within 1 percent 12 If necessary perform the process indicator zero and span calibration procedure in this section Otherwise perform the flapper alignment procedure in this section Flapper Alignment Note Perform the process indicator zero and span calibration procedure and for controllers with remote set point suffix letter M the remote set point zero and span calibration procedure before the flapper alignment Flapper leveling screw numbers and adjustments are shown in figure 16 Key number locations are shown in figure 48 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Do not apply supply pressure at this time Note 4196B and C controllers with anti reset windup suffix letter F are supplied with two O rings key 52 a valve cover key 51 and two machine screws key 53 Use these parts in the next step 1 For controllers with anti reset windup suffix letter F record the direction of the arrow on the anti reset windup relief valve key 55 Remove the relief valve and install the two O rings key 52 and valve cover key 51 supplied with the controller Secure the
34. arms in the same holes noted instep 1 4 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing Link B This procedure describes the link B key 126 replacement of the remote set point assembly Figure 46 shows the link location 1 Note the holes where link B is connected Disconnect link B key 126 from the pivot arm and from the set point indicator 2 Loosen the screw in the replacement link B and adjust the length to match the link being replaced Tighten the screw 3 Refer to figure 46 for the correct orientation of link B Attach replacement link B to the pivot arm and to the set point indicator in the same position as noted in step 1 4 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Remote Set Point suffix letter M Maintenance Calibration Refer to figure 46 for parts and adjustment locations Refer to figure 51 for key number locations WARNING Refer to the Maintenance WARNING on page 59 Precalibration Procedures 1 Remove the two screws key 6 and lift off proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Remove the two screws key 103 and remove the tie bar key 106 from t
35. decrease the rate by changing the setting to the lower value The rate is now tuned 8 Check the stability of the recommended tuning settings by introducing a disturbance and monitoring the process 9 Once stable control is attained the process pointer and set point indicator should be in line If they are aligned adjust the set point to the desired value If they are not readjust the set point to the desired control point and proceed with step 10 10 If the process pointer is within 5 percent of the set point indicator turn the link 3 adjustment see figure 41 for location until the process pointer aligns with the set point indicator Turn the link 3 adjustment screw clockwise to increase the process indication or counterclockwise to decrease it If the process pointer is misaligned with the set point indicator by more than 5 percent of the scale span perform the calibration procedures for 4196B and C controllers Calibration of 4196B and C Controllers A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given in this manual 33 4196 and S Controllers Instruction Manual March 2012 D200299X012 General Calibration Instructions Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing calibration If the prestartup checks or startup reveal faulty contro
36. instability e Then the low gain provided by the proportional action keeps the system stable Finally reset action slowly increases the gain and returns the process temperature toward the set point 42 Instruction Manual D200299X012 4196A C and S Controllers March 2012 Figure 19 Fisher 4196C Controller Schematic SET POINT INDICATOR PROCESS POINTER REMOTE SET POINT CONNECTED HERE INPUT ELEMENT CONNECTED HERE CONNECTING LINK BEAM SUPPLY PRESSURE 4 OUTPUT PRESSURE NOZZLE PRESSURE RESET PRESSURE 46A9764 C C0529 4 PROPORTIONAL BELLOWS FLAPPER REVERSE ACTION QUADRANT RESET BELLOWS PROPORTIONAL BAND ADJUSTMENT FEEDBACK LINK oe FEEDBACK X MOTION FLAPPER DIRECT ACTION QUADRANT INPUT MOTION FLAPPER DETAIL OUTPUT PRESSURE 22 TO FINAL CONTROL 72 492 ELEMENT ZN NOZZLE m d gt RELAY b MIO PRESSURE RATE VALVE RESET VALVE PROPORTIONAL PLUS RESET PLUS RATE CONTROL TO RESET TO TO BELLOWS NOZZLE PROPORTIONAL BELLOWS 2 RELIEF RELAY SUPPLY PRESSURE RATE VALVE RESET VALVE PROPORTIONAL PLUS RESET PLUS RATE CONTROL WITH ANTI RESET WINDUP 43 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 20 Reset Rate Schematic RELAY OUTPUT PRESSURE RESET PROPORTIONAL BELLOWS BELLOWS 19A5000 A A3237 2 Anti Reset Windup su
37. is a mark owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com 1984 2012 Fisher Controls International LLC All rights reserved ar EM 4 ranr agge hii I pa TWEE
38. it is removed and tape the process pointer to the lower limit on the process scale The output pressure may be anywhere between 0 2 and 1 0 bar 3 and 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output signal range or between 0 4 and 2 0 bar 6 and 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output signal range If the output is not within the specified range adjust the flapper leveling screw nearest the nozzle until the output is within the range specified Record the output pressure Adjust the set point to the upper limit on the process scale Remove the tape and move the process pointer until the controller output equals the pressure recorded in step 24 Note the process temperature indication The process temperature indication should be within 2 percent of the upper limit on the process scale If the process temperature indication in step 26 is greater than the upper limit of the process scale by 2 percent loosen the shoe adjustment screws key 30 shown in figure 31 and move the set point beam shoe key 29 slightly away from the center of the flapper assembly If the process temperature indication in step 26 is less than the upper limit of the process scale by 2 percent loosen the shoe adjustment screws key 30 shown in figure 31 and move the set point beam shoe key 29 slightly toward the center of the flapper assembly Repeat steps 23 through 27 until the error is less than 2 percent of the process scale range at the upper
39. key 31 to each bellows ass y key 48 2 req d 36 Proportional band indicator cover ABS w polyester label 37 Self tapping screw 18 8 SST 4 req d to attach process scale key 61 to process scale bracket key 376 100 Key 38 39 40 41 42 43 44 45 46 48 49 50 51 927 53 54 55 56 57 Instruction Manual D200299X012 Description Part Number Self tapping screw 18 8 SST Used to attach frame inside case 9 req d Supply gauge tubing ass y SST Proportional tubing assembly SST For 4196A or 4196B controllers For 4196C controllers Plug 530300 303 55 For all 4196A amp B controllers 1 req d For 4196C CM CE and CME 2 req d For 4196CF CFM CFE and CFME 1 req d Reset valve tubing ass y for 4196B controllers w o ext feedback SST Reset tubing ass y SST For 4196B controllers For 4196C controllers Relief tubing assembly SST For 4196BF BFE BFM and BFME only For 4196CF CFE CFM and CFME only Positive feedback tubing ass y for 4196S controllers only SST Brass Pressure gauges 2 req d Bellows ass y 2 req d Brass 532100 530400 Bellows beam A96061 aluminum 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig See Key 46 table Relay assembly Relay 0 2 to 1 0 bar 3 to 15 psig Relay 0 4 to 2 0 bar 6 to 30 psig Relief valve cover plate A03600 aluminum O ring nitrile Used w key 51 2 req d Machine screw fill hd 18 8 SST Used w k
40. key 43 into the rate reset valve assembly 5 Unscrew the nut holding the proportional tubing assembly key 40 into the rate reset valve assembly 6 For controllers with anti reset windup suffix letter F unscrew the nut holding the relief tubing assembly key 44 into the rate reset assembly 7 While holding the rate reset valve assembly remove the machine screw key 162 from the frame 8 Remove the rate reset valve assembly from the frame 9 Inspect and if necessary replace the gasket key 5 10 To install the replacement rate reset valve assembly position the assembly on the frame key 3 and secure it with the mounting screw key 162 11 Position the gasket key 5 on the rate reset valve assembly Hold the gasket in place while installing the rate tubing assembly key 137 the valve assembly using the two machine screws key 71 78 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 12 13 14 15 16 17 18 19 20 Insert the reset tubing assembly key 43 into the rate reset valve assembly and tighten the nut Insert the proportional tubing assembly key 40 into the rate reset valve assembly and tighten the nut For controllers with anti reset windup suffix letter F insert the relief tubing assembly key 44 into the rate reset valve assembly and tighten the nut Set the reset to 0 01 minutes per repeat and the rate to OFF Apply the correct supply pressure to the con
41. limit of the process scale Remove the tape from the process pointer and reconnect link 1 to the temperature element Be sure to reconnect link 1 in the same hole noted in step 24 Perform steps 6 through 9 of the case and cover replacement procedure Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Replacing the Flapper Assembly And Flapper Flexure Pivot Assembly 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 2 Remove the two screws key 6 and lift off the proportional band cover key 36 3 Disconnect link 3 from the set point beam shoe part of the set point beam assembly key 23 Refer to figure 31 for the link location 4 Remove the set point beam bias spring key 28 refer to figure 31 for the spring location 5 Remove the screw and washer keys 19 and 20 that hold the adjustable set point pivot assembly key 17 to the frame 6 Remove the adjustable set point pivot assembly key 17 7 Unscrew the nut that secures the relay nozzle tubing assembly key 18 to the frame manifold key 135 Refer to figure 3
42. nozzle at any time while performing this procedure If it does adjust flapper screw 2 the screw nearest the nozzle to provide clearance Refer to figure 45 for adjustment locations Refer to figure 48 for the key number locations Note Any adjustment of the process pointer span adjustment screw requires readjustment of the process pointer zero adjustment screw When checking the zero and span adjustments ensure that the temperature element assembly does not contact the travel stops 1 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 84 Instruction Manual 41964 B C and S Controllers D200299X012 March 2012 Figure 45 Fisher 4196 Controller Calibration Adjustment Locations 1 0 7 TEMPERATURE ELEMENT Wa ADJUSTING SCREW UNDER PROCESS POINTER ei M PROCESS POINTER ZERO ADJUSTMENT PROCESS POINTER ZERO ADJUSTMENT LOCKING SCREW TEMPERATURE PROCESS POINTER SPAN ELEMENT ADJUSTMENT TAKEOFF ASSEMBLY ANTI RESET WINDUP VALVE ADJUSTING SCREW ANTI RESET WINDUP DIFFERENTIAL RELIEF VALVE lt 2 REMOTE SET POINT RESET lt 1 REMOTE SET POINT SUFFIX LETTER M ADJUSTMENT RATE SUFFIX LETTER M ZERO ADJUSTMENT ADJUSTMENT RESET ZERO ADJUSTMENT LOCKING SCREW W3599 1 ADJUSTMENT FRONT VIEW 4196B CONTROLLERS 4196C CONTROLLERS NOTES AVAILABLE ON 4196B CONTROLLERS ONLY 2 gt AVAILABLE ON 4196B AND C CONTROLLERS SUFFIX
43. or external set point adjustment turn the adjustment knob clockwise to increase the process set point and counterclockwise to decrease the process set point 4196 and S Controllers Instruction Manual March 2012 D200299X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point Manually moving the set point indicator could damage the controller If the controller is equipped with remote set point suffix letter M vary the remote set point pressure to change the set point Increase the pressure to increase the set point and decrease the pressure to decrease the set point Proportional Band Adjustment PB ADJ The proportional band determines the output sensitivity of the controller The proportional band adjustment is marked in percentages of process temperature required to drive the controller from zero output to full output To adjust the proportional band open the controller cover and locate the proportional band adjustment PB ADJ knob Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action To change the controller action from direct to reverse or vice versa loosen the screws on the proportional band indicator cover Lift the cover out as shown in figure 10 and rotate the proportional band adjustment to the desired action Setting the proportional band to the val
44. psig 40 psig Table 4 Available Temperature Ranges of Temperature Bulbs Element Operating CWaxmum mm 0 to 100 50to150 ERI 85 5to 75 5to 135 50 to 200 5 to 200 0 to 300 25to325 to 325 15to 150 Metric Units a 200 100 to 300 to 300 ETE 300 EX to 100 E 5010150 251020 100 to 200 75 to 300 0 to 150 50 to 200 2510225 2 p 100 to 200 100 to 275 100 to 400 25 to 400 1 Contact your Emerson Process Management sales office about other spans and ranges 175 200 U S Units Temperature Bulb Diameter Meum 76 4 3 3 3 190 a 3050 uml L EEG EXE 400 750 2 All temperature bulbs are tested to 50 percent of overrange limits With travel stops in place if the overrange limits are exceeded the controller may require recalibration 3 With travel stops in place temperatures in excess of these values may cause permanent dam age to the temperature element 4196 B and S Controllers Instruction Manual March 2012 D200299X012 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Section 2 Installation To avoid personal injury or property damage from sudden release of process pressure e Always wear protective clothing gloves and eyewear when performing any installation operations to avoid personal injury e Person
45. supply pressure to zero pressure Narrow or widen the proportional band slowly until the output switches from full supply pressure to zero pressure N O Repeat steps 4 through 6 until the controller output switches at the desired points 8 Observe the process pointer when the output switches at the upper switching point The process pointer indication should be within 2 percent of the set point indication Reverse Acting Controllers The controller output switches from zero pressure to full supply pressure when a decreasing process temperature passes the lower switching point The controller output does not return to zero pressure until an increasing process temperature passes the upper switching point When making adjustments as described in the following steps keep in mind that e Changing the set point moves both switching points equally in the direction of adjustment 54 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 e Changing the proportional band adjustment widens or narrows the differential gap between the two switching points by moving the upper switching point Figure 26 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller The following example illustrates how to use figure 26 Example The sensing element has a range of 38 C 100 F The lower switching point is to be set at 1 C 30 F and the upper swit
46. temperature change and backs the flapper away from the nozzle Pressure in the reset bellows opposes the action of the proportional bellows and slowly moves the flapper closer to the nozzle The result of this interaction is that when the process temperature changes proportional action temporarily reduces the gain of the controller for improved stability The process temperature then slowly returns to set point as pressure in both bellows equalizes via the reset action Moving the set point indicator changes the distance between the nozzle and flapper as does a change in process temperature except that when the set point is changed the nozzle moves with respect to the flapper The proportional band adjustment positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle to a position on the flapper where less input and more feedback motion occurs which decreases the gain of the controller Decreasing narrowing the proportional band moves the nozzle toward a position where more input and less feedback motion occurs which increases the gain The controller action is changed from direct to reverse by turning the proportional band adjustment to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed as shown in the flapper detail of figure 18 or 19 With the controller in the reverse acting mode an increase in process temperature causes a decr
47. the locking screw 93 4196 and S Controllers Instruction Manual March 2012 D200299X012 12 Adjust the remote set point pressure to the upper and lower limits of the the remote set point input range and make sure the set point indicator is still within 1 percent at the lower and upper limits of the process scale 13 Perform the appropriate flapper alignment procedure and if necessary the process indicator zero and span calibration procedure in Section 3 4 or 5 Remote Set Point Linearity Adjustment Adjust the linearity by loosening and repositioning the linearity adjustment screw in the curved slot on the lever arm of pivot assembly B key 115 Adjusting the linearity affects the zero and span adjustment 1 Adjust the remote set point pressure to 50 percent of the remote set point input range The set point indicator should indicate 50 1 percent of the process scale span If not make fine adjustments by loosening the zero adjustment locking screw and turning the zero adjustment screw 2 Adjust the remote set point pressure to 0 percent of the remote set point input range and note the indicator position relative to the process scale lower limit 3 Adjust the remote set point pressure to 100 percent of the remote set point input range and note the indicator position relative to the process scale upper limit 4 f the greatest misalignment is positive the set point indicator is to the right of the process scale limi
48. the nozzle and flapper as does a change in process temperature except that when the set point is changed the nozzle moves with respect to the flapper The proportional band adjustment positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle to a position on the flapper where less input and more feedback motion occurs which decreases the gain of the controller Decreasing narrowing the proportional band moves the nozzle toward a position where more 25 4196 and S Controllers Instruction Manual March 2012 D200299X012 input and less feedback motion occurs which increases the gain The controller action is changed from direct to reverse by turning the proportional band adjustment to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed as shown in the flapper detail of figure 12 With the controller in the reverse acting mode an increase in process temperature causes a decrease in output pressure Remote Set Point suffix letter M Operation The capability to adjust the controller set point from a remote location is available with all 4196A controllers This option is designated by the suffix letter M in the type number A control pressure is applied to the capsular element within the remote set point assembly The expansion and contraction of the capsule moves the set point indicator via a connecting linkage Increa
49. the pressure to increase the set point and decrease the pressure to decrease the set point Proportional Band Adjustment PB ADJ The proportional band adjusts the width of the gap between switching points To adjust the proportional band open the controller cover and locate the proportional band adjustment PB ADJ knob Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action To change the controller action from direct to reverse or vice versa loosen the screws on the proportional band indicator cover Lift the cover out as shown in figure 24 and rotate the proportional band adjustment to the desired action Setting the proportional band to the values in the white portion of the adjustment provides direct controller action setting proportional band in the black portion provides reverse controller action Figure 24 Changing Controller Action Fisher 41965 Controllers W3439 48 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 25 Fisher 4196S Controller Calibration Adjustment Locations Y o e T e s WO 15 20 25 7 PROCESS POINTER ZERO ADJUSTMENT PROCESS POINTER ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT REMOTE SET POINT REMOTE SET POINT SUFFIX LETTER M SUFFIX LETTER M ZERO ADJUSTMENT ZERO ADJUSTMENT LOCKING SCREW W639
50. the span for a low indication below the upper limit counterclockwise to decrease span for a high indication above the upper limit 7 Repeat steps 3 through 6 until the error is eliminated 8 Place the temperature bulb in the 50 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the mid scale mark 2 percent of span If the error is greater than 2 percent refer to the Maintenance section and perform the zero and span adjustment procedure 9 Adjust the process pointer to within 1 percent of the mid scale mark by loosening the zero adjustment locking screw and turning the zero adjustment screw This distributes the error over the entire scale span and brings all points within 1 percent of the process scale span Tighten the zero adjustment locking screw 10 Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize 11 The process pointer should indicate the process scale lower limit 1 percent of the scale span 12 Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize 13 The process pointer should indicate process scale upper limit 1 percent of the process scale span 14 If the error is greater that 1 percent repeat steps through 13 52 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Remote Set Point suffix letter M Zero an
