Emerson Fisher 4196 Instruction Manual
Instruction Manual
D200299X012
4196A, B, C, and S Controllers
Fisherr 4196A, B, C, and S Temperature
Indicating Controllers
March 2012
Contents
1. Introduction 3...............................
Scope of Manual 3.............................
Description 4.................................
Specifications 4...............................
Educational Services 4.........................
2. Installation 9................................
Controller Mounting Orientation 9...............
Pipestand Mounting 10........................
Panel Mounting 10............................
Wall Mounting 10.............................
Actuator Mounting 11.........................
Temperature Sensing Bulb, Bushings,
and Thermowells 11.........................
Pressure Connections 14.......................
Supply Pressure Connection 15..............
Remote Set Point (suffix letter M)
Pressure Connection 15..................
External Feedback Pressure Connection
(4196B Controllers Only) 15...............
Vent 16......................................
3. 4196A Proportional‐Only Controllers 17.........
Adjustments for 4196A Controllers 17............
Manual Set Point Adjustment 17.............
Remote Set Point (suffix letter M)
Adjustment 18..........................
Proportional Band Adjustment (PB ADJ) 18.....
Changing Controller Action 18...............
Switching the Auto/Manual Station
(suffix letter E) 19.......................
Prestartup Checks for 4196A Controllers 19.......
Startup for 4196A Controllers 20.................
Calibration of 4196A Controllers 21..............
General Calibration Instructions 21...........
Temperature Baths 21......................
Process Indicator Zero and Span
Calibration 21..........................
Remote Set Point (suffix letter M)
Zero and Span Calibration 22..............
Flapper Alignment 23......................
Principle of Operation for
4196A Controllers 25........................
Overall Operation 25.......................
Remote Set Point (suffix letter M)
Operation 26...........................
Auto/Manual Station (suffix letter E)
Operation 26...........................
4. 4196B Proportional‐Plus‐Reset Controllers
and 4196C Proportional‐ Plus‐Reset‐Plus‐Rate
Controllers 29.................................
Adjustments for 4196B and C Controllers 29.......
Manual Set Point Adjustment 29.............
Remote Set Point (suffix letter M)
Adjustment 30..........................
Proportional Band Adjustment (PB ADJ) 30.....
Changing Controller Action 30...............
Reset Adjustment 31.......................
Rate Adjustment 31........................
Anti‐Reset Windup (suffix letter F)
Adjustment 31..........................
Switching the Auto/Manual Station
(suffix letter E)
Prestartup Checks for 4196B and C
Controllers 31..............................
Startup for 4196B and C Controllers 32...........
Calibration of 4196B and C Controllers 33.........
General Calibration Instructions 34...........
Temperature Baths 34......................
Process Indicator Zero and Span
Calibration 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
Controllers 41..............................
Overall Operation 41.......................
Anti‐Reset Windup Option (suffix letter F)
Operation 44...........................
Remote Set Point (suffix letter M)
Operation 44...........................
Auto/Manual Station (suffix letter E)
Operation 44...........................
External Feedback Operation 46..............
31.......................
www.Fisher.com
4196A, B, C, and S Controllers
March 2012
Instruction Manual
D200299X012
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)
Adjustment 48..........................
Proportional Band Adjustment (PB ADJ) 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 51...........
Temperature Baths 51......................
Process Indicator Zero and Span
Calibration 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)
Operation 56...........................
Auto/Manual Station (suffix letter E)
Operation 57...........................
6. Maintenance 59.............................
Inspection and Maintenance 59..................
Troubleshooting 60............................
Replacing Common Controller Parts 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
Bellows 75.............................
Replacing the Reset Restriction Valve
(4196B) 78.............................
Replacing the Rate/Reset Valve Assembly
(4196C) 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 79............................
Replacing the Temperature Element 79.......
Replacing the Links 80......................
Replacing Link 1 81........................
Replacing Link 2 81........................
