Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Fisherr 4196A, B, C, and S Temperature Indicating Controllers Contents 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Educational Services . . . . . . . . . . . . . .
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Contents (cont'd) 5. 4196S Differential Gap Controllers . . . . . . . . . . . Adjustments for 4196S Controllers . . . . . . . . . . . . Manual Set Point Adjustment . . . . . . . . . . . . . Remote Set Point (suffix letter M) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . Proportional Band Adjustment (PB ADJ) . . . . . Changing Controller Action . . . . . . . . . . . . . . .
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 1. Fisher 4196 Temperature Controllers NAMEPLATE W6393 INTERIOR OF CONTROLLER Contents (cont'd) Controller Mounting Parts . . . . . . . . . . . . . . . . . . . Pipestand Mounting . . . . . . . . . . . . . . . . . . . . Pipestand Mounting with Regulator . . . . . . . Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . .
196A, B, C, 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Table 1. Specifications Maximum Allowable Pressure In Closed Vessel (For Temperature Bulb)(2) Available Configurations See table 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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Table 1. Specifications (continued) Exhaust Capacity (All 4196 Controllers)(3) Mounting 0.2 to 1.0 Bar (3 to 15 psig) Output: 4.6 normal m3/h Controller can be mounted on actuator, panel, wall, or pipestand. (186 scfh) 0.4 to 2.0 Bar (6 to 30 psig) Output: 7.0 normal m3/h (295 scfh) Approximate Weight Operative Ambient Temperature Limits 4.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Table 3. Supply Pressure Data Output Signal Range Normal Operating Supply Pressure(1) Maximum Pressure to Prevent Internal Part Damage(2) Metric Units 0.2 to 1.0 bar 0.4 to 2.0 bar 1.4 bar 2.4 bar 2.8 bar 2.8 bar U.S. Units 3 to 15 psig 6 to 30 psig 20 psig 35 psig 40 psig 40 psig 1. If this pressure is exceeded, control may be impaired. 2. If this pressure is exceeded, damage to the controller may result. Table 4.
4196A, B, C, and S Controllers March 2012 8 Instruction Manual D200299X012
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Section 2 Installation WARNING To avoid personal injury or property damage from sudden release of process pressure: D Always wear protective clothing, gloves, and eyewear when performing any installation operations to avoid personal injury. D 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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Pipestand Mounting 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 4. Panel Mounting Figure 5. Wall Mounting 84 (3.29) 161 (6.35) 63 (2.49) LOCK WASHER (KEY 67) TOP VIEW HEX HEAD CAP SCREW (KEY 66) TOP VIEW 13 (0.50) BRACKET (KEY 68) 260 (10.25) 62 (2.43) ROUND HEAD MACHINE SCREW (KEY 70) 306 (12.06) LOCKWASHER (KEY 67) HEX HEAD CAP SCREW (KEY 66) 152 (6.00) 14 (0.56 R) 236 (9.31) REAR VIEW 36A9760‐A A6733 13 (0.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 6.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 7. Bushing and Thermowell Dimensions BUSHING Dimension Temperature Bulb Diameter mm Inch 10 3/8 14 9/16 A(1) B C mm Inch mm Inch 1/2‐14 NPSM 11 0.44 11 0.44 1‐20 UNEF 19 0.75 16 0.63 1. Seat area per SAMA Standard RC‐17‐10. LAGGED BUSHING Dimension Temperature Bulb Diameter mm B A(1) Inch 10 3/8 1/2‐14 NPSM 14 9/16 1‐20 UNEF C D E mm Inch mm Inch mm Inch mm Inch 11 0.44 12 0.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Table 6. Maximum Process Pressures for Thermowells Thermowell Size Temperature _C (_F) Temperature Bulb Diameter mm 1/2 NPT 10 Material Inch 21 (70) 93 (200) 204 (400) 316 (600) 427 (800) 538 (1000) Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig 3/8 Brass Carbon steel 304 SST 316 SST N04400 193.9 218.0 284.3 284.3 263.6 2810 3160 4120 4120 3820 174.6 209.8 258.1 284.3 243.
Instruction Manual D200299X012 4196A, B, C, and S Controllers March 2012 Supply Pressure Connection 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.
4196A, B, C, and S Controllers March 2012 Instruction Manual D200299X012 Vent WARNING 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 supply pressure medium.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Section 3 4196A Proportional‐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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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.
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.