51. then position a plastic washer key 22 and the proportional band adjustment knob key 25 on the set point beam assembly key 23 as shown in figure 31 2 Position the retaining clip key 26 on the three posts of the proportional band adjustment knob 3 Place the second plastic washer on the nozzle assembly Apply a suitable lubricant such as key 317 to the nozzle assembly O ring Insert the nozzle assembly key 21 through the set point beam assembly key 23 the plastic washer key 22 the proportional band adjustment knob key 25 and the retaining clip key 26 into the cap Align the nozzle with the tab on the proportional band adjustment knob shown in figure 32 make sure the proportional band adjustment knob engages the flats on the nozzle assembly Figure 32 Proportional Band Adjustment Knob Setting 68 Ys p W3761 While holding the nozzle assembly key 21 against the set point beam assembly key 23 depress the retaining clip key 26 and install the E ring key 27 into the E ring groove on the nozzle assembly key 21 Ensure that all three tabs of the E ring are engaged Inspect the O ring on the relay nozzle tubing assembly key 18 and replace it if necessary Apply a suitable lubricant to the O ring 7 Install the relay nozzle tubing assembly key 18 into the set point beam assembly 8 Set the proportional band adjustment between DIRECT and REVERSE Do this by aligning t
52. with an external gauge Ensure that itis set correctly and does not fluctuate Note the number of instruments being supplied by the regulator 1 3 Note if the pointer is bent 1 4 Inspect the element for loose screws and damaged flexures links or pivots Using a soap solution check the sensing element for leaks 1 5 Check for links bent or not connected properly flexures bent or broken pivots broken 1 6 By changing the process set point and observing the output verify that the output moves at about the same speed in both directions 1 7 The minimum relief valve setting is dependent on the loop dynamics and the controller settings If under normal load changes the relief valve opens instability can occur Check by observing the controller reaction to a set point or load change under closed loop conditions 2 1 Check with an external source 2 2 Inspect for loose screws and damaged flexures links or pivots 2 3 Using soap solution check the input element and tubing for leaks 2 4 Refer to the process indicator and remote set point if applicable zero and span calibration procedures in Section 3 4 or 5 2 5 Refer to the Flapper alignment procedures in Section 3 4 or 5 Continued 1 1 If stable control cannot be attained and all other elements of the loop are functionally correct examine other possible causes related to the controller 1 2 Correct as necessary One regulator per instrument is
53. within 1 percent but is within 2 percent of the mid scale mark then proceed with step 10 If the set point indicator is not within 2 percent proceed to the remote set point calibration procedure in the Maintenance section Loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw to correct for half the error at mid scale Tighten the zero adjustment locking screw Apply remote set point pressure equal to the lower and upper range limits and make sure the set point indicator is within 1 percent If necessary perform the process indicator zero and span calibration procedure in this section Otherwise perform the flapper alignment procedure in this section Flapper Alignment Note Perform the process indicator zero and span calibration procedure and for controllers with remote set point suffix letter M the remote set point zero and span calibration procedure before the flapper alignment Flapper leveling screw numbers and adjustments are shown in figure 11 Key number locations are shown in figure 48 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 After performing the flapper alignment procedure go to the startup procedure 1 For a controller with manual set poin
54. 0 11 12 13 14 Place the temperature bulb in the 50 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the mid scale mark 2 percent of span If the error is greater than 2 percent refer to the Maintenance section and perform the zero and span adjustment procedure Adjust the process pointer to within 1 percent of the mid scale mark by loosening the locking screw and turning the zero adjustment screw This distributes the error over the entire scale range and brings all points within 1 percent of the process scale span Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the process scale lower limit 1 percent of the scale span Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the process scale upper limit 1 percent of the process scale span If the error is greater than 1 percent repeat steps 3 through 13 Remote Set Point suffix letter M Zero and Span Calibration Refer to figures 14 and 16 for adjustment locations Refer to figures 49 and 51 for key number locations Note Any adjustment of the remote set point span adjustment screw requires readjustment of the remote set point zero adjustment screw 1 Remove the two screws key 6 and lift off the proportional
55. 02 SST 108 Key 80 83 86 87 93 99 102 103 104 105 106 107 108 109 110 111 112 114 115 116 118 99e 6 Instruction Manual D200299X012 90 O Description Diaphragm capsule 55 1 bar 12 psi span N09902 Nickel Alloy or SST 1 6 bar 24 psi span N09902 Nickel Alloy or SST Travel stop CF8 SST casting Travel stop nut 530300 Set screw hex socket 18 8 SST Union 531600 Plain washer 18 8 SST Machine screw fill hd 18 8 SST 4 req d Machine screw pan hd 18 8 SST 2 req d Remote set pt tubing ass y 530400 Pedestal ass y SST Tie bar G10100 pl steel Spring pl steel Zero adj screw 30300 Pivot screw 530300 Zero adj bracket 530400 Mounting plate G10100 pl steel Spring washer pl steel Pivot clevis ass y A plastic SST Pivot clevis ass y B plastic SST Connecting link ass y aluminum bronze brass Cap screw hex socket 18 8 SST Instruction Manual D200299X012 Figure 51 Remote Set Point Assembly Drawing 8 8 9 JAR i GAS wa E S Mie 1 H Or qu bY T 6 1k 065 3 S 8 B APPLY LUB SEALANT 36A6988 C Key Description 119 Guide flexure 530200 121 Drive bracket 530400 122 Machine screw fill hd SST 2 req d 123 Plain washer 18 8 SST 124 Hexnut 18 8 SST 125 Spacer A92011 aluminum 126 X Connecting link ass y aluminum bronze brass 134 Diaphragm
56. 032 109 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 52 Auto Manual Station Assembly Drawing 21398 38 88 SECTION EL L 275 310 Soy NT 292 277 MT AE a cm 281 lt lt 4 5595 p A SR Ora 9e eH 4 283 SECTION 284 ica Se ar 299 CIAPPLY LUB SEALANT SECTION C C 48A290 Key Description Key Description Part Number 299 Rocker A96061 aluminum 305 Switch lever cover plate aluminum chromate 300 Clip SST 306 Closing plate gasket chloroprene 18A2898X012 301 Lever spring seat SST 307 Closing plate SST 302 Leverspring A228 music wire 308 Machine screw pan hd 18 8 SST 2 req d alt desgntn K08500 pl steel 309 Continuous output tubing ass y SST 303 Groove pin SST 310 Lithium grease not furnished with controller 304 Switch lever plastic SST 311 Anti seize sealant not furnished with controller 110 Recommended spare parts Instruction Manual D200299X012 Figure 53 Internal and External Set Point Option 1 LUB ADHESIVE 56A9752 S Key Description Part Number Internal External Set Point Assembly Option figure 53 340 Bracket alloy steel pl 341 Pinion gear PPS 342 shaft PPS For int set pt ass y only 343 J Spring SST 344 E ring SST 345 Pinion rack polycarbonate 346 Machine screw rd hd 18 8 SST 347 Driv
57. 1 8 While holding the proportional band adjustment knob remove the screw and washer keys 19 and 20 that hold the relay nozzle tubing assembly key 18 to the frame 9 Remove the proportional band adjustment knob relay nozzle tubing assembly and the set point beam assembly from the controller 10 Disconnect link 2 from the flapper assembly key 11 Refer to figure 35 for the link location Figure 35 Bellows Assembly and Proportional Band Adjustment Process Scale and Proportional Band Indicator Cover Removed 1 i gt FA e A 2 B E La PROPORTIONAL BELLOWS BELLOWS BRACKET KEY 31 ADJUSTABLE SET POINT PIVOT ASSEMBLY KEY 17 SCREW AND WASHER KEYS 19 AND 20 m gt i A NS AW m jii A SW SM n LINK 4 W4199 mM LINK 2 11 Disconnect link 4 from the bellows bracket key 31 Refer to figure 35 for the link location 71 4196A B C and S Controllers Instruction Manual March 2012 D200299X012 12 Remove the two cap screws key 12 from the flexure pivot assembly key 9 See figure 36 for screw location 13 Remove the flapper assembly and link 4 as shown in figure 37 14 Remove the four machine screws key 10 shown in figure 37 that hold the flexure pivot assembly to the frame Figure 36 Leveling Screw Alignment Figure 37 Exploded View of Flexure Pivot Assembly FLAPPER LEVELING FLAPPER SCREW NUMBER 2 ASSEMBLY FL
58. 34 and 131 and remove the tubing assembly and frame gaskets keys 4 and 5 94 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 7 Inspect the gaskets keys 4 and 5 and O rings key 312 for wear Replace if necessary Assembly 1 Install the gaskets and the tubing assembly to the frame Start but do not tighten the three screws keys 34 and 131 and the nut on the nozzle tubing assembly key 18 2 Install the switch manifold O rings key 312 and secure the auto manual station to the controller frame with the screw key 316 and to the tubing assembly key 138 with two screws keys 314 and 315 Do not tighten screws CAUTION In the next step take care to tighten the two screws keys 314 and 315 evenly Uneven tightening could damage the tubing assembly UJ Position the auto manual station as far down on the frame and toward the scale as possible Carefully tighten the two screws keys 314 and 315 so that the auto manual station contacts the three pads the tubing assembly Carefully tighten the remaining screws and nuts Plug the controller output connection and apply supply pressure to the controller Check for leaks Install the controller into the case by performing steps 6 through 9 of the case and cover replacement procedure Mou Bf Perform the appropriate calibration procedure in Section 3 4 or 5 Replacing the Switch Body Assembly Lever O Ring Switch Bod
59. 4 FRONT VIEW I SCREW 1 2 SCREW 2 A SCREW 3 REMOTE SET POINT SPAN SPAN ADJUSTMENT ADJUSTMENT SUFFIX LETTER M SIDE VIEW i EL SET POINT PROCESS a INDICATOR ASSEMBLY Ek STA SIDE VIEW Re CONTROLLER SHOWING FLAPPER LEVELING SCREWS 49 4196 B and S Controllers Instruction Manual March 2012 D200299X012 Switching the Auto Manual Station suffix letter E Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 23 if the controller has the auto manual station suffix letter E To switch from automatic to manual mode or from manual to automatic you must first balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output To switch from automatic to manual mode carefully adjust the loader knob until the metal ball inside the plastic tube moves into the switching zone Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counterclockwise to decrease it To switch from manual to automatic mode adjust the set point to move the ball into the switching zone Turn the switch to AUTO and adjust the set point to control the output When the automatic manual switch is in AUTO adjusting the loader k
60. 65 Description Part Number Machine screw fill hd 18 8 SST Used to attach remote set pt ass y suffix letter M to indicator ass y key 56 Machine screw hex hd 18 8 SST Used to attach the reset valve 4196B controllers or rate reset valve 4196C controllers to the frame For 4196B and C controllers only Rate reset valve 55 for 4196C controllers only Brass bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig SST bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig Auto manual station suffix letter E Individual assembly parts are listed in the Auto Manual Station subsection of the parts list Key numbers for individual ass y parts also appear in figure 52 Lithium grease not furnished with controller Anti seize sealant not furnished with controller O ring nitrile For all types w suffix letter E auto manual station 3 req d Auto Manual Scale plastic For all types w suffix letter E auto manual station Machine screw fill hd 530400 304 SST For all types w suffix letter E auto manual station Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station Silicone based lubricant not furnished with controller Lubricant silicone sealant not furnished with controller External feedback assembly SST Spring Retaining Washer SST Washer 18 8 SST 1P8453X0022 101 4196
61. 71 C 100 and 700 F See table 4 for available ranges Minimum Span 60 C or 100 F Maximum Span 300 C or 600 F Output Signal Proportional Only Proportional Plus Reset or Proportional Plus Reset Plus Rate Range 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Differential Gap Range 0 and 1 4 bar 0 and 20 psig or 0 and 2 4 bar 0 and 35 psig Action Field reversible between direct increasing sensed temperature increases output pressure or reverse increasing sensed temperature decreases output pressure Process Scale Standard scale is matched to the range of the sensing element Optional scales available Supply and Output Connections 1 4 NPT internal Supply Pressure Requirements See table 3 Supply Pressure Medium Air or natural gas Air Supply pressure must be clean dry air that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Natural Gas Natural gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 Remote Set Point Pressures 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig continued 4196A C and S Controllers March 2012 Maximum Allowable Pressure In Closed Ve
62. 8 Troubleshooting Chart Continued Possible Cause 6 Controller will not attain full 6 4 Input element or linkage 6 4 Inspect the element for 6 4 Repair or replace parts as necessary output range failure alignment loose screws and damaged flexures links or pivots Using soap solution check the sensing element for leaks 6 5 Leak in nozzle pressure 6 5 Using soap solution check for 6 5 Replace faulty parts as necessary tubing leaks in the nozzle tubing assembly Clean outthe relay primary orifice with the cleanout wire attached to the relay to ensure the orifice is not clogged Refer to the Maintenance warning on page 59 6 6 Relay malfunction 6 6 Manually push the flapper away 6 6 If the output does not change as from the nozzle The output described remove the relay Replace pressure should be zero Cap the O rings if necessary Replace relay if nozzle The output should increase necessary rapidly to within 35 mbar 0 5 psig of the supply pressure 7 Controller remains at full output 7 1 Supply pressure too high 7 1 Check with an external pressure 7 1 Replace supply pressure regulator or gauge gauge as necessary 7 2 Output gauge not 7 2 Vary supply pressure to see if 7 2 If output gauge does not respond functioning output gauge responds replace it 7 3 Input element or linkage 7 3 Vary the process temperature 7 3 Repair or replace parts as necessary failure and observe the flapper for movement
63. Cap screw hex hd SST 2 req d for use w each pressure control block key 57 Process scale aluminum for indicator ass y key 101 Remote set pt ass y suffix letter M Individual assembly parts are listed in the Remote Set Point Assembly subsection of the parts list Key numbers for individual ass y parts also appear in figure 51 N09902 Nickel Alloy 0 8 bar 12 psi span 1 7 bar 24 psi span SST 0 8 bar 12 psi span 1 7 bar 24 psi span Machine screw fill hd 18 8 SST 4 req d to attach process and set pt indicator ass y key 56 to frame Feedback link ass y aluminum brass SST Machine screw fill hd 18 8 SST For all 4196A and B controllers 4 req d For all 4196C controllers 6 req d Blow out plug Machine screw fill hd 18 8 SST 2 req d to attach remote set pt ass y suffix letter M to indicator ass y base plate key 56 Machine screw SST 2 req d Machine screw fill hd 530400 304 SST 2 req d to attach rate reset manifold key 136 to frame manifold key 135 Frame manifold A03600 aluminum For all types except w suffix letter E auto manual station Rate reset manifold A03600 aluminum For all types except 4196C controllers Rate tubing assembly for 4196C controllers only SST aluminum Automatic manual tubing assembly SST aluminum Use w suffix letter E auto manual station only Recommended spare parts Key 140 162 262 2 3 310 311 2127 313 314 315 316 317 318 339 362 3
64. Controllers D200299X012 March 2012 Set the linearity adjustment screw in the center of the slot on the lever arm of pivot clevis assembly B key 115 See figure 46 for the linearity adjustment location Set the length of link A key 116 so the lever arms of pivot assembly A and pivot assembly B are parallel and link A is perpendicular to them 4 Setthe length of link B key 126 so the set point indicator indicates mid scale on the process scale span Replace the tie bar key 106 and install the two screws key 103 Remote Set Point Zero and Span Adjustment Note For routine remote set point zero and span calibration refer to the appropriate procedures in Section 3 4 or 5 Use the following maintenance remote set point zero and span adjustment procedure only if difficulty is encountered with the routine procedures or if nonlinearity occurs Refer to figures 45 and 46 for adjustment locations Decrease remote set point pressure to 0 percent of remote set point input range The set point indicator should indicate the lower limit of the process scale span If not loosen the adjustment screw on link A key 116 and adjustthe length so that the set point indicator points to the lower limit of the process scale Tighten the screw Make fine zero adjustments by loosening the zero adjustment locking screw key 102 and turning the zero adjustment screw key 108 Tighten the locking screw Refer to figure 46 for the
65. EXURE PIVOT FLAPPER FOUR SCREWS ASSEMBLY ASSEMBLY OBLONG HOLE IN FRAME FLEXURE PIVOT WA770 ASSEMBLY SCREWS KEY 12 W4198 15 Remove the flexure pivot assembly key 9 16 Install the replacement flexure pivot assembly with the four screws key 10 Do not tighten the screws 17 With the controller in the upright position slide the flexure pivot assembly down as far as possible and tighten the four screws key 10 18 Place the flapper assembly key 11 on the flexure pivot assembly key 9 with link 4 through the hole in the frame 19 Start the two cap screws key 12 that hold the flapper assembly key 11 to the flexure pivot assembly key 9 Do not tighten the screws 20 Align flapper leveling screw number 2 with the centerline of the oblong hole in the frame as shown in figure 36 Tighten the cap screws key 12 Note The following procedure steps 21 through 23 adjusts link 2 to ensure that it will always be in tension to eliminate possible instability due to lost motion 21 Note to which hole link 1 is connected and then disconnect link 1 from the temperature element and manually position the process pointer to the process scale upper limit Tape the pointer in this position 22 Adjust the length of link 2 by turning the adjustment screw shown in figure 38 clockwise to increase the length or counterclockwise to decrease the length so that the pin on the end of the link is approximately one half of its diam
66. Handle Kit xa y Contains lever and mounting hardware R4190X00H12 4190 Controller Controller Repair Kit Contains keys 4 5 7 8 24 52 R4190X00C12 1 Case and cover assembly 4190 Controller Pointer and Bracket Repair Kit Contains pointer and bracket 55 three machine screws three washers R4190X00P12 4196BF Anti Reset Windup Retrofit kits int or ext set pt SST tubing contains keys 44 and 55 R4190X00S22 2 Nameplate A9100 aluminum 3 Frame A03600 aluminum 4 Gasket chloroprene Pa rts List for use between frame and frame manifold key 135 18A0749X012 5 Gasket chloroprene 4196A and 4196B 1 req d 4196C 2 req d 18A0742X012 6 Machine Screw fill hd 18 8 SST 2 req d to mount the prop band ind cover to the frame 4 req d to mount bellows bracket key 31 to bellows beam key 49 2 req d to attach process scale brackets keys 376 377 to frame For use w or w o int set pt and w o remote or ext set pt For use w remote set pt and w o Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Recommended spare parts 99 4196 B C and S Controllers March 2012 Key Description Part Number 7 O Ring nitrile Used between frame and case at conns temperature bulb capillary output and supply pressure ext feedback and remote set pt conn 3 req d w o remote set pt and w o ext feedback 4 req d w remote set pt or ext feedback 5 req d w r
67. Instruction Manual D200299X012 4196A C and S Controllers Fisher 4196A B C and S Temperature Indicating Controllers Contents 1 Scope oes Specifications EISE IAE vx Vi Educational Services 22 InstalldtlOEl s std cucu as eo etre be eot Controller Mounting Orientation Pipestand Mounting Panel Mounting Wall Mounting Actuator Mounting Temperature Sensing Bulb Bushings 6 Pressure Connections Supply Pressure Connection Remote Set Point suffix letter M Pressure Connection External Feedback Pressure Connection 4196B Controllers Only VOID 25 3 4196A Proportional Only Controllers Adjustments for 4196A Controllers Manual Set Point Adjustment Remote Set Point suffix letter M Proportional Band Adjustment ADJ Changing Controller Action Switching the Auto Manual Station suffix letter E Prestartup Checks for 4196A Controllers Startup for 4196A Controllers Calibration of 4196A Controllers
68. S Controllers D200299X012 March 2012 Section 6 Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and parts replacement depends upon the severity of the service conditions When inspection or repairs are required disassemble only those parts necessary to accomplish the job Inspection and Maintenance A WARNING The following maintenance procedures require taking the controller out of service To avoid personal injury and property damage caused by uncontrolled process pressure observe the following before performing any maintenance procedures e Always wear protective clothing gloves and eyewear when performing any installation operations to avoid personal injury e Do notremove the actuator from the valve while the valve is still pressurized e Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 16 e Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere if the relay cleanout wire is used to clean the relay primary