Replacing Link 3 82........................
Replacing Link 4 83........................
Process Indicator Zero and Span
Adjustment
Remote Set Point (suffix letter M)
Maintenance 87............................
Replacing The Remote Set Point
Assembly 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 Link B 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 93..........................
Remote Set Point Linearity Adjustment 94.....
Auto/Manual Station (suffix letter E)
Maintenance 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,
Tubing, and Ball 96......................
Replacing the Loader Valve Plug and
Valve Plug Spring 97.....................
7. Parts 99....................................
Parts Ordering 99.............................
Parts Kits 99..................................
Parts List 99..................................
Controller Common Parts 99................
Process and Set Point Indicator
Assembly 107...........................
Indicator Assembly 107.....................
Remote Set Point Assembly
(suffix letter M) 108......................
Auto/Manual Station (suffix letter E) 109.......
Internal/External Set Point Assembly
(Option) 111...........................
84.............................
2
Instruction Manual
D200299X012
Figure 1. Fisher 4196 Temperature Controllers
4196A, B, C, and S Controllers
March 2012
NAMEPLATE
W6393
Contents (cont'd)
Controller Mounting Parts 111...................
Pipestand Mounting 111....................
Pipestand Mounting with Regulator 111.......
Panel Mounting 112........................
Wall Mounting 112.........................
Controller Mounting Parts for Actuator
with Casing‐Mounted Controller 112.......
Controller Mounting Parts for Actuator
with Yoke‐Mounted Controller 112.........
INTERIOR OF CONTROLLER
Regulator Mounting Parts 112...................
Regulator Mounting Parts for
Casing‐Mounted Regulator 112............
Regulator Mounting Parts for
Yoke‐Mounted Regulator (Mounting
Bracket Not Required) 112................
Regulator Mounting Parts for
Yoke‐Mounted Regulator with Mounting
Bracket 112............................
Fittings 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 4196S 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.
3
4196A, B, C, and S Controllers
March 2012
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 regarding these instructions contact your Emerson Process
Management sales office before proceeding.
Instruction Manual
D200299X012
Description
The controllers described in this manual provide temperature control with options as shown in table 1.
D 4196A: Proportional‐only control
D 4196B: Proportional‐plus‐reset control
D 4196C: Proportional‐plus‐reset‐plus‐rate control
D 4196S: 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, C, 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
4
Instruction Manual
D200299X012
Table 1. Specifications
4196A, B, C, and S Controllers
March 2012
Available Configurations
See table 2
Process Sensor Range (Input Signal)
Type: Temperature between ‐73 and 371_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
(1)
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
ppm.
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-
Maximum Allowable Pressure In Closed Vessel
(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 500% 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: 0.4% of output span
Dead Band: Less than 0.3% of process scale span
Time Constant of Temperature Bulb: 6 to 12 seconds
for a 93_C (200_F) span (bare bulb in agitated liquid)
Steady‐State Air Consumption
(A, B, and C Controllers)
(3)
Without Auto/Manual Station
3
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
3
(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
3
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 m3/h
(3.5 scfh)
0 and 2.4 bar (0 and 35 psig) Output: 0.14 normal m
(5.0 scfh)
Delivery Capacity (All 4196 Controllers)
(3)
0.2 to 1.0 Bar (3 to 15 psig) Output: 5.9 normal m3/h
(240 scfh)
0.4 to 2.0 Bar (6 to 30 psig) Output: 10.4 normal m
3
(350 scfh)
/h
/h
3
/h
5
4196A, 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 m3/h
(186 scfh)
0.4 to 2.0 Bar (6 to 30 psig) Output: 7.0 normal m
3
/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
Note: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.
1. Consult your Emerson Process Management sales office for additional information.
2. At 40_C (100_F).
3. Normal m
3
/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).
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
3 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.
