Emerson Fisher 4200 Series, Fisher 4211, Fisher 4212, Fisher 4215, Fisher 4220 Instruction Manual

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Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

4200 Series Electronic Position Transmitters

Contents

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .

Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Educational Services 4. . . . . . . . . . . . . . . . . . . . . .

Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Connections 7. . . . . . . . . . . . . . . . . . .

Sliding-Stem Actuator Mounting 7. . . . . . . . . . .

Rotary-Shaft Actuator Mounting 7. . . . . . . . . . .

Long Stroke Sliding-Stem Actuator

Mounting Type 585C and 470-16 8. . . . . . . .

Long Stroke Sliding-Stem Actuator

Mounting Type 585CLS and 490 9. . . . . . . .

Electrical Connections 9. . . . . . . . . . . . . . . . . . . . .

Conduit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Wiring 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer Alignment 12. . . . . . . . . . . . . . . . .

Direct or Reverse Action 14. . . . . . . . . . . . . . . . . .

Operating Information 16. . . . . . . . . . . . . . . . . . . . .

Initial Considerations 16. . . . . . . . . . . . . . . . . . . . .

Transmitter and Position Switch

Conditions 16. . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Operation 16. . . . . . . . . . . . . . . . . . . . . . . .

Calibration 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Equipment Required 17. . . . . . . . . . . . . . . . .

Test Connections to the Field Wiring

Compartment 17. . . . . . . . . . . . . . . . . . . . . . . . .

Transmitter Circuit Zero and Span

Adjustment 17. . . . . . . . . . . . . . . . . . . . . . . . . . .

High and Low Position Switch Adjustment 19. .

Setting the High Position Switch 19. . . . . . . . . .

Setting the High Position Switch

Deadband 19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Low Position Switch 19. . . . . . . . . .

Setting the Low Position Switch

Deadband 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Position Switch Circuit Shutoff 20. . . . . . . . . . . . .

Principle of Operation 21. . . . . . . . . . . . . . . . . . . . .

Transmitter Circuit 21. . . . . . . . . . . . . . . . . . . . . . .

Position Switch Circuit 21. . . . . . . . . . . . . . . . . . . .

Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Procedures 23. . . . . . . . . . . . . .

Transmitter Circuit 23. . . . . . . . . . . . . . . . . . . . . .

Position Switch Circuit 23. . . . . . . . . . . . . . . . . .

W4273-1

SLIDING-STEM

ACTUATOR MOUNTING

Figure 1. Typical 4200 Series Position Transmitters

Parts Ordering 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loop Schematics and Nameplates 40. . . . . . . . . .

Introduction

Scope of Manual

This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for the 4200 Series electronic position transmitters (figure 1). Refer to separate instruction manuals for information on the actuator and valve.

W4274-1

ROTARY

ACTUATOR MOUNTING

www.Fisher.com

D200354X012

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

No person may install, operate or maintain a 4200 Series electronic position transmitter without first D being fully trained and qualified in valve, actuator and accessory installation, operation and maintenance, and D carefully reading and understanding the contents of this manual. If you have any questions about these instructions, contact your FisherR sales office.

Note

Neither Emerson

, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user.

Description

The 4200 Series electronic position transmitters combine Fisher’s field-proven electronic and mechanical expertise in a versatile, accurate instrument. It senses the position of a sliding stem actuator, rotary actuator, vent, damper, or other device and sends a standard (4 to 20 milliampere) output signal to an indicating device, a process control system or programmable logic controller. The 4200 Series transmitters are available as a transmitter only, as a transmitter with integral high and low position switches, or with high and low position switches only. Refer to the nameplate to determine the type of transmitter. Use the Type number and table 2 to determine the output and travel ranges available from the transmitter.

1000

750

650

500

250

LOAD IMPEDANCE (OHMS)

POWER SUPPLY VOLTAGE (VOLTS dc)

A6765/IL

Figure 2. Power Supply Requirements

OPERATING REGION

3020

MAXIMUM TRANSMITTER TERMINAL VOLTAGE

NOMINAL SUPPLY VOLTAGE

MINIMUM TRANSMITTER TERMINAL VOLTAGE

For instruments equipped with position switches, the high relay position switch can be set at any point of travel. The low relay position switch can be offset from the high relay position switch trip point by as little as 1/20 of the travel. In the event of a power loss both position switch relays de-energize, indicating loss of transmitter power.