69. SCREW LOCKWASHER KEY 362 KEY 67 BRACKET HEX NUT KEY 68 KEY 364 LOCKWASHER KEY 363 PIPE CLAMP ELBOW KEY 69 KEY 365 VERTICAL PIPE HEX HEAD CAP SCREW KEY 362 PIPE CLAMP LOCKWASHER KEY 363 KEY 69 HEX NUT KEY 364 HEX HEAD BRACKET CAP SCREW KEY 68 KEY 66 LOCKWASHER ELBOW KEY 67 KEY 365 49A3196 A HORIZONTAL PIPE Panel Mounting Using the Panel Mounting dimensions shown in figure 4 cut a hole in the panel surface Slide the controller into the hole and attach the bracket key 68 to the rear of the controller using three cap screws key 66 and washers key 67 Tighten the screws key 70 to seat the case snugly and evenly against the panel surface Wall Mounting Using the Wall Mounting dimensions in figure 5 drill holes in the wall to align with the four holes in the bracket key 68 If the tubing is to run through the wall drill a hole in the wall large enough to accept the tubing Mount the controller to the bracket using three cap screws key 66 and lock washers key 67 Attach the bracket to the wall using suitable screws or bolts Instruction Manual D200299X012 Figure 4 Panel Mounting 84 3 29 TL 63 LOCK 2 49 WASHER wee TOP VIEW HEX HEAD 13 CAP SCREW KEY 66 BRACKET KEY 68 ROUND HEAD T MACHINE 12 06 SCREW KEY 70 14 0 56 R 236 9 31 REAR VIEW DIMENSIONS OF PANEL CUTOUT mm PANEL MOUNTING INCH
70. adjustment locations Refer to figures 48 and 51 for key number locations Note Any adjustment of the remote set point span adjustment screw requires readjustment of the remote set point zero adjustment screw 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 Apply remote set point pressure equal to the lower range limit 4 The set point indicator should indicate the process scale lower limit If not loosen the remote set point zero cO Ul 22 adjustment locking screw and adjust the remote set point zero adjustment screw until the set point indicator aligns with the process scale lower limit Tighten the zero adjustment locking screw Apply remote set point pressure equal to the upper range limit he set point indicator should indicate the process scale upper limit If not adjust the remote set point span adjustment screw to correct one half the error as follows clockwise to increase span for a low indication counterclockwise to decrease span for a high indication Repeat steps 3 through 6 until the error is eliminated Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 8 Apply remote set point pressure equal to the mid range value 10 11 12 Make sure the set point indicator is within 1 percent of the mid scale mark and if so proceed to step 12 If the set point indicator is not
71. al injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 16 e If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual e Check with your process or safety engineer for any additional measures that must be taken to protect against process media Controller Mounting Orientation Mount the controller with the housing vertical as shown in figure 2 so that the vent points down Figure 2 Typical Actuator Mounting 657 Ly actuator 4196 CONTROLLER FILTER REGULATOR A MOUNTING ud P y PLATE W5661 4196 and S Controllers Instruction Manual March 2012 D200299X012 Pipestand Mountinq Refer to figure 3 Pipestand mounting parts are provided to mount the controller to a 2 inch nominal pipe Attach a bracket key 68 to the controller with cap screws key 66 and lock washers key 67 Attach two clamps key 69 to the bracket and fasten the controller to the pipe Figure 3 Pipestand Mounting HEX HEAD cap Gre ee REGULATOR KEY 66 CAP
72. ation Note When the reset valve is at 0 01 the controller is very sensitive to any process pointer movement Only a small amount of process pointer movement may be necessary 27 28 29 30 31 32 33 34 35 36 37 38 39 Very slowly move the process pointer until the output pressure stabilizes at 1 0 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output Record the process temperature indication If the difference between the recorded process temperature indications in step 26 and step 27 is larger than 1 percent of the process scale span proceed with step 29 If the difference is less than 1 percent go to step 34 Loosen the proportional bellows screw key 35 If the indication recorded in step 27 is greater than in step 26 adjust the reset gain screw key 34 one half turn in clockwise If the indication recorded in step 27 is less than in step 26 adjust the reset gain screw key 34 one half turn out counterclockwise Tighten the proportional bellows screw key 35 Repeat steps 26 through 31 until the difference is less than 1 percent of the process scale span If X1 percent of the process scale span cannot be achieved by adjusting the reset gain screw key 34 loosen the screw key 35 attaching the reset bellows and slide it to the left if the indication in step 27 is greater than in step 26 or to the right if the indication
73. ature element assembly and withdraw the capillary tube and temperature bulb through the opening in the bottom of the case 5 Thread the bulb and capillary tube of the replacement assembly into the opening and out through the bottom of the case With the assembly in position install and tighten the three screws key 127 Install the screws key 129 at the bottom of the controller case Connect link 1 key 128 to the temperature element takeoff assembly N Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing the Links This section describes the separate replacement of four links in the controller Figure 41 shows the location of each link To clarify the location of each link the links are numbered as follows e Link 1 connects the temperature element assembly and the process pointer e Link 2 connects the process pointer and the flapper assembly key 11 e Link 3 connects the set point indicator and the set point beam assembly key 23 Link 4 key 65 connects the flapper assembly and the bellows bracket key 31 Figure 41 Link Locations LINK 4 LINK 4 ADJUSTMENT LINK 1 LINK 2 LINK 2 ADJUSTMENT LINK 3 W3442 1 LINK 3 ADJUSTMENT 80 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Replacing Link 1 1 Remove the two screws key 6 and lift off the proportional band indicator c
74. band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Apply remote set point pressure equal to the lower range limit 4 The set point indicator should indicate the process scale lower limit If not loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw until the set point indicator aligns with the process scale lower limit Tighten the zero adjustment locking screw 5 Apply remote set point pressure equal to the upper range limit 6 The set point indicator should indicate the process scale upper limit If not adjust the remote set point span adjustment screw to correct one half the error as follows clockwise to increase span for a low indication counterclockwise to decrease span for a high indication 7 Repeat steps 3 through 6 until the error is eliminated Adjust the remote set point pressure to the mid range value Make sure the set point indicator is within 1 percent of the mid scale mark and if so proceed to step 12 If the set point indicator is not within 1 percent but is within 2 percent of the mid scale mark proceed with step 10 If the set point indicator is not within 2 percent proceed to the remote set point zero and span adjustment procedure in the Maintenance section 35 4196 B and S Controllers Instruction Manual March 2012 D200299X012 10 Loosen the remote set point zero adjustment locking screw and
75. bly set point beam assembly and the relay nozzle tubing assembly as a unit to center the nozzle on the flapper After centering the nozzle tighten the two machine screws Turn the proportional band adjustment knob to 5 percent DIRECT Refer to figure 34 to locate the locking nut on the adjustable set point pivot assembly Loosen the locking nut and back out the set screw slightly so that the set point beam assembly falls under its own weight when pivoted upward Also maintain a minimum side play between the adjustable set point pivot assembly and the nozzle tubing assembly Tighten the locking nut At the frame manifold key 135 tighten the nut that secures the tubing from the relay nozzle tubing assembly key 18 Apply full supply pressure with the nozzle capped and check for leaks Remove supply pressure Install the set point beam bias spring key 28 into the frame bore and onto the spring seat on the set point beam assembly Figure 33 Nozzle Flapper Positioning Figure 34 Adjustable Set Point Pivot Assembly Locking Nut Location LOCKING ADJUSTABLE SET POINT NUT PIVOT ASSEMBLY qn 2 SCREW AND WASHER SCREW AND WASHER KEYS 19 AND 20 Z KEYS 19 AND 20 lt NOTES L1 SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY 2 gt SCREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY W4195 FLAPPER NOZZLE W3449 69 4196 and S Controllers Instruction Manual March 2012 D200299X012 18
76. by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 Note Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment Refer to figures 14 and 16 for adjustment locations 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 34 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize he process pointer should indicate the process scale lower limit If not adjust the process pointer to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the process scale upper limit If not adjust the span screw to correct one half the error as follows clockwise to increase the span for a low indication below the upper limit counterclockwise to decrease span for a high indication above the upper limit 7 Repeat steps 3 through 6 until the error is eliminated 1
77. calibration procedure in Section 3 4 or 5 Replacing Link 2 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 2 from the process pointer and from the flapper assembly key 11 Remove the link 81 4196 and S Controllers Instruction Manual March 2012 D200299X012 Install the replacement link with the screw head nearest the process pointer as shown in figure 41 Connect the link to the process pointer only The process pointer should be aligned with the pointer subassembly as shown in figure 42 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the pointer with the process pointer subassembly Tighten the zero adjustment locking screw Move the set point indicator manually or with remote set point pressure to the process scale lower limit and set the proportional band to 5 percent REVERSE The nozzle should not be touching the flapper If it is adjust flapper leveling screw 1 the screw nearest the nozzle until clearance is obtained Note the hole position and disconnect link 1 from the temperature element assembly Manually position the process pointer to the process scale upper limit and tape the process pointer in this position Adjust the length of link 2 by turning the adjusting screw clockwise to increase the length or counterclockwise to decrease the length so that the pin on th
78. ching point is to be set at 27 C 80 F Proceed as follows e Divide the differential gap the difference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap x 100 509F 109C Sensing Element Range ToosE ggoc 100 50 e Locate the 50 percent line on figure 26 Move along this line until you intersect the curve Read the proportional band setting on the left hand axis For this example the setting is approximately 35 percent 1 Using the curve in figure 26 determine the correct proportional band setting for the desired gap expressed as a percent of the maximum input element span between the switching points Setthe proportional band to the desired setting determined in step 1 Adjust the set point to the lower desired switching point Decrease the process temperature until the controller output switches from zero pressure to full supply pressure BR UJ N Increase the process temperature to the desired switching point at which the controller output switches from full supply pressure to zero pressure Narrow or widen the proportional band slowly until the output switches from full supply pressure to zero pressure N OC Repeat steps 4 through 6 until the controller output switches at the desired points 8 Observe the process pointer when the output switches at the lower switching point The process p
79. controller action and replace the proportional band indicator cover Principle of Operation for 4196A Controllers Overall Operation Refer to the schematic diagram in figure 12 The input element is connected to the process pointer and to the flapper by connecting links As the process temperature increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the proportional bellows The action of the proportional bellows counteracts the flapper movement that resulted from the process temperature change and backs the flapper away from the nozzle until equilibrium is reached Figure 12 Fisher 4196A Controller Schematic REVERSE ACTION QUADRANT SET POINT INDICATOR RESET BELLOWS VENTED PLC PROPORTIONAL A PROCESS POINTER REMOTE SET ponr NC CONNECTED HERE S INPUT ELEMENT PROPORTIONAL BAND ADJUSTMENT FEEDBACK LINK 2 FEEDBACK IN 22 FLAPPER PIVOT 1 CONNECTED HERE INPUT CONNECTING MOTION LINK FLAPPER DETAIL BEAM OUTPUT PRESSURE TO FINAL CONTROL 97 ELEMENT FLAPPER 2 feed SUPPLY PRESSURE NOCERE 2 RELAY xera OUTPUT PRESSURE SUPPLY PROPORTIONAL PRESSURE PRESSURE NOZZLE PRESSURE 46A9764 A B1489 2 Moving the set point indicator changes the distance between
80. controllers only to OFF 3 Fora controller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point adjust the remote set point pressure until the set point indicator is at the mid scale mark of the process scale 4 Setthe proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements 5 Referto figure 16 for the location of the anti reset windup differential relief valve For the differential relief valve to relieve on rising controller output pressure install the valve so the arrow on the valve points down To change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall the valve with the arrow pointing down Tighten the two mounting screws 39 4196 and S Controllers Instruction Manual March 2012 D200299X012 6 Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 Note Because of the high controller gain with the reset adjustment at 0 01 minutes per repeat the controller output will not balance perfectly in the following step If the controller output is stable for approximately 5 seconds it is adequately balanced 7 Increase the process temperature to the controller until the controller output pressure balances at 0 4 bar 6 psig for a 0 2 to 1 0 bar 3 to 15 psig output range or 0 8 bar 12 ps
81. d Span Calibration Refer to figures 23 and 25 for adjustment locations Refer to figures 48 and 51 for key number locations Note Any adjustment of the remote set point span adjustment screw will require readjustment of the remote set point zero adjustment screw 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Apply remote set point pressure equal to the lower range limit 4 The set point indicator should indicate the process scale lower limit If not loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw until the set point indicator aligns with the process scale lower limit Tighten the zero adjustment locking screw 5 Apply remote set point pressure equal to the upper range limit 6 The set point indicator should indicate the process scale upper limit If not adjust the remote set point span adjustment screw to correct one half the error as follows clockwise to increase span for a low indication counterclockwise to decrease span for a high indication 7 Repeat steps 3 through 6 until the error is eliminated 8 Apply remote set point pressure equal to the mid range value 9 Make sure the set point indicator is within 1 percent of the mid scale mark and if so proceed to step 12 If the set point indicator is not within 1 percent but is within 2 percent of the mid scal
82. djustment and set point beam Unless otherwise noted refer to this figure while performing the following procedures Disassembly 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 See figure 48 for parts location 3 Disconnect link 3 from the set point beam shoe part of the set point beam assembly key 23 Remove the set point beam bias spring key 28 5 Remove the screw and washer keys 19 and 20 that hold the adjustable set point pivot assembly key 17 to the 10 11 12 13 66 frame and remove the pivot assembly Unscrew the nut that secures the relay nozzle tubing assembly key 18 to the frame manifold key 135 While holding the proportional band adjustment knob remove the screw and washer keys 19 and 20 that hold the relay nozzle tubing assembly key 18 to the frame Remove the proportional band adjustment knob relay nozzle tubing assembly and the set point beam assembly from the controller Remove the relay nozzle tubing assembly key 18 from the set point beam assembly key 23 Remove the E ring key 27 from the nozzle assembly key 21 Remove the nozzle assembly key 21 and plastic washer key 22 from the bottom of the set point beam assembly key 23 Remove the retaining clip key 26 Rem
83. e upper loader assembly key 282 3 Position the ball key 279 the tube key 278 and the ball seats key 280 between the ears of the loader assemblies keys 282 and 274 position the diaphragm assembly key 281 between the main halves of the loader assemblies Note The tube key 278 must be well seated in the cups of the ball seats key 280 4 Boltthe loader assembly halves together using the four screws key 289 CAUTION Be sure that the supply and exhaust seats of the loader are correctly aligned Misalignment will impair loader performance 5 Attach the tubing assembly key 309 6 Perform the assembly procedure in the replacing the auto manual station procedure Replacing the Loader Valve Plug and Valve Plug Spring Refer to figure 52 for key number location 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 2 Loosen the spring seat screw key 275 3 Remove the valve plug spring key 276 and the valve plug key 277 4 Inspect the parts and replace as necessary 5 Install the valve plug spring and valve plug 97 4196 and S Controllers Instruction Manual March 2012 D200299X012 6 Tighten the spring seat screw 7 Temporarily plug the controller output connection apply supply pressure and check for leaks 8 Install the controller into the case by performing steps 6 through 9 of the case and cover replacement proc
84. e coupler polycarbonate For ext set pt ass y only 348 Flexible drive polycarbonate For ext set pt ass y only 349 O ring nitrile For ext set pt ass y only 350 Knob plastic For ext set pt ass y only 351 Knob insert aluminum For int set pt ass y only 352 Spring SST For ext set pt ass y only 353 Machine screw pan head 18 8 SST 354 Adhesive vinyl For int set pt ass y only not furnished with controller 355 Lubricant silicone For ext set pt ass y only not furnished with controller 356 Rack support alloy steel pl 15A1283X012 Recommended spare parts AZ 2 5d HN e OR 356 4196A B C and S Controllers March 2012 354 355 351 42 34 350 52 549 343 a i AN amp amp SECTION N N SECTION N N INTERNAL SET EXTERNAL SET Key Description Part Number Controller Mounting Parts Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Note Contact your Emerson Process Management sales office for any additional parts required for controller mounting Pipestand Mounting figure 3 66 Capscrew hex hd pl steel 3 req d 67 Lock washer pl steel 7 req d 68 Bracket pl steel 69 pl steel 2 req d Pipestand Mounting with Regulator figure 3 66 Capscrew hex hd pl steel 3 req d 67 Lock washer pl steel 7 req d 68 Bracket pl steel 69 pl steel
85. e end of the link is approximately one half of its diameter short of aligning with the hole in the flapper assembly as shown in figure 39 This adjustment provides the proper tension on the link to eliminate lost motion 8 Connect link 2 to the flapper assembly 9 Remove the tape from the process pointer and reconnect link 1 to the hole in the temperature element assembly 10 noted in step 6 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Link 3 gt WN Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link 3 from the set point indicator assembly and the set point beam assembly key 23 Adjust the replacement link to the same length as the link removed Install the replacement link with the screw head toward the set point beam assembly as shown in figure 41 Check that the set point beam bias spring key 28 is correctly located in the frame bore and the spring seat on the set point beam assembly as shown in figure 31 Move the set point indicator to the mid scale mark on the process scale 7 Disconnect link number 1 from the temperature element assembly and tape the process pointer at the mid scale 10 11 12 13 14 82 mark on the process scale Adjust the proportional band to 5 percent DIRECT Turn flapper leveling screw 3
86. e mark then proceed with step 10 If the set point indicator is not within 2 percent proceed to the remote set point calibration procedure in the Maintenance section 10 Loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw to correct for half the error at mid scale Tighten the zero adjustment locking screw 11 Apply remote set point pressure equal to the lower and upper range limits and make sure the set point indicator is within 1 percent 12 If necessary perform the process indicator zero and span calibration procedure in this section Setting Switching Points Direct Acting Controllers The controller output switches from zero pressure to full supply pressure when an increasing process temperature passes the upper switching point The controller output does not return to zero pressure until a decreasing process temperature passes the lower switching point When making adjustments as described in the following steps keep in mind that e Changing the set point moves both switching points equally in the direction of adjustment e Changing the proportional band adjustment widens or narrows the differential gap between the two switching points by moving the lower switching point Figure 26 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller The following example illustrates how to use figure 26