Table 2. Available Configurations
Modes Options
Controller
4196A
4196B
4196C
4196S
1. Reverse‐acting constructions are designated by the suffix letter R in the type number.
(1)
4196A
4196AE
4196AM
4196AME
4196B
4196BE
4196BF
4196BFE
4196BM
4196BME
4196BFM
4196BFME
4196C
4196CE
4196CF
4196CFE
4196CM
4196CME
4196CFM
4196CFME
4196S
4196SE
4196SM
4196SME
Proportional‐
Only
(One‐Mode
Controllers)
X
X
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
Proportional‐
Plus‐Reset
(Two‐Mode
Controllers)
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
X
X
X
X
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
Proportional‐Plus‐
Reset‐Plus‐Rate
(Three‐Mode
Controllers)
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
Differential
Gap
(Snap‐Acting
Controllers)
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
X
X
X
X
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
X
X
Internal Auto/
Manual Station
(Suffix Letter E)
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
‐ ‐ ‐
X
Anti‐Reset
Windup
(Suffix Letter F)
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
‐ ‐ ‐
‐ ‐ ‐
X
X
‐ ‐ ‐
‐ ‐ ‐
X
X
‐ ‐ ‐
‐ ‐ ‐
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
Remote
Set Point
(Suffix Letter M)
‐ ‐ ‐
‐ ‐ ‐
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
X
X
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
X
X
X
X
‐ ‐ ‐
‐ ‐ ‐
X
X
6
Instruction Manual
D200299X012
Table 3. Supply Pressure Data
Output Signal Range Normal Operating Supply Pressure
Metric Units
U.S. Units
1. If this pressure is exceeded, control may be impaired.
2. If this pressure is exceeded, damage to the controller may result.
0.2 to 1.0 bar
0.4 to 2.0 bar
3 to 15 psig
6 to 30 psig
1.4 bar
2.4 bar
20 psig
35 psig
4196A, B, C, and S Controllers
March 2012
(1)
Maximum Pressure to Prevent
Internal Part Damage
2.8 bar
2.8 bar
40 psig
40 psig
(2)
Table 4. Available Temperature Ranges of Temperature Bulbs
Temperature Span
_C Minimum _C Maximum _C _C mm _C Minimum _C Maximum _C
100 100
150 150 0 to 150 ‐30 to 160 ‐15 225
Metric
Units
U. S.
Units
1. Contact your Emerson Process Management sales office about other spans and ranges.
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 damage to the temperature element.
60 60
150 150
170 200 0 to 200 ‐75 to 230 ‐20 300
275 300 0 to 300 ‐75 to 370 ‐30 450 590
_F Minimum _F Maximum _F _F Inch _F Minimum _F Maximum _F
175 200
250 300 0 to 300 ‐25 to 325 ‐30 450
100 100
125 150
270 300
300 400 0 to 400 ‐100 to 450 ‐40 600
525 600 0 to 600 ‐100 to 700 ‐60 900 1100
Element
Range
0 to 100
50 to 150 40 200
‐15 to 85 ‐25 135
‐20 to 40 ‐30 to 95
0 to 60 ‐30 to 95 ‐6 90
60 to 120 38 to 150 54 150
‐75 to 75 ‐75 to 135 ‐90 150
50 to 200 ‐5 to 200 35 275
0 to 200
50 to 250 30 350
100 to 300 80 400
0 to 100
50 to 150 40 200
100 to 200 75 to 300 65 250
0 to 150
50 to 200 35 275
‐100 to 200 ‐100 to 275 ‐130 350
100 to 400 25 to 400 70 550
Operating
Range
‐15 to 150
0 to 300
‐25 to 200
‐25 to 225
(1)
Temperature
Bulb Diameter
9.5
14.3
3/8
9/16
Overrange Limits
‐10 150
‐26 70
‐20 300
‐10 150
‐15 225
(2)
Maximum
Temperature
230
190
400
450
375
750
(3)
7
4196A, B, C, and S Controllers
March 2012
Instruction Manual
D200299X012
8
Instruction Manual
D200299X012
4196A, B, C, and S Controllers
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. 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.