4196A, B, C, 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Calibration of 4196A Controllers 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. General Calibration Instructions Note If the controller has the auto/manual station (suffix letter E), be sure the controller is in the automatic mode prior to performing calibration.
4196A, B, C, and S Controllers Instruction Manual March 2012 D200299X012 Refer to figure 9 and 11 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. The process pointer should indicate the process scale lower limit.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 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‐scale mark, then proceed with step 10.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 11.
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. Set the proportional band to 400 percent in the desired 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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 13.
4196A, 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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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.
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. 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.
4196A, B, C, 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.
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. Set the reset adjustment to 0.5 minutes per repeat.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 3. Place the temperature bulb in the 0 percent bath. Allow a minimum of 5 minutes for the controller to stabilize. 4. The 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. 5.
4196A, B, C, and S Controllers March 2012 Instruction Manual D200299X012 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 16.
4196A, B, C, and S Controllers March 2012 Instruction Manual D200299X012 Note Because of the high controller gain, the controller output will not remain stable in steps 9 through 13. The controller output gauge is adequate to monitor the output pressure during this procedure. 9. Set the proportional band between DIRECT and REVERSE. 10. The controller output should be relatively stable at any value within the output range.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 17. Alignment of the Process Pointer with the Set Point Indicator W4039 RIGHT‐HAND EDGE W4038 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. Set the proportional band to 400 percent in the desired controller action.
4196A, B, C, 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.
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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 18.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 19.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 20. Reset‐Rate Schematic RELAY OUTPUT PRESSURE RESET VALVE RATE VALVE GAIN LIMITER RESET BELLOWS PROPORTIONAL BELLOWS 19A5000-A A3237-2 Anti‐Reset Windup (suffix letter F) Operation Anti‐reset windup is available on all 4196B and C controllers and is designated by the letter F in the type number.
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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 External Feedback Operation 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Section 5 4196S 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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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 the pressure to increase the set point, and decrease the pressure to decrease the set point.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 25.
4196A, B, C, 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.
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.
4196A, B, C, 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Remote Set Point (suffix letter M) Zero and 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.
Instruction Manual 4196A, B, C, and S Controllers 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: D Divide the differential gap (the difference between the upper and lower switching points) by the sensing element range.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 D 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).
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 27.
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.
4196A, B, C, and S Controllers March 2012 58 Instruction Manual D200299X012
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Section 6 Maintenance7 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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Troubleshooting 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 Fault 1. Process wanders or cycles about set point Possible Cause Check Correction 1.1 Proportional band and reset settings 1.1 Refer to the Start‐up section for controller settings. 1.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Table 8. Troubleshooting Chart (Continued) Fault 2. Controlling off set point as reflected by process and set point indicators Possible Cause Check Correction 2.6 Leak in feedback system. 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. 2.6 Repair as necessary.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Table 8. Troubleshooting Chart (Continued) Fault 6. Controller will not attain full output range Possible Cause 6.4 Input element or linkage failure 6.5 Leak in nozzle pressure tubing 6.6 Relay malfunction 7. Controller remains at full output 8. Controller remains at zero output 7.1 Supply pressure too high Check 6.4 Inspect the element for alignment, loose screws and damaged flexures, links or pivots.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Table 8. Troubleshooting Chart (Continued) Fault 8. Controller remains at zero output Possible Cause Check Correction 8.4 Relay malfunction 8.4 Check for air at the nozzle. Cap the nozzle and note that the controller output increases to within 0.5 psig of supply pressure. 8.4 Clean out the relay primary orifice with the cleanout wire attached to the relay to ensure the orifice is not clogged.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 2. Remove the four self‐tapping screws (key 37). 3. 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. 4.
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.
4196A, B, C, and S Controllers Instruction Manual March 2012 D200299X012 2. Unscrew the nuts at each end of the tubing assembly. Remove the tubing assembly. 3. Install the replacement tubing assembly. 4. Set the reset adjustment to 0.01 (4196B and C controllers) and set the rate adjustment to OFF (4196C controllers). 5. Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure. Then, remove the pressure. 6.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 31.
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; 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 10. 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. 11. 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).
4196A, B, C, and S Controllers Instruction Manual March 2012 D200299X012 18. Attach link 3 to the set point beam shoe as shown in figure 31. 19. For controllers with reset or rate adjustment (4196B and 4196C controllers), turn the reset adjustment to the CLOSED (4196B) 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.
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.