87. eaking 4 3 With reset valve positioned at 0 01 minutes repeat put 15 psig 1 0 bar to the output port Using soap solution check for leaks in the reset bellows and attached tubing assembly 5 1 Inspect the flapper 5 2 Refer to flapper alignment procedures in Section 3 4 or 5 6 1 Measure the output with an external pressure gauge 6 2 Check with an external source 6 3 Adjust proportional band setting to 10 Manually cap the nozzle Output should increase Continued 4196A C and S Controllers March 2012 Possible Cause 2 6 Repair as necessary 2 7 Replace the reset valve 2 8 Repair or replace parts as necessary 2 9 Replace input element and adjust travel stops 3 1 Adjust as necessary 4 1 If reset action returns no further action is necessary If not replace the reset valve 4196B controllers or the rate reset valve 4196C controllers 4 2 Replace the reset valve 4196B controllers or the rate reset valve 4196C controllers 4 3 Repair or replace parts as necessary 5 1 Clean or replace flapper as necessary 5 2 Align flapper as necessary 6 1 Replace the gauge if it is defective 6 2 Repair or replace the supply pressure regulator if necessary Replace the supply pressure gauge if necessary 6 3 Use a narrower proportional band setting decrease the proportional band setting 61 4196 and S Controllers Instruction Manual March 2012 D200299X012 Table
88. ease in output pressure 41 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 18 Fisher 4196B Controller Schematic SET POINT INDICATOR RESET BELLOWS REVERSE ACTION QUADRANT PROPORTIONAL BELLOWS PROPORTIONAL BAND ADJUSTMENT FEEDBACK PROCESS POINTER LINK REMOTE SET POINT CONNECTED HERE FEEDBACK X INPUT ELEMENT MOTION FLAPPER CONNECTED HERE PIVOT CONNECTING DIRECT ACTION LINK QUADRANT INPUT MOTION FLAPPER DETAIL BEAM TN OUTPUT PRESSURE 90 ac TOFINALCONTROL 2 ELEMENT FLAPPER 2 221 n RELAY SUPPLY PRESSURE TO RESET BELLOWS NOZZLE PROPORTIONAL PLUS RESET CONTROL OUTPUT SUPPLY PRESSURE PROPORTIONAL BELLOWS WY OUTPUT PRESSURE NOZZLE PRESSURE OO B RESET PRESSURE SUPPLY PRESSURE DIFFERENTIAL RELIEF VALVE 46A9764 C B1908 4 PROPORTIONAL PLUS RESET CONTROL WITH ANTI RESET WINDUP A 4196C controller also has a rate valve as shown in figure 19 and 20 This valve is an adjustable restriction that momentarily increases the controller gain to accelerate the corrective action for slow responding systems A proportional plus reset plus rate controller responds to a change in process temperature as follows e First the rate action delays the proportional action just long enough to allow the controller to respond to the change quickly with high gain but not long enough for the high gain to cause
89. edure 9 Mount the controller as described in the Installation section 10 Connectthe external piping to the controller and install the temperature bulb in the process fluid 98 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Section Parts Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the controller serial number When ordering replacement parts refer to the 11 character part number of each required part as found in the following parts list A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Parts Kits Controller Common Parts figure 48 Description Part Number Key Description Part Number 4190 Controller Auto Manual Repair Kit Contains keys 277 278 279 281 292 293 294 298 306 and 312 4190 0 12 4190 Controller Auto Manual Retrofit Kit SST tubing Contains keys 138 273 312 313 Note Figure 48 shows key numbers for the 4196A 4196B and 4196C controllers Figure 48 continues over several pages Be sure to check all ou ages to find the key numbers 4190 Controller Case
90. embly first put the spring washer key 112 on the screw key 109 Then insert the screw through the replacement pivot assembly and into the mounting plate and tighten Install the mounting screw key 102 and tighten Connect the quide flexure key 119 to the top of the replacement pivot assembly with the screw key 122 washer key 123 and nut key 124 as it was before The guide flexure should be straight and horizontal as shown in figure 46 If not loosen the screws key 122 and retighten to eliminate any bowing Loosen the screws key 139 and raise or lower the pedestal assembly key 105 to get the link horizontal Retighten the screws key 139 and ensure the diaphragm assembly extension key 134 is centered in the upper travel stop key 83 hole Apply remote set point pressure equal to 50 percent of the remote set point input range Note See figure 47 The adjustment arm of the remote set point pivot assembly A turns on a bushing at each end of the shaft supporting the adjustment arm In the next step position the shaft so both bushings float inside the bearings and do not rest against the end of either bearing Figure 47 Cutaway of Long Pivot Clevis Assembly 11 END BUSHING ADJUSTMENT ARM SHAFT 1 END BUSHING BEARING NOTES 1 BEFORE TIGHTENING THE DRIVE FLEXURE MOUNTING SCREWS POSITION THE SHAFT SO THE END BUSHINGS FLOAT IN THE BEARINGS 26A9784 E A5682 Connect the drive flex
91. emote set pt and ext feedback 1 376206992 8 O Ring nitrile 3 req d Used between frame and case on mounting bosses extending from the frame through the back of the case 3 req d 16A6903X012 9 Flexure pivot assembly sapphire SST 10 Machine screw fill hd 18 8 SST Used to attach the flexure pivot ass y key 9 to the frame 4 req d 11 Flapper ass y 29A9518X012 12 Cap screw hex socket 18 8 SST For flapper ass y key 11 2 req d 17 Adjustable set pt pivot ass y SST 18 Relay nozzle tubing SST 19 Machine screw fill hd 18 8 SST 1 req d to attach adjustable set pt pivot ass y key 17 to frame 1 req d to attach relay nozzle tubing ass y key 18 to frame 20 Plain washer 18 8 SST Used w key 19 2 req d 21 Nozzle ass y SST 22 Washer plastic 1 req d 23 Set pt beam 55 aluminum SST 24 O ring nitrile 1 req d for nozzle tubing ass y key 18 1 req d for nozzle ass y key 21 1E222606992 25 Proportional band knob polycarbonate 26 Retaining clip 530200 302 SST 27 Ering SST 28 Set pt beam bias spring pl steel 29 Set pt beam shoe G10100 pl steel 30 screw hex socket 18 8 SST Used w key 29 2 req d 31 Bellows bracket A95052 aluminum 32 Bellows adj bracket G10100 pl steel 33 Bellows adj spring pl steel 34 Machine screw fill hd 18 8 SST Used to attach frame manifold key 135 to frame and for reset gain adjustment 2 req d 35 Machine screw hex hd 18 8 SST Used to attach bellows bracket
92. eter short of aligning with the hole in the flapper assembly as shown in figure 39 23 Connect link 2 to the flapper assembly 72 Instruction Manual 4196A B C and S Controllers March 2012 D200299X012 Figure 38 Link 2 and 4 Adjustment Locations LINK 4 LINK 4 ADJUSTMENT LINK 2 LINK 2 ADJUSTMENT W3442 1 LINK 3 Figure 39 Link 2 Adjustment LEVELING SCREW NUMBER 1 CONNECTING TAB ON FLAPPER ASSEMBLY X LI cing E 3 Li NM T gt 1 lt 12 0F PIN DIAMETER W3451 24 Set the proportional band between DIRECT and REVERSE Do this by aligning the tab on the proportional band adjustment knob with the hole in the set point beam assembly as shown in figure 32 25 Position the proportional band adjustment knob nozzle assembly set point beam assembly and nozzle tubing assembly on the frame and screw the relay nozzle tubing assembly nut loosely onto the frame manifold key 135 26 Insert the machine screw with plain washer keys 19 and 20 through the frame and start it into the relay nozzle tubing assembly key 18 but do not tighten 73 4196 and S Controllers Instruction Manual March 2012 D200299X012 27 Center the nozzle on the flapper as shown in figure 33 while squeezing the set point beam assembly firmly against the relay nozzle tubing assembly With the nozzle centered on the flapper tighten the machine screw key 19
93. ey 51 2 req d Reset restriction valve 4196B controllers only Differential relief valve For all 4196B C controllers w suffix letter F anti reset windup 1C853806992 Process and set pt indicator ass y w temperature element ass y aluminum stainless steel Individual indicator ass y parts are listed in two subsections of this parts list the Process and Set Point Indicator Assembly key 56 subsection and the Indicator Assembly key 101 subsection Key numbers for individual indicator parts also appear in figures 49 and 50 Pressure control block CF8M 316 SST casting 1 req d w remote set pt 2 req d w remote set pt and external feedback Recommended spare parts Instruction Manual D200299X012 Key 46 Pressure Gauge RANGE 4196A C and S Controllers March 2012 GAUGE MATERIAL Dual Scale Gauge 0 to 2 kg cm2 0 to 30 psig 0 to 4 kg cm2 0 to 60 psig 11B8577X042 11B8577X052 11B8583X032 Triple Scale Gauge 0 to 2 bar 0 to 200 kPa 0 to 30 psig 0 to 4 bar 0 to 400 kPa 0 to 60 psig 11B8577X012 11B8577X022 11B8583X012 11B8583X022 1 One type of pressure gauge is used for both output pressure and supply pressure indication Key 58 61 62 64 65 7 1 72 120 129 131 135 136 137 138 Description Cap screw hex hd SST 2 req d for use w each pressure control block key 57 Process scale aluminum for indicator ass y key 101 Remote
94. f input span above the process pointer 5 Adjustthe proportional band for 5 percent DIRECT 4196 and S Controllers Instruction Manual March 2012 D200299X012 6 The process pointer should read ambient temperature 1 percent of span Be sure that the bulb is exposed to air only and is not resting against the floor test bench or other surface 7 The controller output pressure should be 0 bar 0 psig 8 Rotate the proportional band to 5 percent REVERSE 9 The controller output should be within 0 14 bar 2 psig of the supply pressure 10 If the controller output is within tolerance adjust the proportional band to 400 percent in the desired action secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the 41964 calibration procedure for recalibration Startup for 4196A Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure Note When performing the startup procedures keep in mind that the initial settings are guidelines They will vary depending on the actual process being controlled 1 Besure the supply pressure requlator is delivering the proper supply pressure to the controller 2 For controllers with Manual set point Move the set point indicator to the desired set point Remote set point a See figure 8 for the location of t
95. ffix letter F Operation Anti reset windup is available on all 4196B C controllers and is designated by the letter F in the type number The differential relief valve operates when the difference between proportional bellows pressure and reset bellows pressure reaches a predetermined value Anti reset windup reduces overshoot of the process temperature that can result from large or prolonged deviation from set point Remote Set Point suffix letter M Operation The capability to adjust the controller set point from a remote location is available with all 4196B and C controllers This option is designated by the suffix letter M in the type number A control pressure is applied to the capsular element within the remote set point assembly The expansion and contraction of the capsule moves the set point indicator via connecting linkage Increasing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces the set point setting Auto Manual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in figure 21 Supply pressure to the relay is also applied to the manual loader The manual loader functioning as a regulator applies pressure to one side of the plastic tube and to the auto manual switch Output pressure from the relay registers on the other side of the p
96. fix letter E oe e eem oh ev rnv es 94 Replacing the Auto Manual Station 94 Replacing the Switch Body Assembly Lever O Ring Switch Body O Ring and Tubing Assembly 95 Replacing the Loader Range Spring Diaphragm Assembly Ball Seat Tubimg and Ball 96 Replacing the Loader Valve Plug and Valve Plug Spring 97 V jg m PEE 99 Parts Ordering 99 Parts E EE REA 99 EISE 99 Controller Common Parts 99 Process and Set Point Indicator ASSeITIDIV 5554 RAYS 107 Indicator Assembly 107 Remote Set Point Assembly suffix letter 108 Auto Manual Station suffix letter E 109 Internal External Set Point Assembly 111 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 1 Fisher 4196 Temperature Controllers NAMEPLATE INTERIOR OF CONTROLLER Regulator Mounting Parts 112 Contents cont d Regulator Mounting Parts for Controller Mounting 111 Casing Mounted Regulator 112 Pipestand Mounting 111 Regulator Mounting Parts for Pipestand Mounting with Regulator Stk ea eked 111 Yoke Mounted Regulator Mounting Panel Mounting 112 Bracket Not Required 112
97. g Tighten the drive flexure screws to hold the pivot shaft in that position Do not bend or twist the flexure when tightening the screws 4 Decrease the remote set point pressure to 0 bar 0 psig 5 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing the Remote Set Point Tubing 1 Decrease the remote set point pressure to 0 bar 0 psig 90 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 2 Using two 5 16 inch open end wrenches disconnect the pressure connection union key 93 from the pedestal assembly key 105 and the connection to the case exterior at the top of the case 3 Remove the tubing key 104 4 Install the replacement tubing and reconnect the two pressure connections 5 Apply full remote set point pressure and check for leaks Replacing Link A This procedure describes link A key 116 replacement in the input portion of the remote set point assembly Figure 46 shows the link location 1 Note the holes where link A is connected Disconnect link A key 116 from the lever arms on pivot assembly A and pivot assembly B 2 Loosen the screw in the replacement link A and adjust the length to match the link being replaced Tighten the screw 3 Refer to figure 46 for the correct link orientation Attach the replacement link A to the two lever
98. g these instructions contact your Emerson Process Management sales office before proceeding Description The controllers described in this manual provide temperature control with options as shown in table 1 e 4196A Proportional only control e 4196B Proportional plus reset control e 4196C Proportional plus reset plus rate control e 41965 Differential gap control These controllers show process temperature and set point on an easy to read process scale The controller output is a pneumatic signal that operates a final control element Specifications Specifications for the 4196A B and S controllers are listed in table 1 WARNING This product is intended for a specific range of pressure temperatures and other application specifications Applying different pressure temperature and other service conditions could result in malfunction of the product property damage or personal injury Educational Services For information on available courses for 4196 temperature indicating controllers as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 301 S 1st Ave Marshalltown IA 50158 2823 Phone 800 338 8158 or Phone 641 754 3771 FAX 641 754 3431 e mail education emerson com Instruction Manual D200299X012 Table 1 Specifications Available Configurations See table 2 Process Sensor Range Input Signal Type Temperature between 73 and 3
99. gnment procedure If the error is greater the 1 percent but less than 2 percent correct for half of the error with the zero adjustment screw 19 Immerse the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize 20 The process pointer should indicate the process scale lower limit 1 percent of scale span 21 Immerse the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize 22 The process pointer should indicate the process scale upper limit 1 percent of process scale range 23 If the error is greater than 1 percent repeat steps 9 through 22 24 Perform the flapper alignment procedure and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Remote Set Point suffix letter M Maintenance A WARNING Refer to the Maintenance WARNING on page 59 Replacing the Remote Set Point Assembly Use the following procedures to replace the remote set point assembly Figure 46 shows the parts locations Refer to figure 51 for key number locations Note Remove the supply pressure gauge before attempting to remove the remote set point assembly Decrease the remote set point pressure to 0 bar 0 psig Remove the supply pressure gauge Disconnect the union key 93 from the pedestal assembly key 105 Disconnect link B key 126 from the connecting hole on the set point indicator Remove the
100. h the auto manual switch and becomes the controller output When the auto manual switch is in the AUTO position the relay output is channelled through the switch to become the controller output Before the auto manual switch is operated the relay output must equal the manual loader output to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side When the pressures are equal the metal ball is centered in the tube and is held in place by a small magnet A pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube Figure 28 Fisher 41965 Auto Manual Station Schematic MANUAL LOADER TER n fics tiem os AUTO MANUAL qf 7 a SWITCH KT AUTOMATIC POSITION MANUAL LOADER KNOB II LES sna FE pn eti GE Sina nc E OUTPUT PRESSURE TO FINAL CONTROL SE ELEMENT E R208 MANUAL RELAY E POSITION B N AUTO MANUAL SUPPLY SWITCH PRESSURE OUTPUT PRESSURE ETT TO FINAL CONTROL RELAY OUTPUT PRESSURE reale RE SUPPLY PRESSURE J MANUAL LOADER OUTPUT PRESSURE 48A5230 A A2999 1 57 4196 B C and S Controllers March 2012 58 Instruction Manual D200299X012 Instruction Manual 4196A B C and
101. he 41965 controllers are in Section 5 If difficulty is encountered performing the calibration procedures in Sections 3 4 or 5 refer to the calibration procedures in this section Some procedures require temperature baths Please refer to the appropriate calibration procedure for information on temperature baths 59 4196 B C and S Controllers March 2012 Troubleshooting Instruction Manual D200299X012 As an aid to troubleshooting table 8 lists some common operating faults their probable cause and suggests procedures for correcting the fault Table 8 Troubleshooting Chart 1 Process wanders or cycles about set point 2 Controlling off set point as reflected by process and set point indicators Note Some offset is inherent with proportional only controllers 4196A controllers The amount of offset is a function of the proportional band setting 60 1 1 Proportional band and reset settings 1 2 Supply pressure varying 1 3 Process pointer rubbing on cover or scale 1 4 Input element failure 1 5 Linkage failure 1 6 Relay malfunction 1 7 Anti Reset Windup differential relief valve set too low suffix letter F only 2 1 Supply pressure not set correctly 2 2 Linkage not connected correctly 2 3 Leak in input element tubing assembly 2 4 Indicators out of calibration 2 5 Flapper not aligned 1 1 Refer to the Start up section for controller settings 1 2 Monitor the supply pressure
102. he remote set point assembly Aligning the Flexures 1 Apply remote set point pressure input equal to 50 percent of the remote set point input range 91 4196 and S Controllers Instruction Manual March 2012 D200299X012 2 The guide flexure key 119 should be straight and horizontal If not straighten the flexure by loosening the machine screw key 122 on the end of the flexure that is attached to the top of pivot assembly A key 114 and allow the flexure to straighten itself Tighten the machine screw 3 If the flexure is not horizontal loosen the two machine screws key 139 and raise or lower the pedestal assembly key 105 until the guide flexure is horizontal Retighten the machine screws key 139 and ensure the diaphragm assembly extension key 134 is centered in the upper travel stop key 83 hole 4 The drive flexure key 79 should be straight It not proceed as follows a Loosen the screw key 118 on the adjustment arm of pivot assembly A key 114 and loosen the screws holding the drive flexure b Setthe length of the adjustment arm so that the drive flexure is parallel to the centerline of the diaphragm capsule assembly key 80 c Tighten the screw key 118 on the adjustment arm Note See figure 47 The adjustment arm of the remote set point pivot assembly A turns on a bushing at each end of the shaft supporting the adjustment arm In the next step position the shaft so both bushings float
103. he remote set point connection Connect an adjustable pressure source to the remote set point connection b Adjust the pressure source until the set point indicator reaches the desired set point Remember Increasing the remote set point pressure increases the set point 3 Determine the initial proportional band setting in percent from the following equation 200 x Allowable Overshoot m Temperature Span For example 200 x 10 F _ 10046 49 4 If the controller is used in conjunction with a control valve slowly open the upstream downstream manual control valves in the pipeline and close the manual bypass valve if one is used 5 Create a load upset by momentarily changing the set point Check for system cycling If the system does not cycle lower the proportional band setting thus raising the gain and disturb the system again by changing the set point Continue this procedure until the system cycles At this point double the proportional band setting proportional band setting x 2 6 Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring the process 20 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Calibration of 4196A Controllers To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given in this manual General Calibration Instructions Note If the cont