D If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this
instruction manual.
D 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
ACTUATOR
4196
CONTROLLER
67FR
FILTER
REGULATOR
MOUNTING
PLATE
W5661
9
4196A, B, C, and S Controllers
March 2012
Instruction Manual
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. Pipestand Mounting
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
HEX NUT
(KEY 364)
LOCKWASHER
(KEY 363)
PIPE CLAMP
(KEY 69)
VERTICAL PIPE
HEX HEAD
CAP SCREW
(KEY 362)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
REGULATOR
HEX HEAD
CAP SCREW
(KEY 362)
PIPE CLAMP
(KEY 69)
BRACKET
(KEY 68)
ELBOW
(KEY 365)
49A3196‐A
A6732
LOCKWASHER
(KEY 363)
HEX NUT
(KEY 364)
HEX HEAD
CAP SCREW
(KEY 66)
LOCKWASHER
(KEY 67)
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.
10
Instruction Manual
D200299X012
4196A, B, C, and S Controllers
March 2012
Figure 4. Panel Mounting
LOCK
WASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 66)
BRACKET
(KEY 68)
ROUND
HEAD
MACHINE
SCREW
(KEY 70)
36A9760‐A
A6733
TOP VIEW
13
(0.50)
REAR VIEW
PANEL MOUNTING
84
(3.29)
(2.49)
62
(2.43)
DIMENSIONS OF
PANEL CUTOUT
63
14
(0.56 R)
236
(9.31)
306
(12.06)
mm
(INCH)
Figure 5. Wall Mounting
TOP VIEW
260
(10.25)
152
(6.00)
13
(0.50)
36A9761‐B
A6734
13
(0.50)
REAR VIEW
161
(6.35)
LOCKWASHER
(KEY 67)
HEX HEAD
CAP SCREW
(KEY 66)
62
(2.43)
BRACKET
(KEY 68)
mm
(INCH)
Actuator Mounting
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 the temperature element is attached to the bushing with a threaded connection.
11
4196A, B, C, and S Controllers
March 2012
Instruction Manual
D200299X012
Figure 6. Temperature Element Assembly with Adjustable Union
LINE CAPILLARY
SILVER BRAZE
SUPPORT
BRACKET
PACKING NUT
SWIVEL NUT
PACKING RING
ADJUSTABLE SEAT
BENDABLE
NOTE:
1
MINIMUM BEND RADII 1‐1/4
A5434
EXTENSION
If the process pressure exceeds the limitations of the temperature bulb, or if the process fluid is corrosive, a
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
thermowell, the temperature element is then attached to the thermowell with a threaded connection.
(1)
Table 5. Maximum Process Fluid Velocities
Temperature
Thermowell Size
1/2 NPT 10 3/8
3/4 NPT 10 3/8
3/4 NPT 14 9/16
1. For gas, air, or steam. Values may be lower for liquids.
2. This is the U dimension in figure 7.
Bulb Diameter
mm Inch m/s Feet/s m/s Feet/s m/s Feet/s m/s Feet/s
Brass
Carbon steel
304 stainless steel/316 stainless steel
N04400
Brass
Carbon steel
304 stainless steel/316 stainless steel
N04400
Carbon steel
304 stainless steel/316 stainless steel
N04400
for Thermowells
Material
Insertion Length
(2)
, mm (Inch)
191 (7.5) 267 (10.5) 406 (16) 610 (24)
11.6
14.6
15.2
14.6
16.5
21.0
21.9
20.7
29.6
30.5
28.9
100
38
5.8
48
7.6
50
7.9
48
7.3
54
8.2
69
10.7
72
11.3
68
10.7
97
14.9
15.5
95
14.9
19
2.4
25
3.4
26
3.4
24
3.4
27
3.7
35
4.6
37
4.9
35
4.6
49
6.4
51
6.7
49
6.4
8
‐ ‐ ‐
11
‐ ‐ ‐
11
‐ ‐ ‐
11
‐ ‐ ‐
12
‐ ‐ ‐
15
‐ ‐ ‐
16
‐ ‐ ‐
15
‐ ‐ ‐
21
3.0
22
3.0
21
2.7
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
10
10
9
12
Instruction Manual
D200299X012
Figure 7. Bushing and Thermowell Dimensions
BUSHING
Temperature Bulb Diameter
(1)