Specifications

Specifications for the 4200 Series transmitters are listed in table 1.

When the instrument is mounted, the potentiometer shaft (figure 3) is mechanically connected to the device to sense mechanical motion. Except for the Type 4215 transmitter, all types of transmitters use a single potentiometer for position input. The Type 4215 transmitter uses dual potentiometers mounted on the same shaft. This permits using individual potentiometers for the transmitter and the position switch circuits, providing additional electrical isolation. For long stroke applications, a multi-turn potentiometer attached to a cable/pulley assembly senses linear motion of the actuator stem or other device.

WARNING

This product is intended for a specific current range, temperature range and other application specifications. Applying different current, temperature and other service conditions could result in malfunction of the product, property damage or personal injury.

Instruction Manual

(mA)

Form 5596 July 2005

4200 Series Transmitters

Table 1. Specifications

Available Configurations

See table 2

Input Signal

(1)

Source: Single potentiometer is standard or a dual potentiometer is available for the Type 4215 only. Refer to table 3 for zero and span limits

Output Signal

Range

(1)

: 4 to 20 milliampere dc transmitter

output (Type 4210, 4211, 4215, 4220, and 4221 transmitters)

Load Impedance (transmitter only)

(1)

: See

figure 2. Output Current Limit: 30 milliamperes dc maximum Switches: ON/OFF condition of high and low position switch relay (SPDT)

Power Supply Requirements

Transmitter

Terminal Voltage

(Vdc)

Min Max

Transmitter Only 11 30 20 max. Position Switch with

Transmitter Position Switch without

Transmitter

1. Values indicate minimum power supply capabilities.

20 30 80 max.

20 30 50 max.

Current

Required

Operating Influences

Ambient Temperature

(1)

: For a 56_C (100_F)

change in normal operating conditions, maximum zero shift is ±0.5%; maximum span shift is ±0.75% of span Power Supply: Output signal changes less than ±0.1% when operating terminal voltage varies between 11 and 30 volts dc

Electromagnetic Interference (EMI)

(1)

: Tested per IEC 61326-1 (Edition 1.1). Conforms to the European EMC Directive. Meets emission limits for class A equipment (industrial locations) and class B equipment (domestic locations). Meets immunity requirements for industrial locations (Table A.1 in the IEC specification document). Immunity performance shown in table 4.

Operating Conditions

Condition

Ambient Temperature

Ambient Relative Humidity

(−40 to 160_F)

(1)

Normal and

Operative

Limits

−40 to 71_C

10 to 95% 10 to 95% 40%

Transportation

and Storage

Limits

−50 to 71_C

(−60 to 160_F)

Normal

Reference

25_C

(77_F)

Mounting

The instrument can be mounted on the actuator of sliding stem or rotary valves or on other devices

Recommended Power Supply

24 volts dc nominal

Position Switch Relays

Type: Two single-pole, double-throw relays

(SPDT) Service Rating: The relay contact rating is 5 amperes at either 30 volts dc or 120 volts ac (resistive load) Life Expectancy: 100,000 operations at rated load, or 50,000 operations at a typical inrush current of 10 amperes with 120 volts ac lamp or motor load

Reference Accuracy

±1% of output span. Includes combined effects of hysteresis, linearity, and deadband

Repeatability

(1)

±0.25% of span

1. These terms are defined in ISA Standard S51.1.

Electrical Classification

Explosion proof, Dust-Ignition proof, Intrinsically Safe

APPROVED

ATEX

Intrinsically Safe and Type n

Refer to tables 5 and 6, figures 24, 25, 26, 27, and 28, and the Hazardous Area Classification bulletins 9.2:001 series and 9.2:002 for additional information and/or approvals.

Housing

NEMA 4X; CSA Enclosure 4; IP66

Approximate Weight

Transmitter Without Mounting Bracket: 1.8 kg (4 pounds)

4200 Series Transmitters

ELECTRICAL

POTENTIOMETER

CONNECTION

TYPE

CONNECTION

(1)

Zero

4211

0 to 90

4221

0 to 884

150

884

Enclosure

I/O signal/control

Table 2. Available Configurations

TYPE

NUMBER

4210 4211 4212 4215

4220 4221 4222

1. See table 3 for zero and span limits.

TRANSMITTER

X X

− − − X

X X

− − −

POSITION

SWITCHES

− − − X X

− − − X

Standard Stroke Up to 105 mm

(Up to 4.125 Inches)

(1)

X X X X

− − −

TRAVEL

Long Stroke

Up to 610 mm

(Up to 24 Inches)

(1)

− − −

− − − X

X X

Instruction Manual

Form 5596

July 2005

DUAL

POTENTIOMETER

− − −

− − − X

− − −

Zero

(2)

SLIDING STEM ACTUATOR TRAVEL

mm INCHES

Span

Min. Max.