104. he tab on the proportional band adjustment knob with the hole in the set point beam assembly as shown in figure 32 Position the proportional band adjustment knob relay nozzle tubing assembly and the set point beam assembly on the frame Screw the relay nozzle tubing nut loosely into the frame manifold Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 10 11 12 13 14 15 16 Insert the machine screw with plain washer keys 19 and 20 through the frame and start it into the relay nozzle tubing assembly key 18 but do not tighten Center the nozzle on the flapper as shown in figure 33 while squeezing the set point beam assembly firmly against the relay nozzle tubing assembly With the nozzle centered on the flapper tighten the machine screw key 19 Ensure that the nozzle is still centered on the flapper Insert the pivot of the adjustable set point pivot assembly key 17 into the hole in the set point beam assembly key 23 Insert the screw with washer keys 19 and 20 through the frame key 3 and start it into the adjustable set point pivot assembly key 17 but do not tighten Squeeze the adjustable set point pivot assembly against the set point beam assembly Check to be sure the nozzle is still centered on the flapper and tighten the machine screw key 19 If necessary loosen both machine screws key 19 to allow slightly moving the adjustable set point pivot assem
105. ig for a 0 4 to 2 0 bar 6 to 30 psig output range 8 Turn the reset adjustment to the CLOSED 4196B controllers or OFF 4196C controllers position 9 Increase the controller output pressure in small steps approximately 0 04 bar 0 5 psig by changing the process temperature or by changing the controller set point After each change in temperature or set point the controller output pressure should quickly change and then stabilize at the new value 10 Continue to change the controller output pressure in 0 04 bar 0 5 psi steps and check the output pressure after each step to make sure it stabilizes At some point the controller output will start to ramp upward to supply pressure with no further change to the controller input or set point Record the controller output pressure where this ramping action begins because this is the point at which the differential relief valve has relieved 11 To obtain the differential relief valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 12 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential pressure by turning the differential relief valve adjustment screw shown in figure 16 Turn the screw clockwise to decrease the differential pressure or counterclockwise to increase the differential pressure The differential relief valve is set a
106. in step 27 is less than in step 26 Tighten the screw and repeat steps 26 through 32 Remove the supply pressure and the output measurement device Reconnect link 1 to the temperature element Be sure to connect link 1 in the same hole noted in step 25 Install the controller into the case by performing steps 6 through 9 of the case and cover replacement procedure Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid 77 4196 and S Controllers Instruction Manual March 2012 D200299X012 Replacing the Reset Restriction Valve 4196B Controller Refer to the 4196B portion of figure 48 for key number locations 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 2 Remove the reset valve tubing assembly key 42 from the reset restriction valve key 54 3 Remove the reset tubing assembly key 43 from the reset restriction valve 4 For controllers with anti reset windup suffix letter F remove the relief valve tubing assembly key 44 from the reset restriction valve 5 Remove the screw key 162 that fastens the reset restriction valve to the frame 6 Install the replacement reset restriction valve a
107. ing key 298 12 Inspect the O ring and gaskets for damage or wear replace if necessary Assembly 1 Insert the lever assembly key 297 into the switch body assembly key 291 and hold the rocker key 299 with the flats on the lever assembly shaft 2 Insert the clip key 300 in the groove of the lever assembly shaft to hold the lever assembly key 297 in the switch body assembly key 291 3 Position the closing plate gasket key 306 and the closing plate key 307 Secure with two screws key 308 Note After assembly in step 3 be sure the side of the closing plate marked OUT is visible 4 Place the balls key 296 switch body springs key 295 and O rings keys 292 293 and 294 in the switch body assembly key 291 Note In the following step the ends of the springs must be in the counterbored spring seats before compression 5 Compress the switch body springs with the loader assembly key 282 and bolt the switch body assembly key 291 to the loader assembly using the two screws key 290 6 Reconnect the tubing assembly key 309 7 Locate the lever spring key 302 and the spring seat key 301 on the switch lever key 304 and position these parts in the opening of the loader assembly key 282 8 Push the switch lever down using the lever spring seat key 301 and the lever assembly key 297 to preload the spring Make sure the notch of the switch lever engages the pin of the lever assembly 9 Drive i
108. l into the switching zone Turn the switch to AUTO and move the set point to control the output When the auto manual switch is in AUTO adjusting the loader knob has no effect on the controller output When the auto manual switch is in MANUAL changing the set point has no effect on the controller output Prestartup Checks for 4196A Controllers Refer to figure 9 for adjustment locations and refer to figure 48 for key number locations When performing the checks open loop conditions must exist An open loop exists when the controller output does not affect the input temperature or other control signal to the controller Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing prestartup checks 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge Connect supply pressure to the supply pressure requlator and be sure it is delivering the proper supply pressure to the controller Do not exceed the normal operating pressure in table 3 2 Fora controller with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 1 bar 6to 30 psig to the remote set point connection at the top of the controller case 3 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 4 Adjustthe set point a minimum of 20 percent o
109. lastic tube as well as in the auto manual switch 44 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 When the auto manual switch is in the MANUAL position the manual loader output is channeled through the auto manual switch and becomes the controller output When the auto manual switch is in the AUTO position The output of the relay is channeled through the switch to become the controller output Before the auto manual switch is operated the relay output must equal the manual loader output to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side When the pressures are equal the metal ball is centered in the tube and is held in place by a small magnet A pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube Figure 21 Fisher 4196B and C Controller Auto Manual Station Schematic MANUAL LOADER TER T AUTO MANUAL P SWITCH P AUTOMATIC POSITION E MANUAL LOADER KNOB TO FINAL CONTROL ELEMENT MANUAL POSITION d xs B N AUTO MANUAL SUPPLY SWITCH PRESSURE OUTPUT PRESSURE RELAY OUTPUT PRESSURE TO FINAL CONTROL ELEMENT J SUPPLY PRESSURE 48A5230 A A2999 2 45 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 External Feedback Opera
110. ller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided that open process loop conditions exist Unless otherwise noted key numbers refer to figure 48 Do not use gauges supplied with the controller during calibration Monitor supply pressure controller output pressure and if applicable remote set point pressure with external gauges Temperature Baths Some calibration procedures require that the process temperature be simulated A temperature bath liquid or sand depending on temperature requirements is recommended Bath temperature should be able to cover 0 to 100 percent of the temperature element input span The bath should be capable of maintaining a temperature to within 0 10 percent of the input span and should be agitated so that the temperature is consistent throughout If available three baths preset at 0 percent 50 percent and 100 percent of input span could be used to simplify and speed up the calibration process Also provide a means of measuring bath temperature Use a thermometer or resistance temperature detector RTD accurate to within 0 05 percent of input span Process Indicator Zero and Span Calibration Before starting this procedure e Provide a means of changing the process temperature to the controller and a means of measurement external to the controller e Provide a means of measuring the controller output pressure
111. loosen the screws on link 1 and adjust the length so that the process pointer indicates 50 percent of scale span Tighten the two screws 9 Immerse the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize 10 Check for 0 80 to 1 0 mm 0 03 to 0 04 inch clearance between the temperature element takeoff assembly and the travel stop located farthest from the process pointer If the clearance is incorrect loosen the travel stop locking nut and readjust the travel stop Retighten the locking nut 11 The process pointer should indicate the process scale lower limit If not loosen the zero adjustment locking screw and adjust the zero adjustment screw until the process pointer indicates the lower limit Tighten the zero adjustment locking screw 12 Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize 13 Checkfor 0 80 to 1 0 mm 0 03 to 0 04 inch clearance between the temperature element takeoff assembly and the travel stop located nearest the process pointer If the clearance is incorrect loosen the travel stop locking nut and readjust the travel stop Retighten the locking nut 14 The process pointer should indicate the process scale upper limit If not proceed as follows a If the pointer indication is less than the process scale upper limit rotate the pointer span adjustment clockwise to increase the span Adjust the span adjustmen
112. move the controller assembly 5 Carefully draw the capillary tube and the temperature bulb through the process connection opening in the case Inspect the O rings around the external piping connections and replace as necessary 6 Carefully feed the temperature bulb through the opening in the replacement case and pull the capillary tube all the way through 7 Position the controller assembly in the replacement case and cover 8 Start the nine mounting screws but do not tighten 9 Slide the controller assembly down to assure an O ring seal at the pressure connections and thermal system connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 10 Remove the blow out plug key 72 from the original case and install in the replacement case 11 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 12 Mount the controller as described in the Installation section 13 Connectthe external piping to the controller and install the temperature bulb in the process fluid Replacing the Gauges CAUTION Before performing this procedure be sure the replacement gauges are the correct range so that they are not damaged by overpressure 1 Unscrew the output pressure gauge key 46 or the supply pressure gauge key 46 from the frame key 3 2 Before installing the replacement gauge coat
113. mowell the temperature element is then attached to the thermowell with a threaded connection Table 5 Maximum Process Fluid Velocities for Thermowells Temperature Insertion Length 2 mm Inch ThermowellSize Bulb L 191 7 5 267 10 5 406 16 610 24 pue Carbon steel 1 2 10 3 8 304 stainless steel 316 stainless steel 04400 i Brass Carbon steel SANET 19 xs 304 stainless steel 316 stainless steel N04400 Carbon steel 3 4 14 9 16 304 stainless steel 316 stainless steel N04400 1 For gas air or steam Values may be lower for liquids 2 Thisis the U dimension in figure 7 12 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 7 Bushing and Thermowell Dimensions BUSHING 1 Seat area per SAMA 17 10 1 Seat area SAMA Standard RC 17 10 THERMOWELL Temperature Bulb U Diameter NEM Insertion Length 191 7 5 1 2 14 NPT 16 0 63 3 4 14 NPT 20 0 77 1 2 14 NPSM 2B 267 406 191 7 5 267 10 5 9 16 3 4 14 22 0 88 1 20 UNEF 2B 406 16 610 24 1 Seat area per SAMA Standard RC 17 10 3 4 NPT BUSHINGS WITH 76 mm 3 INCH LAGGING THERMOWELLS WITH 76 mm 3 INCH LAGGING NOTES 1 gt TOLERANCES FOR THIS DIMENSION AS FOLLOWS 1 5 mm 0 06 INCH WHEN LENGTH IS 305 mm 12 INCHES OR LESS 3 2 mm 0 125 INCH WHEN LENGTH IS GREATER THAN 305 mm 12 INCHES mm 2 gt 7
114. n the groove pin key 303 to hold the switch lever 10 Replace the lever cover plate key 305 and attach with two screws key 288 11 Install the auto manual station on the controller as described in steps 3 through 7 of the Replacing the Auto Manual Station procedure Replacing the Loader Range Spring Diaphragm Assembly Ball Seat Tubing and Ball Refer to figure 52 for key number location Disassembly 1 Remove the auto manual station from the controller as described in steps 1 through 4 of the Replacing the Auto Manual Station procedure 96 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 2 Remove the tubing assembly key 309 A WARNING To avoid personal injury caused by preload from the range spring key 283 turn the loader knob key 287 counterclockwise opposite to the arrow to relieve pressure on the spring 3 Loosen the four screws key 289 and separate the upper loader assembly key 282 and the lower loader assembly key 274 4 Remove the loader range spring key 283 range spring cup key 284 and diaphragm assembly key 281 5 Remove the tube key 278 ball seats key 280 and ball key 279 Assembly 1 Turn the loader knob key 287 counterclockwise to back the spring adjustment screw key 285 all the way out to eliminate loading the range spring 2 Position the range spring cup key 284 the range spring key 283 and the diaphragm assembly key 281 on th
115. n the link 10 Raise link 4 out of the hole in the bellows bracket key 31 and ensure that it drops back into the hole under its own weight If not repeat steps 8 and 9 11 Fora controller with reset adjust the reset adjustment to 0 01 The rate adjustment 4196C should remain in the OFF position 12 The controller output should be within 0 14 bar 2 psig of the supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 13 Remove the tape from the process pointer and connect link 1 to the temperature element assembly 14 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Zero and Span Adjustment Refer to the Maintenance WARNING on page 59 Note For routine zero and span calibration refer to the appropriate procedures in Section 3 4 or 5 Use the following maintenance zero and span procedure only if difficulty is encountered with the routine procedure or if nonlinearity occurs Provide a means of changing the process temperature to the controller and a means of measurement external to the controller Also provide a regulated supply pressure adjusted to the normal operating pressure see table 3 Plug the controller output or connect it to a gauge Monitoring the controller output is not necessary However the flapper should not contact the
116. nal Only Controllers Adjustments for 4196A Controllers This section includes descriptions of adjustments and procedures for prestartup startup and calibration Adjustment locations are shown in figures 9 and 11 To better understand the adjustments and overall controller operation refer to the principle of operation section and to the schematic diagrams in figures 12 and 13 Unless otherwise noted key numbers given in this section are found in figure 48 Figure 9 Fisher 4196A Controller Adjustment Locations METAL BALL SETPOINT INDICATOR ort 4 it PA SWITCHING B ZONE 9 INDICATOR y 3 m ZONE LOADER KNOB NOM M AUTO MANUAL MANUAL J Y TULUN wt bio 15 22 A 0 30 AUTO AUTO MANUAL STATION SUFFIX LETTER E PROCESS POINTER PROPORTIONAL BAND ADJUSTMENT 2 7 PROPORTIONAL BAND v E A Wi INDICATOR COVER OUTPUT PRESSURE GAUGE Manual Set Point Adjustment Adjust the set point by moving the set point indicator until the line on the set point indicator is over the desired value on the process temperature scale Move the indicator to the right to increase the set point and to the left to decrease it Adjusting the set point does not affect the proportional band setting If the controller is equipped with the optional internal
117. nd reposition the bellows bracket to provide clearance Be sure the bellows bracket does not rub the frame then tighten the screws Lift link 4 out of the hole in the bellows bracket key 31 and ensure it drops back into the hole under its own weight If not perform steps 35 through 41 of the Flapper Assembly and Flapper Flexure Pivot Assembly replacement procedures Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 20 If the controller is proportional only 4196A go the step 34 If the controller has reset 4196B or C continue with step 21 Note The following procedure steps 21 through 33 adjusts the reset gain of the controller to minimize steady state offset 21 Apply the correct supply pressure to the controller and provide an accurate means of measuring controller output pressure 22 Adjust the proportional band to 100 percent DIRECT 23 Adjustthe set point to the mid scale mark on the process scale 24 Adjustthe reset adjustment to 0 01 minute per repeat For a 4196C controller set the rate adjustment to OFF 25 Note to which hole link 1 is connected and then disconnect link 1 from the temperature element 26 Starting from the process scale lower limit manually move the process pointer to the right until the output pressure stabilizes at 0 2 bar 3 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 0 4 bar 6 psig for a 0 4 to 2 0 bar 6 to 30 psig output Record the process temperature indic
118. nd secure it with the screw removed in step 5 7 Install the reset valve tubing assembly key 42 the reset tubing assembly key 43 and for controllers with anti reset windup the relief tubing assembly key 44 Tighten all connections 8 Set the reset adjustment to 0 01 minutes per repeat 9 Apply the correct supply pressure to the controller cap the nozzle and check for leaks Remove the supply pressure 10 Install the controller into the case by performing steps 6 through 9 of the case and cover replacement procedure 11 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 12 Mount the controller as described in the Installation section 13 Connectthe external piping to the controller and install the temperature bulb in the process fluid Replacing the Rate Reset Valve Assembly 4196C Controller Note Read this entire procedure before removing any parts Refer to the 4196C portion of figure 48 for key number locations 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 2 Remove the two machine screws key 71 on the side of the rate reset valve assembly key 262 3 Gently pull the rate tubing assembly away from the rate reset assembly and remove the gasket key 5 from the side of the rate reset assembly 4 Unscrew the nut holding the reset tubing assembly
119. nob has no effect on the controller output When the automatic manual switch is in MANUAL changing the set point has no effect on the controller output Prestartup Checks for 41965 Controllers Refer to figure 23 for adjustment locations and refer to figure 48 for key number locations When performing the checks open loop conditions must exist An open loop exists when the controller output does not affect the input temperature or other control signal to the controller Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing prestartup checks 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller Do not exceed the normal operating pressure in table 3 2 For controllers with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 1 bar 6 to 30 psig to the remote set point connection at the top of the controller case Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjustthe set point a minimum of 20 percent of input span above the process pointer Adjust the proportional band for 5 percent DIRECT process pointer should read ambient temperature 1 pe
120. nozzle 8 Set the proportional band to 30 percent REVERSE 9 The controller output should be 0 62 0 02 bar 9 0 25 psig or 1 2 0 04 bar 18 0 5 psig If not adjust flapper 10 leveling screw 1 the screw nearest the nozzle Repeat steps 4 through 9 until the controller output remains in tolerance without further leveling screw adjustment 23 4196 B C and S Controllers March 2012 Instruction Manual D200299X012 Figure 11 Fisher 4196A Controller Calibration Adjustment Locations LiT 15 2 E 52 12 c NEN 30 1 025 E eod PROCESS POINTER ZERO ADJUSTMENT PROCESS POINTER REMOTE SET POINT ZERO ADJUSTMENT SUFFIX LETTER M LOCKING SCREW ZERO ADJUSTMENT REMOTE SET POINT SUFFIX LETTER M ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER W6394 FRONT VIEW SPAN ADJUSTMENT SCREW 1 y SCREW 2 d SCREW REMOTE SET POINT POINTER SPAN A ADJUSTMENT SPAN ADJUSTMENT h SUFFIX LETTER M SIDE VIEW OF E SET POINT PROCESS xd INDICATOR ASSEMBLY 5949752 5 SHT 1 39 1126 6731 24 SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 11 If link 1 was disconnected remove the tape and reconnect link 1 to the temperature element using the hole noted in step 2 12 Setthe proportional band to 400 percent in the desired