A
mm Inch mm Inch mm Inch
10 3/8 1/2‐14 NPSM 11 0.44 11 0.44
14 9/16 1‐20 UNEF 19 0.75 16 0.63
1. Seat area per SAMA Standard RC‐17‐10.
LAGGED BUSHING
Temperature
Bulb Diameter
mm Inch mm Inch mm Inch mm Inch mm Inch
10 3/8
14 9/16 1‐20 UNEF 19 0.75 17 0.66 121 4.75 16 0.63
1. Seat area per SAMA Standard RC‐17‐10.
(1)
A
1/2‐14
NPSM
B C D E
11 0.44 12 0.47 113 4.44 11 0.44
THERMOWELL
Temperature Bulb
Diameter
(1)
A
mm Inch mm Inch mm Inch
10 3/8
14 9/16 3/4‐14 NPT 22 0.88 1‐20 UNEF‐2B
1. Seat area per SAMA Standard RC‐17‐10.
1/2‐14 NPT
3/4‐14 NPT
16
20
Dimension
B C
Dimension
Dimension
B
0.63
1/2‐14 NPSM‐2B
0.77
U
C
(Insertion Length)
191
267
406
191
267
406
610
4196A, B, C, and S Controllers
March 2012
7.5
10.5
16
7.5
10.5
16
24
44
2
B
(1.75)
44
(1.75)
2
C
A
BUSHINGS WITHOUT LAGGING
2
B
E
A
3/4‐14 NPT
D
C
3/4‐NPT
C
THERMOWELLS WITHOUT LAGGING
2
C
BUSHINGS WITH 76 mm (3‐INCH) LAGGING THERMOWELLS WITH 76 mm (3‐INCH) LAGGING
NOTES:
TOLERANCES FOR THIS DIMENSION ARE AS FOLLOWS: ±1.5 mm (0.06 INCH) WHEN LENGTH IS 305 mm (12 INCHES) OR LESS
1
±3.2 mm (0.125 INCH) WHEN LENGTH IS GREATER THAN 305 mm (12 INCHES).
2
7/8 INCH HEX FOR 3/8‐INCH TEMPERATURE BULB; 1‐1/8 INCH HEX FOR 9/16‐INCH TEMPERATURE BULB
A3240‐2
(100)
121
(4.75)
U
25
1
B
1
25
(100)
A
U
B
mm
(INCH)
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4196A, B, C, and S Controllers
March 2012
Table 6. Maximum Process Pressures for Thermowells
Thermowell
Size
1/2 NPT 10 3/8
3/4 NPT 10 3/8
3/4 NPT 14 9/16
Temperature
Bulb Diameter
Material
21 (70) 93 (200) 204 (400) 316 (600) 427 (800) 538 (1000)
mm Inch Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig Bar Psig
Brass
Carbon steel
304 SST
316 SST
N04400
Brass
Carbon steel
304 SST
316 SST
N04400
Carbon steel
304 SST
316 SST
N04400
193.9
218.0
284.3
284.3
263.6
345.0
358.8
483.0
483.0
448.5
159.4
239.4
239.4
211.8
2810
3160
4120
4120
3820
5000
5200
7000
7000
6500
2310
3470
3470
3070
Pressure Connections
174.6
209.8
258.1
284.3
243.6
289.8
345.0
427.8
483.0
414.0
140.1
212.5
239.4
173.2
2530
3040
3740
4120
3530
4200
5000
6200
7000
6000
2030
3080
3470
2510
Temperature _C (_F)
30.4
440
200.1
2900
234.6
3400
265.7
3850
224.3
3250
69.0
1000
331.2
4800
386.4
5600
441.6
6400
372.6
5400
131.1
1900
173.9
2520
223.6
3240
169.7
2460
‐ ‐ ‐
191.1
226.3
259.4
221.5
‐ ‐ ‐
317.4
372.6
427.8
365.7
125.6
167.7
217.4
166.3
Instruction Manual
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
2110
3180
3680
3130
‐ ‐ ‐
3500
5200
6100
5200
1430
1850
3100
2150
2770
3280
3760
3210
‐ ‐ ‐
4600
5400
6200
5300
1820
2430
3150
2410
145.6
219.4
253.9
215.9
241.5
358.8
441.6
358.8
98.7
127.7
213.9
148.4
D200299X012
‐ ‐ ‐
‐ ‐ ‐
63.4
920
189.8
2750
212.5
3080
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
‐ ‐ ‐
1500
4500
5100
1500
‐ ‐ ‐
1630
2600
‐ ‐ ‐
103.4
310.5
351.9
103.4
112.5
179.4
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 NPT
REMOTE SET CONNECTION
WHEN APPLICABLE
268
(10.56)
FRONT VIEW
A3239‐2
130
(5.12)
330
(13.00)
102
(4.00)
REAR VIEW
51
(2.00)
(3.44)
5/16‐18UNC‐2B
3 HOLES
225
(10.04)
87
CAPILLARY
TUBE
1/4‐18 NPT
EXTERNAL
FEEDBACK
CONNECTION
WHEN
APPLICABLE
(4196B ONLY)
BOTTOM VIEW
148
(5.81)
1/4‐18 NPT
SUPPLY PRESSURE
CONNECTION
1/4‐18 NPT
CONTROLLER OUTPUT
CONNECTION
1/4‐18 NPT
VENT CONNECTION
mm
(INCH)
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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. 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
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.
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4196A, B, C, and S Controllers
March 2012
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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. 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) and a