Instruction Manual 4196A, B, C, and S Controllers 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 FLAPPER LEVELING SCREW NUMBER 2 OBLONG HOLE IN FRAME W4770 Figure 37.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 38. Link 2 and 4 Adjustment Locations LINK 4 ADJUSTMENT LINK 4 LINK 2 LINK 2 ADJUSTMENT LINK 3 W3442‐1 Figure 39. Link 2 Adjustment LEVELING SCREW NUMBER 1 CONNECTING TAB ON FLAPPER ASSEMBLY W3451 W4191 1/2 OF PIN DIAMETER 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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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). 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 44. 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.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 40. Bellows Assembly, Bellows Bracket, and Bellows Beam Location FOUR SCREWS (KEY 6) RESET BELLOWS WASHER (KEY 362) TWO SCREWS (KEY 35) PROPORTIONAL BELLOWS RESET GAIN BELLOWS BRACKET (KEY 31) LINK 4 (KEY 65) W4199 9. 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). 10.
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.
4196A, B, C, 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 12. Insert the reset tubing assembly (key 43) into the rate/reset valve assembly and tighten the nut. 13. Insert the proportional tubing assembly (key 40) into the rate/reset valve assembly and tighten the nut. 14. 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. 15. Set the reset to 0.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 3. Remove the two screws (key 129) at the bottom of the controller case. 4. Lift off the temperature 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. 6. With the assembly in position, install and tighten the three screws (key 127). 7.
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 cover (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.
4196A, B, C, and S Controllers Instruction Manual March 2012 D200299X012 3. 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. 4. 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 43. Flapper Leveling Screw and Clinch Nut CLINCH NUT FLAPPER LEVELING 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.
4196A, B, C, 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 45.
4196A, B, C, and S Controllers Instruction Manual March 2012 D200299X012 2. Set the 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.
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 alignment 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.
Instruction Manual 4196A, B, C, and S Controllers 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 2. 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). 4. Disconnect the drive flexure (key 79) from the adjustment arm of pivot assembly A. Be careful not to bend or kink the drive flexure. 5.
4196A, B, C, 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.
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.
4196A, B, C, and S Controllers March 2012 Instruction Manual 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.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 2. 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. 3. 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. Set the length of link B (key 126) so the set point indicator indicates mid‐scale on the process scale span. 5.
4196A, B, C, 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.
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.
4196A, B, C, 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‐ring (key 298). 12.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 2. Remove the tubing assembly (key 309). 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.
4196A, B, C, 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 procedure. 9. Mount the controller as described in the Installation section. 10. 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 Section 7 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. WARNING Use only genuine Fisher replacement parts.
Instruction Manual 4196A, B, C, and S Controllers March 2012 Key Description 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/remote set pt and ext feedback) 8* O‐Ring, nitrile (3 req'd) Used between frame and case on mounting bosses extending from the frame through the back of the c
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Key 46* Pressure Gauge(1) GAUGE MATERIAL RANGE Brass SST Dual Scale Gauge 0 to 2 kg/cm2/ 0 to 30 psig 11B8577X042 11B8583X032 0 to 4 kg/cm2/ 0 to 60 psig 11B8577X052 --- 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 11B8583X012 11B8577X022 11B8583X022 1. One type of pressure gauge is used for both output pressure and supply pressure indication.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 48.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Key 46* Pressure Gauge(1) GAUGE MATERIAL RANGE Brass SST Dual Scale Gauge 0 to 2 kg/cm2/ 0 to 30 psig 11B8577X042 11B8583X032 0 to 4 kg/cm2/ 0 to 60 psig 11B8577X052 --- 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 11B8583X012 11B8577X022 11B8583X022 1. One type of pressure gauge is used for both output pressure and supply pressure indication.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 48.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 48.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 48.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 49.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 50.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 51.
Instruction Manual 4196A, B, C, and S Controllers March 2012 D200299X012 Figure 52.
Instruction Manual 4196A, B, C, and S Controllers D200299X012 March 2012 Figure 53.
Instruction Manual 4196A, B, C, and S Controllers March 2012 Key Description Panel Mounting (figure 4) 66 67 68 70 Cap screw, hex hd, pl steel (3 req'd) Lock washer, pl steel (3 req'd) Bracket, A569 (pl steel) Machine Screw, rd hd, pl steel (4 req'd) Wall Mounting (figure 5) 66 67 68 Cap screw, pl steel (3 req'd) Lock washer, pl steel (3 req'd) 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 r