121. off the proportional band indicator cover key 36 Disconnect link 4 key 65 from the bellows bracket key 31 Remove the two machine screws key 35 and washers key 362 from the bellows assemblies Remove the four machine screws key 6 from the bellows beam key 49 and remove the bellows bracket key 31 Remove the proportional tubing assembly key 40 from the proportional bellows or remove the reset tubing assembly key 43 from the reset bellows depending on which bellows is to be replaced Remove the four machine screws key 71 from the bellows beam and remove the bellows beam from the frame CAUTION When removing and replacing the proportional or reset bellows keep in mind that the bellows has left hand threads Overtightening could damage the threads 8 Unscrew the bellows assembly key 48 If the bellows assembly cannot be removed by hand thread a machine screw key 35 into the bellows until tight then loosen the bellows assembly by applying clockwise torque to the machine screw 75 4196A B C and S Controllers Instruction Manual March 2012 D200299X012 Figure 40 Bellows Assembly Bellows Bracket and Bellows Beam Location 10 1 2 13 14 9 16 TJ 18 19 76 FOUR SCREWS KEY 6 RESET bh BELLOWS AA WASHER KEY 362 PROPORTIONAL TWO SCREWS TA Mle EN KEY 35 2 A RESET I GAIN BRACKET KEY 31 3 BELLOWS
122. ointer indication should be within 2 percent of the set point indication Principle of Operation for 41965 Controllers Overall Operation Refer to the schematic diagram in figure 27 The input element is connected to the process pointer and to the flapper by connecting links As the process temperature increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the positive feedback bellows The action of this bellows is a positive feedback action that moves the flapper closer to the nozzle increasing the nozzle pressure even higher which in turn increases the relay output Thus the output pressure to the final control element switches to full supply pressure 55 4196 B C and S Controllers Instruction Manual March 2012 D200299X012 Figure 27 Fisher 4196S Controller Schematic SET POINT POSITIVE FEEDBACK INDICATOR PROPORTIONAL BELLOWS UA SA SN S BELLOWS PROPORTIONAL VENTED BAND ADJUSTMENT FEEDBACK X 7 PROCESS POINTER LINK X fa CONNECTED HERE Cu INPUT ELEMENT FEEDBACK FLAPPER CONNECTED HERE MOTION PIVOT DIRECT ACTION NL CONNECTING QUADRANT INPUT MOTION LINK FLAPPER DETAIL OUTPUT PRESSURE TO FINAL CONTROL FLAPPER NOZZLE
123. operating pressure in table 3 Note Because of the high controller gain with the reset adjustment at 0 01 minutes per repeat the controller output will not balance perfectly in the following step If the controller output is stable for approximately 5 seconds it is adequately balanced 40 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 7 Increase the process temperature to the controller until the controller output pressure balances at 0 8 bar 12 psig for a 0 2 to 1 0 bar 3 to 15 psig output range or 1 6 bar 24 psig for a 0 4 to 2 0 bar 6 to 30 psig output range 8 Turn the reset adjustment to the CLOSED 4196B controllers or OFF 4196C controllers position 9 Decrease the controller output pressure in small steps approximately 0 04 bar 0 5 psig by changing the process temperature or by changing the controller set point After each change in temperature or set point the controller output pressure should quickly change and then stabilize at the new value 10 Continue to change the controller output pressure in 0 04 bar 0 5 psi steps and check the output pressure after each step to make sure it stabilizes At some point the controller output will start to ramp downward to 0 psig with no further change to the controller input or set point Record the controller output pressure where this ramping action begins because this is the point at which the differential relief valve has relieved 11 To ob
124. orifice Personal injury or property damage may result from fire or explosion if preventive measures are not taken such as adequate ventilation and the removal of any ignition sources e Provide some temporary means of control for the process before taking the controller out of service e Shut off the supply pressure to the controller e Disconnect any operating lines providing supply air pressure a process input signal or other pressure source to the controller e Check with your process or safety engineer for any additional measures that must be taken to protect against process media Note Unless otherwise noted key numbers refer to figure 48 Figures 9 and 11 show the adjustment locations for 4196A controllers Figures 14 and 16 show adjustment locations for 4196B and C controllers Figures 23 and 25 show adjustment locations for 41965 controllers For maintenance on the indicator assembly please refer to figures 49 and 50 Select the appropriate maintenance procedure and perform the numbered steps Shut off supply pressure before beginning maintenance The maintenance procedures section describes part replacement common to 41964 B C and S controllers After completing the maintenance procedures perform the appropriate calibration procedures Unless otherwise noted calibration procedures for the 4196A controller are in Section 3 calibration procedures for the 4196B and C controller are in Section 4 and calibration procedures for t
125. ormal m3 hr Normal cubic meters per hour 0 C and 1 01325 bar absolute Scfh Standard cubic feet per hour 60 F and 14 7 psia Table 2 Available Configurations Proportional Proportional Proportional Plus Reset Plus Rate Three Mode Controllers Controller Only Plus Reset One Mode Two Mode Controllers Controllers 4196A 4196AE 4196AM 4196AME 4196B 4196BE 4196BF 4196BFE 4196BM 4196BME 4196BFM 4196BFME 4196C 4196CE aus 4196CF nes ua 4196CFE SS 4196CM as 4196CME a 4196 4196 me 41965 41965 41965 41965 4196 1 Reverse acting constructions are designated by the suffix letter R in the type number Differential Gap Snap Acting Controllers Internal Auto Anti Reset Remote Manual Station Windup Set Point Suffix Letter E Suffix Letter Suffix Letter M X mee ma mein X ee X X sur me X X X X X X X X Instruction Manual D200299X012 Table 3 Supply Pressure Data Output Signal Range Metric Units U S Units 1 If this pressure is exceeded control be impaired 2 If this pressure is exceeded damage to the controller may result 4196A C and S Controllers March 2012 Maximum Pressure to Prevent 1 Normal Operating Supply Pressure Internal Part Damage 2 0 2 to 1 0 bar 1 4 bar 2 8 bar 0 4 to 2 0 bar 2 4 bar 2 8 bar 3to 15 psig 20 psig 40 psig 6 to 30 psig 35
126. ove the proportional band adjustment knob key 25 and plastic washer from the set point beam assembly key 23 Inspect the nozzle assembly key 21 and replace it if necessary Inspect the nozzle orifice and clean it if necessary Also inspect the plastic washers and replace them if necessary Inspect the nozzle assembly O ring key 24 and replace it if necessary Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 31 Proportional Band Adjustment and Set Point Beam Details RELAY NOZZLE TUBING WASHER ASSEMBLY KEY 20 7 18 P SCREW E RING 19 27 AN Sg A RETAINING CLIP i 26 PROPORTIONAL BAND ADJUSTMENT KEY 25 ADJUSTABLE PLASTIC SET POINT WASHER PIVOTASSEMBLY 27 22 SET POINT Lo SET POINT NOZZLE BEAM ASSEMBLY BEAM SHOE ASSEMBLY W4193 KEY 23 KEY 29 KEY 21 EXPLODED VIEW FLAPPER RETAINING CLIP E RING CAP PROPORTIONAL BAND ADJUSTMENT KNOB D 2 D 4 SET POINT BEAM BIAS SPRING SHOE ADJUSTMENT SCREWS SET POINT SET POINT LINK 3 RELAY NOZZLE BEAM ASSEMBLY BEAM SHOE TUBING ASSEMBLY NONO ASSEMBLED VIEW CONTROLLER REMOVED FROM CASE 67 4196A B C and S Controllers Instruction Manual March 2012 D200299X012 Assembly 1 Apply a suitable lubricant such as key 318 to the set point beam assembly
127. over key 36 2 Note the hole position of link 1 in the temperature element assembly and the process pointer assembly Disconnect the link from the temperature element assembly and from the process pointer Remove the link 3 Adjust the length of the replacement link to the same length as the link being replaced 4 Attach the replacement link in the same holes noted in step 2 to the process pointer and temperature element assembly 5 Move the set point indicator manually or with remote set point pressure to the mid scale mark on the process scale and set the proportional band between DIRECT and REVERSE 6 The process pointer should be aligned with the pointer subassembly as shown in figure 42 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw Figure 42 Process Pointer Alignment 7 p i E f T M ALIGNED ZERO ADJUSTMENT FINE ZERO LOCKING SCREW MISALIGNED ADJUSTMENT W3443 1 W3475 1 7 Place the temperature bulb in the 50 percent bath The process pointer should indicate 50 3 percent of the process scale span If not loosen the screws on link 1 move the pointer to 50 percent of process scale span and tighten the screws 8 Perform the controller calibration procedures and if necessary the appropriate remote set point
128. put will not remain stable in steps 9 through 13 The controller output gauge is adequate to monitor the output pressure during this procedure Set the proportional band between DIRECT and REVERSE The controller output should be relatively stable at any value within the output range If not adjust flapper leveling screw 2 the screw nearest the nozzle until the output is relatively stable 11 Setthe proportional band to 30 percent DIRECT The controller output should be relatively stable at any value within the output range If not adjust flapper leveling screw 3 the screw nearest the nozzle until the output is relatively stable 12 Setthe proportional band to 30 percent REVERSE The controller output should be relatively stable within the output range If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is relatively stable 13 Repeat steps 9 through 12 until the controller output remains relatively stable without further flapper leveling screw adjustment Note Steps 14 through 20 check the flapper alignment 14 15 16 17 18 19 38 Set the proportional band to 30 percent DIRECT If link number 1 was previously disconnected remove the tape and align the process pointer with the right hand edge of the set point indicator as shown in figure 17 If link number 1 was not disconnected and a temperature bath is used adjust the set point indicator so the process pointer align
129. rcent of span Be sure that the bulb is exposed to air only and is not resting against the floor test bench or other surface Ou KR Uu controller output pressure should be 0 psig 8 Rotate the proportional band to 5 percent REVERSE 50 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 9 The controller output should be within 0 14 bar 2 psig of the supply pressure 10 If the controller output is within tolerance adjust the proportional band to 400 percent in the desired action secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the 41965 calibration procedure for recalibration Startup for 41965 Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure Note When performing the startup procedures keep in mind that the initial settings are guidelines and will vary depending on the actual process being controlled Set the controller switching points as described in the calibration procedures When placing a controller in service slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve if such valves are used Calibration of 4196S Controllers To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed
130. re e Provide a means of changing the process temperature to the controller and a means of measurement external to the controller e Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 Note Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment 21 4196 and S Controllers Instruction Manual March 2012 D200299X012 Refer to figure 9 and 11 for adjustment locations 1 2 3 4 Ov Ul Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Set the proportional band between DIRECT and REVERSE Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize process pointer should indicate the process scale lower limit If not adjust the process pointer to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize process pointer should indicate the process scale upper limit If not adjust the span screw to correct one half the error as follo
131. re and check for leaks Remove supply pressure 33 Install the set point beam bias spring key 28 into the frame bore and onto the spring seat of the set point beam assembly as shown in figure 31 34 Attach link 3 to the set point beam shoe as shown in figure 31 Note The following procedure steps 35 through 41 adjusts link 4 so it will always be in compression to eliminate possible instability due to lost motion 35 For controllers with reset and rate adjustments 4196B or 4196C controllers remove the supply pressure then turn the reset adjustment to the CLOSED 4196B or OFF 4196C position The controller output must be 0 bar 0 psig To be sure the controller output is at 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4196B or OFF 4196C position 36 Apply the correct supply pressure refer to table 3 to the controller and provide an accurate means of measuring the controller output pressure 37 Adjustthe proportional band to 5 percent REVERSE and adjust the set point to the process scale upper limit 38 With link 1 disconnected tape the process pointer at the process scale lower limit The output pressure should be within 0 14 bar 2 psig of the supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 39
132. recommended 1 3 Bend pointer to provide clearance 1 4 Repair or replace parts as necessary 1 5 Replace or repair as necessary 1 6 If the output moves fast in one direction and sluggishly in the other replace the relay 1 7 If the anti reset windup differential relief valve appears to be set too low perform the anti reset windup calibration procedures on page in Section 4 2 1 Reset the supply pressure if necessary If the condition occurs again rebuild or replace the regulator 2 2 Repair or replace parts as necessary 2 3 Repair or replace parts as necessary 2 4 Adjust as necessary 2 5 Align the flapper as necessary Instruction Manual D200299X012 Table 8 Troubleshooting Chart Continued 2 Controlling off set point as reflected by process and set point indicators Note Some offset is inherent with proportional only controllers 4196A controllers The amount of offset is a function of the proportional band setting 3 Controlling off set point but not reflected by process and set point indicators 4 No reset action 4196B 4196C controllers 5 Abnormal control point shift when proportional band is changed 6 Controller will not attain full output range 2 6 Leak in feedback system 2 7 Reset valve leaks 2 8 Leak in the remote set point system suffix letter M only 2 9 Input element over pressured 3 1 Out of calibration 4 1 Reset valve is plugged 4 2 Re
133. remote set pt For use w remote set pt Temperature Element Ass y Key 127 128 Description Machine screw fill hd 18 8 SST For mounting temperature element ass y to indicator ass y 3 req d Connecting link assembly aluminum SST Indicator Assembly key 101 figure 50 Note Key numbers 37 61 376 377 and 378 are not included as part of the indicator assembly Key 101 If replacing the indicator assembly and these parts are required order them separately 37 61 Self tapping screw 18 8 SST 4 req d Process scale aluminum 107 4196 B C and S Controllers March 2012 Figure 50 Indicator Assembly 39A1126 H Key Description 367 Support bracket 55 zinc brass 353 Machine screw pan hd 18 8 SST 4 req d 366 Controller mounting plate 18 8 SST 368 Linkass y SST brass 2 req d 369 Process pointer adj 55 aluminum SST brass 370 Set pt pointer adj ass y aluminum SST brass 371 Pivotpin 18 8 SST 2 req d 372 Plain washer 18 8 SST 4 req d 374 Pointer and bracket ass y aluminum steel 375 Setptindicator ass y A93003 aluminum for controllers w remote set pt for controllers w o remote set pt 376 Dialbracket G10080 steel 377 Dialbracket G10080 steel 378 Self tapping screw 18 8 SST 2 req d Remote Set Point Assembly suffix letter M key 62 figure 51 12 Capscrew hex socket 18 8 SST 2 req d 13 Plain washer 18 8 SST 3 req d 79 Driveflexure 530200 3
134. roller has the auto manual station suffix letter E be sure the controller is in the automatic mode prior to performing calibration If the prestartup checks or startup reveal faulty controller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided that open process loop conditions exist Unless otherwise noted key numbers are found in figure 48 Do not use gauges supplied with the controller during calibration Monitor supply pressure controller output pressure and if applicable remote set point pressure with external gauges Temperature Baths Some calibration procedures require that the process temperature be simulated A temperature bath liquid or sand depending on temperature requirements is recommended Bath temperature should be able to cover 0 to 100 percent of the temperature element input span The bath should be capable of maintaining a temperature to within 0 10 percent of the input span and should be agitated so that the temperature is consistent throughout If available three baths preset at 0 percent 50 percent and 100 percent of input span could be used to simplify and speed up the calibration process Also provide a means of measuring bath temperature Use a thermometer or resistance temperature detector RTD accurate to within 0 05 percent of input span Process Indicator Zero and Span Calibration Before starting this procedu
135. rtional band indicator cover Reset Adjustment To adjust reset open the controller cover and locate the RESET adjustment Rotate the adjustment clockwise to decrease the minutes per repeat or counterclockwise to increase the minutes per repeat Increasing the minutes per repeat provides a slower reset action Rate Adjustment To adjust rate open the controller cover and locate the RATE adjustment Rotate the adjustment clockwise to decrease the minutes less rate action or counterclockwise to increase the minutes more rate action Anti Reset Windup suffix letter F Adjustment If the arrow on the differential relief valve points toward the bottom of the controller case as shown in figure 14 the relief valve opens with increasing controller output pressure If the arrow points in the opposite direction the relief valve opens with decreasing controller output pressure Differential relief pressure is factory set at 0 3 bar 5 psi Maximum differential relief pressure is 0 5 bar 7 psi minimum is 0 1 bar 2 psi Turn the adjusting screw counterclockwise to increase differential relief pressure clockwise to decrease it Switching the Auto Manual Station suffix letter E Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 14 if the controller has the auto manual station suffix letter E To switch from automatic to manual mode
136. s 34 Process Indicator Zero and Span CalIDFaEIOE iic xr ema dodi WM 34 Remote Set Point suffix letter M Zero and Span Calibration 35 Flapper Alignment 36 Anti Reset Windup Differential suffix letter F Relief Valve Calibration 39 Principle of Operation for 4196B and C CONOCEIS 1 052 xe e aiv a UTR 41 Overall Operation 41 Anti Reset Windup Option suffix letter F OPEAUOM Deo 44 Remote Set Point suffix letter M 44 Auto Manual Station suffix letter E Sardo m 44 External Feedback Operation 46 EM ERSON i VLD 2 4196 B C and S Controllers March 2012 Contents cont d 5 4196S Differential Gap Controllers 47 Adjustments for 4196S Controllers 47 Manual Set Point Adjustment 47 Remote Set Point suffix letter M 48 Proportional Band Adjustment PB 48 Changing Controller Action 48 Switching the Auto Manual Station suffix letter E 50 Prestartup Checks for 4196S Controllers 50 Startup for 4196S Controllers 51 Calibration of 4196S Controllers 51 General Calibration Instructions
137. s with the right hand edge The controller output should be within 0 14 bar 2 psig of the supply pressure If link number 1 was previously disconnected remove the tape and align the process pointer with the left hand edge of the set point indicator as shown in figure 17 If link number 1 was not disconnected and a temperature bath is used adjust the set point indicator so the process pointer aligns with the left hand edge The controller output pressure should go to 0 bar 0 psig Set the proportional band to 30 percent REVERSE If link number 1 was previously disconnected remove the tape and align the process pointer with the right hand edge of the set point indicator as shown in figure 17 If link number 1 was not disconnected and a temperature bath is used adjust the set point indicator so the process pointer aligns with the right hand edge The controller output pressure should be 0 bar 0 psig If link number 1 was previously disconnected remove the tape and align the process pointer with the left hand edge of the set point indicator as shown in figure 17 If link number 1 was not disconnected and a temperature bath is used adjust the set point indicator so the process pointer aligns with the left hand edge The controller output should be within 0 14 bar 2 psig of supply pressure Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Figure 17 Alignment of the Process Pointer with the Set Point Indicator
138. screw locations 4 Apply a remote set point pressure equal to 100 percent of the remote set point input range he set point indicator should indicate the upper limit of the process scale span 6 To increase the span proceed as follows 11 a Turn the remote set point span adjustment screw clockwise b To increase the span further than the adjustment screw allows move both ends of link A key 116 to the right c Make fine adjustments with the remote set point span adjustment screw To decrease the span proceed as follows a Turn the remote set point span adjustment screw counterclockwise b To decrease the span further than the adjustment screw allows move both ends of link A key 116 to the left c Make fine adjustments with the remote set point span adjustment screw Repeat the adjustments until the upper and lower indications are aligned with the upper and lower limits on the process scale Adjust the remote set point pressure for 50 percent of the remote set point input range The set point indicator should indicate mid scale 2 percent of the process scale span If the error is within 2 percent proceed to step 11 If the error is greater than 2 percent of the scale span proceed to the remote set point linearity adjustment procedure Adjust the set point indicator to 50 1 percent of the process scale span by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten