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.
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Instruction Manual
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4196A, B, C, and S Controllers
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. 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
SETPOINT
INDICATOR
METAL BALL
SWITCHING
ZONE
INDICATOR
LOADER KNOB
AUTO/MANUAL
SWITCH
W3679
AUTO/MANUAL STATION
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE
GAUGE
W6394
(SUFFIX LETTER E)
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.
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4196A, B, C, and S Controllers
March 2012
Instruction Manual
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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 values 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.
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Instruction Manual
D200299X012
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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 ball 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 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 a 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 (6 to 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. Adjust the set point a minimum of 20 percent of input span above the process pointer.
5. Adjust the proportional band for 5 percent DIRECT.
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4196A, B, C, and S Controllers
March 2012
Instruction Manual
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 4196A 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. 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.
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. Determine the initial proportional band setting in percent from the following equation:
P.B. +
200 Allowable Overshoot
Temperature Span
For example:
100
o
F
+ 20%
o
F
200 10
4. 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.
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 × 2).
6. Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring
the process.
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Instruction Manual
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4196A, B, C, and S Controllers
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.
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 procedure:
D Provide a means of changing the process temperature to the controller and a means of measurement external to
the controller.
D 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.
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4196A, B, C, and S Controllers
March 2012
Instruction Manual
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. 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. 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 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 3 through 13.
Remote Set Point (suffix letter M) Zero and Span Calibration
Refer to figure 9 and 11 for 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. 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.
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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. 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. 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 point, 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.
2. 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.
3. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36).
4. Set the proportional band between DIRECT and REVERSE.
5. The controller output should be 0.62 ±0.007 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. Set the proportional band to 30 percent DIRECT.
7. 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
leveling screw 3 (the screw nearest the 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
leveling screw 1 (the screw nearest the nozzle).
10. Repeat steps 4 through 9 until the controller output remains in tolerance without further leveling screw
adjustment.
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4196A, B, C, and S Controllers
March 2012
Figure 11. Fisher 4196A Controller Calibration Adjustment Locations
REMOTE SET POINT
(SUFFIX LETTER M)
ZERO ADJUSTMENT
REMOTE SET POINT
(SUFFIX LETTER M)
ZERO ADJUSTMENT
LOCKING SCREW
Instruction Manual
D200299X012
PROCESS POINTER
ZERO ADJUSTMENT
PROCESS POINTER
ZERO ADJUSTMENT
LOCKING SCREW
W6394
PROCESS
POINTER SPAN
ADJUSTMENT
SET POINT/PROCESS
INDICATOR ASSEMBLY
39A1126‐B
A6731
REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)
SIDE VIEW OF
FRONT VIEW
59A9752‐S SHT 1
PROCESS POINTER
SPAN ADJUSTMENT
SCREW 1
SCREW 2
SCREW 3
SIDE VIEW OF
CONTROLLER SHOWING
FLAPPER LEVELING SCREWS
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Instruction Manual
D200299X012
4196A, B, C, and S Controllers
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.
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
SET POINT INDICATOR
PROCESS POINTER
REMOTE SET POINT
CONNECTED HERE
INPUT ELEMENT
CONNECTED HERE
CONNECTING
LINK
SUPPLY PRESSURE
OUTPUT PRESSURE
PROPORTIONAL PRESSURE
NOZZLE PRESSURE
46A9764‐A
B1489‐2
BEAM
RESET BELLOWS (VENTED)
PROPORTIONAL
BELLOWS
FLAPPER
NOZZLE
PROPORTIONAL
BAND ADJUSTMENT
FEEDBACK
LINK
FEEDBACK
MOTION
DIRECT ACTION
QUADRANT
SUPPLY
PRESSURE
REVERSE ACTION
QUADRANT
FLAPPER PIVOT
INPUT
MOTION
FLAPPER DETAIL
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY
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
25
4196A, B, C, and S Controllers
March 2012
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.
Instruction Manual
D200299X012
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. 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 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.
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Instruction Manual
D200299X012
Figure 13. Fisher 4196A Auto/Manual Station Schematic
4196A, B, C, and S Controllers
March 2012
AUTOMATIC
POSITION
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
RELAY OUTPUT PRESSURE
SUPPLY PRESSURE
MANUAL LOADER OUTPUT PRESSURE
48A5230‐A
A2999‐1
SUPPLY
PRESSURE
AUTO/MANUAL
SWITCH
RELAY
MANUAL LOADER
MANUAL
LOADER
KNOB
PLASTIC
TUBE
METAL BALL
MANUAL
POSITION
AUTO/MANUAL
SWITCH
OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT
27
4196A, B, C, and S Controllers
March 2012
Instruction Manual
D200299X012
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Instruction Manual
D200299X012
4196A, B, C, and S Controllers
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
SUPPLY
PRESSURE
GAUGE
W6395
TYPICAL ADJUSTMENTS 4196B SHOWN
RESET
ADJUSTMENT
Manual Set Point Adjustment
PROCESS POINTER
PROPORTIONAL BAND
ADJUSTMENT
PROPORTIONAL BAND
INDICATOR COVER
OUTPUT PRESSURE
GAUGE
ANTI‐RESET WINDUP
DIFFERENTIAL RELIEF
VALVE (SUFFIX LETTER F)
RATE
ADJUSTMENT
W3599-1
LOADER KNOB
AUTO/MANUAL
SWITCH
W3679
AUTO/MANUAL STATION
(SUFFIX LETTER E)
RESET
ADJUSTMENT
4196C RESET AND RATE ADJUSTMENTS
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.
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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. 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.
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