139. set pressure leak 4 3 Tubing leak 5 1 Flapper is dirty or pitted 5 2 Flapper is out of alignment 6 1 Output pressure gauge not functioning 6 2 Supply pressure not correct 6 3 Proportional band setting too wide 4196A controllers only 2 6 Open the reset valve to 01 minutes repeat Adjust output pressure to 1 4 bar 20 psig Using soap solution check for leaks in the proportional and reset bellows and in the tubing that connects these bellows 2 7 Adjust output to 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output Close the reset valve If the controller output varies and no leaks were found in the rest of the feedback system Step 2 6 the reset valve is leaking 2 8 Adjust remote set point pressure to 1 0 bar 15 psig Using soap solution check for leaks in the remote set point element and tubing assembly 2 9 Check for zero shift 3 1 Refer to the process indicator remote set point if applicable and flapper alignment procedures in Section 3 4 or 5 4 1 Turn the reset valve through its range several times to remove any restrictions 4 2 Adjust the output to 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output Close the reset valve If the output varies and no leaks were found in the rest of the feedback system see Step 2 6 the reset valve is l
140. set pt ass y suffix letter M Individual assembly parts are listed in the Remote Set Point Assembly subsection of the parts list Key numbers for individual ass y parts also appear in figure 51 N09902 Nickel Alloy 0 8 bar 12 psi span 1 7 bar 24 psi span SST 0 8 bar 12 psi span 1 7 bar 24 psi span Machine screw fill hd 18 8 SST 4 req d to attach process and set pt indicator ass y key 56 to frame Feedback link ass y aluminum brass SST Machine screw fill hd 18 8 SST For all 4196A and B controllers 4 req d For all 4196C controllers 6 req d Blow out plug Machine screw fill hd 18 8 SST 2 req d to attach remote set pt ass y suffix letter M to indicator ass y base plate key 56 Machine screw SST 2 req d Machine screw fill hd 530400 304 SST 2 req d to attach rate reset manifold key 136 to frame manifold key 135 Frame manifold A03600 aluminum For all types except w suffix letter E auto manual station Rate reset manifold A03600 aluminum For all types except 4196C controllers Rate tubing assembly for 4196C controllers only SST aluminum Automatic manual tubing assembly SST aluminum Use w suffix letter E auto manual station only Key 140 162 262 2 3 310 311 2127 313 314 315 316 317 318 339 362 365 Description Part Number Machine screw fill hd 18 8 SST Used to attach remote set pt ass y suffix letter M to indicator ass y key 56 Machine screw hex hd 18
141. sing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces the set point setting Auto Manual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in figure 13 Supply pressure to the relay is also applied to the manual loader The manual loader functioning as a regulator applies pressure to one side of the plastic tube and to the auto manual switch Output pressure from the relay registers on the other side of the plastic tube as well as in the auto manual switch When the auto manual switch is in the MANUAL position the manual loader output is channeled through the auto manual switch and becomes the controller output When the auto manual switch is in the AUTO position the relay output is channeled through the switch to become the controller output Before the auto manual switch is operated the relay output must equal the manual loader output to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side When the pressures are equal the metal ball is centered in the tube and is held in place by a small magnet A pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube
142. ss temperature at mid scale value 36 Instruction Manual 41964 B C and S Controllers D200299X012 March 2012 Figure 16 Fisher 4196B and C Controller Calibration Adjustment Locations m A a h MW PROCESS POINTER ZERO MANUAL V oap HE LTT ADJUSTMENT 0 PROCESS POINTER ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT ANTI RESET WINDUP VALVE ADJUSTING SCREW SUFFIX LETTER F ANTI RESET WINDUP DIFFERENTIAL RELIEF VALVE SUFFIX LETTER F RATE REMOTE SET POINT REMOTE SET POINT RESET RATE RESET SUFFIX LETTER M SUFFIX LETTER M ADJUSTMENT d ADUSTA ZERO ADJUSTMENT ADJUSTMENT ADJUSTMENT 8 LOCKING SCREW 4196 CONTROLLERS FRONT VIEW 4196B CONTROLLERS RF RF SCREW 1 SCREW 2 E F 217 L AI MACC I k 7 JT SCREW 3 T LLLA o id 2 2 L T 1 l P 4 y LJ EN D lh pinim TE rj E LL EL Lu y LECCE TEL BAN REMOTE SET POINT ADJUSTMENT SPAN ADJUSTMENT SUFFIX LETTER M me SIDE VIEW OF p SET POINT PROCESS 3911268 INDICATOR ASSEMBLY T NEC SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 37 4196 and S Controllers Instruction Manual March 2012 D200299X012 Note Be cause of the high controller gain the controller out
143. ss temperature indication in step 47 is greater than the process scale upper limit by 2 percent loosen the shoe adjustment screws key 30 shown in figure 31 and move the set point beam shoe key 29 slightly away from the center of the flapper assembly If the process temperature indication in step 47 is less than the process scale upper limit by 2 percent loosen the shoe adjustment screws key 30 shown in figure 31 and move the set point beam shoe key 29 slightly toward the center of the flapper assembly Repeat steps 43 through 47 until the error is less than 2 percent of the process scale span at the process scale upper limit Remove the tape from the process pointer and reconnect link 1 to the temperature element Be sure to reconnect link 1 in the same hole noted in step 21 Perform steps 6 through 9 of the case and cover replacement procedure Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid Replacing the Proportional or Reset Bellows Refer to figure 40 unless otherwise noted 1 Du UUN 7 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures Remove the two screws key 6 and lift
144. ssel For Temperature Bulb 2 9 7 mm 3 8 inch Diameter Temperature Bulb 69 bar 1000 psig 14 3 mm 9 16 inch Diameter Temperature Bulb 34 5 bar 500 psig Also see tables 5 and 6 for thermowell maximum process fluid velocities and maximum process pressures Controller Adjustments Proportional Band 5 to 50026 of process scale range Reset Adjustable from 0 01 to more than 74 minutes per repeat from 100 to less than 0 0135 repeats per minute Rate Adjustable from 0 to 20 minutes Differential Gap Controller 5 to 100 of process scale range Set Point Adjustable from 0 to 100 of the scale range Controller Performance Repeatability 0 475 of output span Dead Band Less than 0 326 of process scale span Time Constant of Temperature Bulb 6 to 12 seconds for a 93 200 F span bare bulb in agitated liquid Steady State Air Consumption B and C Controllers Without Auto Manual Station 0 2 to 1 0 Bar 3 to 15 psig Output 0 1 normal m h 3 5 scfh 0 4 to 2 0 Bar 6 to 30 psig Output 0 14 normal m h 5 0 scfh With Auto Manual Station suffix letter E 0 2 to 1 0 Bar 3 to 15 psig or 0 4 to 2 0 Bar 6 to 30 psig Output 0 28 normal m h 10 0 scfh Steady State Air Consumption Differential Gap S Controllers 3 0 and 1 4 bar 0 and 20 psig Output 0 1 normal m h 3 5 scfh 0 and 2 4 bar 0 and 35 psig Output 0 14 normal m h 5 0 scfh Delivery Capacity All 4196 Controllers 3
145. ssembly Dg TFT 78 Replacing the Anti Reset Windup suffix letter F Differential Relief Valve 79 Replacing the Anti Reset Windup suffix letter F Relief Valve Tubing Assembly or ER S Ded A 79 Instruction Manual D200299X012 Replacing the Temperature Element 79 Replacing the Links 80 Replacing Rc RR 81 Replacing S 81 ReplacingLink3 92 ReplacingLink4 83 Process Indicator Zero and Span oues seri UV das 84 Remote Set Point suffix letter M Maintenance HEU a 87 Replacing The Remote Set Point 87 Replacing Remote Set Point Assembly Parts 88 Replacing Pivot Assembly A key 114 88 Replacing Pivot Assembly B key 115 90 Replacing the Drive Flexure 90 Replacing the Remote Set Point Tubing 90 Replacing Link A 91 Replacing LinkB 91 Remote Set Point suffix letter M Maintenance Calibration 91 Precalibration Procedures 91 Aligning the Flexures 91 Setting the Travel Stops 92 Aligning the Linkage 92 Remote Set Point Zero and Span Adjustment 2t e 93 Remote Set Point Linearity Adjustment 94 Auto Manual Station suf
146. supply pressure medium Because the instrument case and cover assembly do not form a gas tight seal when the assembly is enclosed a remote vent line adequate ventilation and necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas However a remote vent pipe alone cannot be relied upon to remove all flammable and hazardous gas Vent line piping should comply with local and regional codes and should be as short as possible with adequate inside diameter and few bends to reduce case pressure buildup CAUTION When installing a remote vent pipe take care not to over tighten the pipe in the vent connection Excessive torque will damage the threads in the connection If a remote vent is required the vent line must be as short as possible with a minimum number of bends and elbows Vent line piping should have a minimum inside diameter of 19 mm 3 4 inch for runs up to 6 1 meters 20 feet anda minimum inside diameter of 25 mm 1 inch for runs from 6 1 to 30 5 meters 20 to 100 feet The vent must be protected against the entrance of any foreign material that could plug it or if a remote vent is not required the vent opening in the case shown in figure 8 must be protected against the entrance of any foreign material that could plug it Check the vent periodically to be certain it is not plugged 16 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Section 3 4196 Proportio
147. t move the set point indicator to the mid scale mark on the process scale For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at mid scale on the process scale If a temperature bath is available adjust the bath for 50 percent of the scale range and place the temperature bulb in the bath Allow 5 minutes for the controller to stabilize If a bath is not available an alternate method is to disconnect link number 1 at the temperature element and tape the process pointer at the mid scale mark of the process scale Note the hole from which link number 1 was removed for proper replacement This method should only be used if a temperature bath is not available to simulate a process temperature at mid scale value Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 4 Setthe proportional band between DIRECT and REVERSE controller output should be 0 62 40 007 bar 9 0 10 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 1 2 0 01 bar 18 0 2 psig for a 0 4 to 2 0 bar 6 to 30 psig output If not adjust flapper leveling screw 2 the screw nearest the nozzle until the output is within tolerance 6 Setthe proportional band to 30 percent DIRECT 7 controller output should be 0 62 0 02 bar 9 0 25 psig or 1 2 0 04 bar 18 0 5 psig If not adjust flapper leveling screw 3 the screw nearest the
148. t the factory to relieve at approximately 0 4 bar 5 psi differential pressure 13 Repeat steps 7 through 12 until the required differential pressure is obtained Calibration for the differential relief valve to relieve on falling controller output pressure 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Do not apply supply pressure at this time 2 Setthe reset adjustment to 0 01 minutes per repeat wide open and the rate adjustment 4196C controllers to the OFF position 3 Fora controller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale 4 Setthe proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements 5 Referto figure 16 for the location of the anti reset windup differential relief valve For the differential relief valve to relieve on falling controller output pressure install the valve so the arrow on the valve points up To change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall the valve with the arrow pointing up Tighten the two mounting screws 6 Provide a regulated supply pressure to the controller Do not exceed the normal
149. t screw to correct for one half of the error b If the pointer indication is greater than the process scale upper limit rotate the pointer span adjustment counterclockwise to decrease the span Adjust the span adjustment screw to correct for one half of the error 15 Repeat steps 9 through 14 until the zero and span indications are within 1 percent of the scale limits with no further adjustment If the span adjustment screw is adjusted to its limit and the span is still too short or too long proceed with step 16 If proper span is achieved proceed to step 17 16 Ateither end of link 1 there are three holes in which the link may be connected A coarse span adjustment can be made by moving both ends of link 1 up or down a If the span is short process pointer indication is less than the process scale upper limit disconnect both ends of link 1 move the link down one set of holes and return to step 5 b If the span is long process pointer indication is greater than the process scale upper limit disconnect both ends of link 1 move the link up one set of holes and return to step 5 17 Immerse the temperature bulb in the 50 percent bath Allow a minimum of 5 minutes for the controller to stabilize 86 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 18 If the process pointer indicates 50 1 percent of process scale span tighten the zero adjustment locking screw and proceed to the appropriate flapper ali
150. tain the differential relief valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 12 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential pressure by turning the differential relief valve adjustment screw shown in figure 16 Turn the screw clockwise to decrease the differential pressure or counterclockwise to increase the differential pressure The differential relief valve is set at the factory to relieve at approximately 0 4 bar 5 psi differential pressure 13 Repeat steps 7 through 12 until the required differential pressure is obtained Principle of Operation for 4196B and C Controllers Overall Operation Refer to the schematic diagram in figure 18 for 4196B controllers Refer to the schematic diagram in figure 19 for 4196C controllers The input element connects to the process pointer and to the flapper by connecting links As the process temperature increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the proportional bellows and to the reset bellows The action of the proportional bellows quickly counteracts the flapper movement that resulted from the process
151. the set point Increase the pressure to increase the set point and decrease the pressure to decrease the set point Proportional Band Adjustment PB ADJ The proportional band determines the output sensitivity of the controller The proportional band adjustment is marked in percentages of process temperature required to drive the controller from zero output to full output To adjust the proportional band open the controller cover and locate the proportional band adjustment PB ADJ knob Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action To change the controller action from direct to reverse or vice versa loosen the screws on the proportional band indicator cover Lift the cover out as shown in figure 15 and rotate the proportional band adjustment to the desired action Setting the proportional band to the values in the white portion of the adjustment provides direct controller action setting proportional band in the black portion provides reverse controller action Figure 15 Fisher 4196B and C Controller Changing Controller Action W3439 For direct control action An increasing process temperature increases output pressure 30 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 For reverse control action An increasing process temperature decreases output pressure After changing the action tighten the two screws on the propo
152. the bottom of the controller as shown in figure 44 Figure 44 Position of Link 4 Adjustment Screws payed aac LINK 4 ADJUSTMENT SCREW HEADS W4195 4 For controllers with reset 4196B or reset and rate 4196C turn the reset adjustment to the CLOSED 4196B or OFF 4196C position Turn the rate adjustment 4196C to the OFF position The controller output must be 0 bar 0 psig To be sure the controller output is at 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4196B or OFF 4196C position 83 4196 and S Controllers Instruction Manual March 2012 D200299X012 5 Adjust the proportional band to 5 percent REVERSE and move the set point indicator to the process scale upper limit 6 Disconnect link 1 from the temperature element assembly Tape the process pointer to the process scale lower limit the last mark on the left side of the scale 7 Apply the correct supply pressure to the controller The output of the controller should be within 0 14 bar 2 psig of supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 8 Loosen the two adjusting screws on link 4 Connect the free end of the link to the bellows bracket and allow the link to find its free length 9 Tighten the two adjusting screws o
153. the following procedure Refer to figure 29 Figure 29 Changing the Scale Ww it 1 0 S 0 5 y Inm 30 DEFLECT LOWER PORTION OF THE SLOT id AND LIFT THE SCALE UP AND OFF 20 1 Adjust the set point indicator either manually or with the remote set point pressure to the mid scale mark on the process scale 63 4196A B C and S Controllers Instruction Manual March 2012 D200299X012 2 3 Remove the four self tapping screws key 37 Slide the process scale key 61 downward so that the top of the slot touches the set point indicator Deflect the lower portion of the slot outward and carefully slide the scale upward and off clearing the set point indicator as shown in figure 29 To install the replacement scale deflect the lower part of the slot slightly so that the scale slides downward over the set point indicator and under the process pointer Secure the scale with the four self tapping screws key 37 Ifthe controller has remote set point suffix letter M perform the appropriate remote set point zero and span calibration procedure in Section 3 4 or 5 Perform the appropriate process indicator zero and span calibration and the flapper alignment procedures in Section 3 4 or 5 Replacing the Relay 1 2 3 Loosen the two captive screws that hold the relay key 50 in place Tip the relay slightly toward the side of the case to clear the ou
154. the operating limits given in this manual General Calibration Instructions Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing calibration If the prestartup checks or startup reveal faulty controller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided that open process loop conditions exist Unless otherwise noted key numbers are shown in figure 48 Do not use gauges supplied with the controller during calibration Monitor supply pressure controller output pressure and if applicable remote set point pressure with external gauges Temperature Baths The calibration procedure requires that the process temperature be simulated A temperature bath liquid or sand depending on temperature requirements is recommended Bath temperature should be able to cover 0 to 100 percent of the temperature element input range 51 4196 and S Controllers Instruction Manual March 2012 D200299X012 If available two baths could be used to simplify and speed up the calibration process The minimum bath should be preset at 0 percent of input range and the maximum bath should be set at 100 percent of input range Also provide a means of measuring bath temperature Use a thermometer or resistance temperature detector RTD accurate to within 0 05 percent of input span
155. the temperature element is attached to the bushing with a threaded connection 4196 and S Controllers Instruction Manual March 2012 D200299X012 Figure 6 Temperature Element Assembly with Adjustable Union LINE CAPILLARY N SILVER BRAZE O PS SUPPORT 274 BRACKET Q cm SWIVEL NUT PACKING RING ADJUSTABLE SEAT NOTE EXTENSION 1 gt MINIMUM BEND RADII 1 1 4 5434 If the process pressure exceeds the limitations of the temperature bulb or if the process fluid is corrosive thermowell dimensions are shown in figure 7 is recommended which penetrates the vessel and isolates the temperature bulb from the process fluid Table 5 lists process fluid velocities for thermowells Table 6 lists maximum process pressures for thermowells With the controller case mounted so the temperature bulb reaches the process screw the bulb into the bushing or thermowell To make installation of the temperature bulb easier bend the bendable extension The bendable extension has a minimum bend radii of 1 1 4 inch If the temperature bulb is to be installed in a pipe process velocity is an important consideration Install a thermowell where the process temperature is to be measured keeping in mind the velocity limits shown in table 5 Tapered thermowells built to withstand even greater process velocities are also available After proper installation of the ther
156. the threads on the gauge with a suitable sealant such as key 311 3 Screw the replacement gauge into the frame 4 Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure Replacing the Supply Gauge Proportional Reset and Reset Valve Tubing Assemblies 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 65 4196 and S Controllers Instruction Manual March 2012 D200299X012 BR UJ N Unscrew the nuts at each end of the tubing assembly Remove the tubing assembly Install the replacement tubing assembly Set the reset adjustment to 0 01 4196B and C controllers and set the rate adjustment to OFF 4196C controllers Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure Then remove the pressure Perform steps 6 through 9 of the case and cover replacement procedure 7 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 8 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid Replacing the Proportional Band Adjustment Knob Nozzle Assembly and Set Point Beam Assembly Figure 31 shows the parts locations for the proportional band a
157. three mounting screws keys 120 and 140 that attach the remote set point assembly to the process set point indicator assembly Figure 46 shows the mounting screw locations CAUTION In the following step do not lift out the remote set point assembly by holding the capsular element or linkages These parts may be damaged BR WN 6 Lift out the remote set point assembly by holding the tie bar key 106 mounting plate key 111 travel stop key 83 or pedestal assembly key 105 7 Align the replacement assembly with the mounting screw holes Replace the mounting screws 87 4196 and S Controllers Instruction Manual March 2012 D200299X012 8 Reconnect the remote set point pressure connection union key 93 Apply full remote set point pressure and check for leaks 9 Connect link B key 126 to the connecting hole on the set point indicator 10 Replace the supply pressure gauge 11 Perform the remote set point maintenance calibration procedures Perform the appropriate process indicator zero and span calibration and flapper alignment procedure in Section 3 4 or 5 Replacing Remote Set Point Assembly Parts Figure 46 shows the parts and adjustment locations Refer to figure 51 for key number locations Figure 46 Remote Set Point suffix letter M Parts and Adjustment Locations GUIDE FLEXURE MOUNTING SCREW LINK A ADJUSTMENT DRIVE FLEXURE 2 LOWER TRAVEL PIVOT KD ASSEMBLY A
158. tion External feedback is available with all 4196B controllers Controllers with this option have an external connection on the bottom of the controller case as shown in figure 8 This connection breaks the positive feedback reset loop inside the controller and brings it outside as shown in figure 22 The connection allows the positive feedback loops of two controllers primary and secondary to be tied together when the controllers are used in an override application When connected the secondary controller tracks the primary controller minimizing reset windup Figure 22 Schematic of External Feedback Option TO TO RESET BELLOWS NOZZLE OUTPUT mA RELAY SUPPLY PROPORTIONAL PRESSURE BELLOWS EXTERNAL FEEDBACK TO OUTPUT OF HIGH OR LOW SELECT RELAY Eo NOZZLE PRESSURE 1 SUPPLY PRESSURE RESET PRESSURE OUTPUT PRESSURE nea 47A0975 A A3342 1 46 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Section 5 41965 Differential Gap Controllers Adjustments for 4196S Controllers This section includes descriptions of adjustments and procedures for prestartup startup and calibration Adjustment locations are shown in figures 23 and 25 To better understand the adjustments and overall controller operation refer to the Principle of Operation section and to the schematic diagram in figure 27 Unless otherwise noted key numbers given in this section are found in fig
159. tput is within tolerance adjust the proportional band to 400 percent in the desired action Secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the 4196B and C calibration procedure for recalibration Startup for 4196B and C Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure Note When performing the startup procedures keep in mind that the initial settings are guidelines They will vary depending on the actual process being controlled 1 Be sure the supply pressure regulator is delivering the proper supply pressure to the controller 2 For controllers with Manual set point Move the set point indicator to the desired set point 32 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Remote set point a See figure 8 for the location of the remote set point connection Connect an adjustable pressure source to the remote set point connection b Adjust the pressure source until the set point indicator reaches the desired set point Remember Increasing the remote set point pressure increases the set point 3 Setthe reset adjustment to 0 5 minutes per repeat For controllers with rate set the rate adjustment to OFF 4 Determine the initial proportional band setting in percent from the following equation PB 200
160. tput pressure gauge key 46 and lift out the relay Make sure the replacement relay has three O rings keys 13 and 15 installed as shown in figure 30 The fourth port is for exhaust and does not require an O ring Install the replacement relay making sure the tab on the relay shown in figure 30 aligns with the tab on the frame 5 Tighten the two screws that hold the relay in place Perform the appropriate Flapper Alignment procedure in Section 3 4 or 5 Figure 30 Relay Construction 64 CLEANOUT WIRE EXHAUST PORT NO O RING USED O RINGS uo C RELAY MOUNTING SCREWS Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Replacing the Case and Cover CAUTION The case and cover are an integral unit attempting to separate them will damage the hinge If the cover needs to be replaced replace the case also 1 Remove the external piping and fittings from the controller 2 If the temperature bulb is not in a thermowell make provisions to ensure that the process fluid does not escape from the process vessel as the temperature bulb is removed 3 Remove the controller from its mounting to a maintenance area 4 Remove the nine screws key 38 from the case and cover assembly key 1 and lift out the controller assembly If the controller has remote set point suffix letter M use a screwdriver or appropriate tool to deflect the case slightly at the remote set point connection to re
161. troller cap the nozzle and check for leaks Install the controller into the case by performing steps 6 through 9 of the case and cover replacement procedure Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller and install the temperature bulb in the process fluid Replacing the Anti Reset Windup suffix letter F Differential Relief Valve Refer to the 4196B or 4196C suffix letter F portion of figure 48 for key number locations 1 Loosen the two screws the differential relief valve key 55 and remove the relief valve 2 Inspect the O rings on the replacement relief valve Apply a suitable lubricant key 318 to the O rings 3 Install the replacement relief valve into the controller frame keeping in mind that e When the arrow points up the valve relieves with decreasing output pressure e When the arrow points down the valve relieves with increasing output pressure Tighten the two screws that hold the relief valve to the frame The relief valve differential pressure is factory set at 0 3 bar 5 psi Maximum differential pressure is 0 5 bar 7 psi minimum differential pressure is 0 14 bar 2 psi If a different differential pressure setting is desired refer to the anti reset windup valve calibration procedure in Section
162. troller changing the proportional band adjustment widens or narrows the differential gap between the two switching points This is accomplished by changing the position of the upper switching point Remote Set Point suffix letter M Operation The capability to adjust the controller set point from a remote location is available with all 4196 controllers This option is designated by the suffix letter M in the type number A control pressure is applied to the capsular element within the remote set point assembly The expansion and contraction of the capsule moves the set point indicator via a connecting linkage Increasing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces the set point setting 56 Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 Auto Manual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in figure 28 Supply pressure to the relay is also applied to the manual loader The manual loader functioning as a regulator applies pressure to one side of the plastic tube and to the auto manual switch Output pressure from the relay registers on the other side of the plastic tube as well as in the auto manual switch When the auto manual switch is in the MANUAL position the manual loader output is channelled throug
163. truction Manual 4196A B C and S Controllers D200299X012 March 2012 Table 8 Troubleshooting Chart Continued Posbecase O emen E 8 Controller remains at zero output 8 4 Relay malfunction 8 4 Check for air at the nozzle 8 4 Clean out the relay primary orifice the nozzle and note that the with the cleanout wire attached to the controller output increases to relay to ensure the orifice is not clogged within 0 5 psig of supply pressure If the problem persists replace the relay 8 5 Nozzle pressure leak 8 5 Using a soap solution checkfor 8 5 Tighten the relay nozzle tubing nut nozzle tubing leaks with the nozzle key 18 tighten manifold screws keys capped by the flapper Press the 34 and 131 or replace nozzle assembly nozzle cap key 23 gently to ensure O ring or set point beam assembly as nozzle O ring key 24 is sealing appropriate Ensure the relay nozzle tubing nut key 18 and the manifold screws keys 34 and 131 are tight Replacing Common Controller Parts A WARNING To avoid personal injury or property damage caused by the uncontrolled release of pressure be sure any trapped process pressure is properly vented from the controller Vent any supply pressure from the controller before disassembly Replacing the Process Temperature Scale CAUTION To prevent inaccurate indication and operation take care not to bend the process pointer or the set point indicator while performing
164. ts loosen the linearity screw and move it clockwise in the slot If the misalignment is negative move the linearity screw counterclockwise in the slot 5 If misalignment is greater than 1 percent of the process scale span at the lower and upper limits with one positive and the other negative perform the remote set point zero and span adjustment procedure to correct a span error 6 Repeat steps 1 through 4 until lower middle and upper indications are within 1 percent of the process scale markings Auto Manual Station suffix letter E Maintenance Replacing the Auto Manual Station Refer to figure 48 and 52 for key number locations Note This procedure also permits replacement of the switch manifold O rings key 312 the auto manual tubing assembly key 138 and the frame gaskets keys 4 and 5 Disassembly 1 Remove the controller assembly from the case by performing steps 1 through 5 of the case and cover replacement procedures 2 Loosen the screw key 316 that holds the auto manual station key 273 to the controller frame 3 Loosen the two screws keys 314 and 315 that hold the auto manual station to the auto manual tubing assembly key 138 4 Remove the auto manual station from the controller frame 5 Remove the switch manifold O rings key 312 6 Carefully loosen the nut on the relay nozzle tubing assembly key 18 where it connects to the auto manual tubing assembly key 138 Loosen three screws keys
165. ues in the white portion of the adjustment provides direct controller action setting proportional band in the black portion provides reverse controller action Figure 10 Fisher 4196A Controller Changing Controller Action W3439 For direct control action An increasing process temperature increases output pressure Instruction Manual 4196A B C and S Controllers D200299X012 March 2012 For reverse control action An increasing process temperature decreases output pressure After changing the action tighten the two screws on the proportional band indicator cover Switching the Auto Manual Station suffix letter E Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 9 if the controller has the auto manual station suffix letter E To switch from automatic to manual mode or from manual to automatic you must first balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output To switch from automatic to manual mode carefully adjust the loader knob until the metal ball inside the plastic tube moves into the switching zone Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counterclockwise to decrease it To switch from manual to automatic mode adjust the set point to move the bal
166. ure key 79 to the arm on the replacement pivot assembly making sure it stays straight and vertical Adjust the length of the pivot arm if necessary until the flexure is vertical Before tightening the drive 89 4196 and S Controllers Instruction Manual March 2012 D200299X012 flexure screws hold the pivot assembly shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing Tighten the drive flexure screws to hold pivot assembly A in this position Do not bend or twist the flexure when tightening the screws 12 Decrease the remote set point pressure to 0 bar 0 psig 13 Connectthe end of link A key 116 to the pivot lever arm in the same holes noted in step 3 14 Replace the tie bar key 106 15 Perform the remote set point maintenance calibration procedures Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing Pivot Assembly B Key 115 1 Decrease the remote set point pressure to 0 bar 0 psig 2 Note the holes where links A and B are connected Disconnect links A and B keys 116 and 126 from the arms of pivot assembly B key 115 3 Remove the two screws key 102 that attach pivot assembly B to the mounting plate key 111 Remove the pivot assembly 4 Loosen the linearity adjustment screw on the replacement pivot assembly and set it in the same position as the adj
167. ure 48 Figure 23 Fisher 4196S Controller Adjustment Locations METAL BALL SWITCHING 1 2 ZONE Mp 5 INDICATOR SWITCHING TON m e LOADER KNOB AUTO MANUAL SWITCH SETPOINT INDICATOR AUTO MANUAL STATION SUFFIX LETTER E PROCESS POINTER PROPORTIONAL BAND ADJUSTMENT PROPORTIONAL BAND INDICATOR COVER OUTPUT PRESSURE GAUGE Manual Set Point Adjustment The set point indicator adjusts the upper or lower switching point depending on controller action Adjust the set point by moving the set point indicator until the line on the set point indicator is over the desired value on the process temperature scale Move the indicator to the right to increase the set point and to the left to decrease it Adjusting the set point does not effect the differential gap setting If the controller is equipped with the optional internal or external set point adjustment turn the adjustment knob clockwise to increase the process set point and counterclockwise to decrease the process set point 47 4196 B and S Controllers Instruction Manual March 2012 D200299X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point Moving the set point indicator could damage the controller If the controller is equipped with remote set point suffix letter M vary the remote set point pressure to change the set point Increase
168. ustment on the original pivot assembly Tighten the screw 5 Set the replacement pivot assembly on the mounting plate and attach it with the two machine screws 6 Attach links A and B keys 116 and 126 to the arms of the replacement pivot assembly in the same holes noted in step 2 7 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing the Drive Flexure 1 Using an Allen wrench remove the cap screws key 12 and washers key 13 to disconnect the drive flexure key 79 from the drive bracket key 121 and from the adjustment arm of pivot assembly A Remove the drive flexure 2 Set the remote set point pressure to 50 percent of the remote set point input range Note See figure 47 The adjustment arm of the remote set point pivot assembly A turns on a bushing at each end of the shaft supporting the adjustment arm In the next step position the shaft so both bushings float inside the bearings and do not rest against the end of either bearing 3 Connect the new drive flexure making sure it stays straight and vertical Adjust the length of the pivot arm if necessary until the drive flexure is straight Before tightening the drive flexure screws hold the pivot assembly A shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearin
169. valve cover with the two machine screws key 53 provided 2 If the controller has the external feedback option available with the 4196B only connect the controller output to the external feedback connection See figure 8 for the location of the output and external feedback connections 3 If necessary remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 4 Provide regulated supply pressure to the controller Do not exceed the normal operating pressure in table 3 5 Foracontroller with manual set point move the set point indicator to the mid scale mark of the process scale span For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at the mid scale mark of the process scale 6 Set the reset adjustment to 0 01 minutes per repeat 7 If the controller has rate 4196C controllers turn the rate adjustment to OFF 8 If atemperature bath is available adjust the bath for 50 percent of the scale range and place the temperature bulb in the bath Allow 5 minutes for the controller to stabilize If a bath is not available an alternate method is to disconnect link number 1 at the temperature element and tape the process pointer at the mid scale mark of the process scale Note the hole from which link number 1 was removed for proper replacement This method should only be used if a temperature bath is not available to simulate a proce
170. ws clockwise to increase the span for a low indication below the upper limit counterclockwise to decrease span for a high indication above the upper limit 7 Repeat steps 3 through 6 until the error is eliminated 10 11 12 13 14 Place the temperature bulb in the 50 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the mid scale mark 2 percent of span If the error is greater than 2 percent refer to the Maintenance section and perform the zero and span adjustment procedure Adjust the process pointer to within 1 percent of the mid scale mark by loosening the zero adjustment locking screw and turning the zero adjustment screw This distributes the error over the entire scale span and brings all points within 1 percent of the process scale span Tighten the zero adjustment locking screw Place the temperature bulb in the 0 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate the process scale lower limit 1 percent of the scale span Place the temperature bulb in the 100 percent bath Allow a minimum of 5 minutes for the controller to stabilize The process pointer should indicate process scale upper limit 1 percent of the process scale span If the error is greater that 1 percent repeat steps 3 through 13 Remote Set Point suffix letter M Zero and Span Calibration Refer to figure 9 and 11 for
171. x Allowable Overshoot Temperature Span For example 200 x 10 F _ 100F 20 5 Turn the proportional band adjustment PB ADJ to the percentage calculated from the equation 6 If the controller is used in conjunction with a control valve slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve if one is used 7 Tune the various controller actions Tuning proportional action Create a load upset by momentarily changing the set point Check for system cycling If the system does not cycle lower the proportional band setting thus raising the gain and disturb the system again by changing the set point Continue this procedure until the system cycles At this point double the proportional band setting proportional band setting x 2 and begin tuning the reset Tuning reset action Disturb the system If the system does not cycle speed up the reset by changing the setting to a lower value faster reset and disturb the system again Continue this procedure until the system cycles When the system cycles multiply the reset time setting by a factor of three reset setting x 3 and slow down the reset by changing the reset setting to the higher value The reset is now tuned Tuning rate action For a controller with rate 4196C adjust the rate toward the higher setting until cycling occurs When the system cycles divide the rate value by a factor of three rate setting 3 and
172. y O Ring and Tubing Assembly Refer to figure 52 for key number locations Disassembly 1 Remove the auto manual station from the controller as described in steps 1 through 4 of the Replacing the Auto Manual Station procedure 2 Loosen the two screws key 288 and remove the lever cover plate key 305 A WARNING The lever spring key 302 is under preload To avoid personal injury or parts loss carefully remove the switch cover plate 3 Using a 1 16 inch 1 5 mm punch push the groove pin key 303 out toward the surface of the lever cover plate 4 Remove the switch lever key 304 lever spring key 302 and lever spring seat key 301 5 Remove the tubing assembly key 309 CAUTION The switch body springs key 295 are under preload Take care not to lose any parts when separating the switch body assembly from the loader assembly 6 Loosen the two screws key 290 and separate the switch body assembly key 291 from the loader assembly key 282 4196 and S Controllers Instruction Manual March 2012 D200299X012 7 Remove the O rings keys 292 293 and 294 switch body springs key 295 and balls key 296 8 Loosen two screws key 308 and remove the closing plate key 307 and the closing plate gasket key 306 9 Pull the clip key 300 from its engagement with the lever assembly shaft key 297 10 Pull the lever assembly from the switch body assembly key 291 and rocker key 299 11 Remove the O r

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