Zero

Position

Span

Min. Max.

Table 3. Zero and Span Limits

DEGREES OF

TYPE

NUMBER

4210 4211 4212 4215

4220 4222

1. Refer to figures 15, 22, and 23 for locations of connections.

2. Zero position is the range of values over which the transmitter zero can be adjusted. Span is the range of shaft rotation or stem travel the transmitter span can be adjusted. For example, a zero position of 45 degrees and a span of 15 degrees means the transmitter output is 4 mAdc after 45 degrees of shaft rotation. The output then increases from 4 mAdc to 20 mAdc as the shaft rotates from 45 to 60 degrees.

Zero

Position

ROTATION

Min. Max.

Span

(1)

Position

1 0 to 51 8 51 0 to 2 0.315 2

2 0 to 105 17 105 0 to 4.125 0.670 4.125

12-Inch Transducer 0 to 305 105 305 0 to 12 4.125 12 24-Inch Transducer 0 to 610 305 610 0 to 24 12 24

Table 4. Immunity Performance

Port Phenomenon Basic Standard Performance Criteria

Electrostatic discharge (ESD) IEC 61000-4-2 A

Enclosure

I/O signal/contro

Specification limit = ±1% of span

1. A = No degradation during testing. B = Temporary degradation during testing, but is self-recovering.

Radiated EM field IEC 61000-4-3 A Rated power frequency magnetic field IEC 61000-4-8 A Burst (fast transients) IEC 61000-4-4 A Surge IEC 61000-4-5 B Conducted RF IEC 61000-4-6 A

(1)

Educational Services

For information on available courses for 4200 Series electronic position transmitters, 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@emersonprocess.com

Instruction Manual

ATEX

Form 5596 July 2005

CERTIFICATION

BODY

CSA

MODEL/

TYPE

4211, 4221

4210, 421 1, 4212, 4215, 4220, 4221, 4222

4211, 4221

4210, 421 1, 4212, 4215, 4220, 4221, 4222

4211, 4221 Class I Division 2 GP A,B,C,D − − − 4210, 421 1,

4212, 4215, 4220, 4221, 4222

4200 Series Transmitters

Table 5. Hazardous Area Classifications for North America

CERTIFICATION OBTAINED ENTITY RATING

(Intrinsic Safety) Class/Division SClass I,II,III Division 1 GP A,B,C,D,E,F,G per drawing 20B6503

(Explosion Proof) Class/Division SClass I, Division 1 GP C,D

Class II Division 1 GP E,F,G

(Intrinsic Safety) Class/Division SClass I,II,III Division 1 GP A,B,C,D,E,F,G per drawing 20B6408

(Explosion Proof) Class/Division SClass I, Division 1 GP C,D

Class II Division 1 GP E,F,G − − −

= 40 Vdc

max

= 200 mA

max

= 5 nF

= 0 mH

− − −

TEMPERATURE

CODE

TC3 (T

T5 (T

T4A (T

T5 (T

amb

 71°C)

ENCLOSURE

RATING

CERTIFICATE

(AGENCY)

ATEX

(LCIE)

MODEL/

TYPE

4211, 4221

Table 6. Hazardous Area Classifications for Europe and Asia-Pacific

CERTIFICATION OBTAINED ENTITY RATING

(Intrinsic Safety) II 1 G Gas SEEx ia IIC T4/T5 Dust ST81C (T

 71°C)

amb

Ui = 30 Vdc I

= 150 mA

= 1.0 W

= 5 nF

= 0 mH

(Type n) II 3 G Gas SEEx nL IIC T4 Dust ST81C (T

 71°C)

amb

− − −

TEMPERATURE

T4 (T

amb

T5 (T

amb

T4 (T

amb

CODE

 71°C)  40°C)

 71°C)

ENCLOSURE

RATING

IP66

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

PORT 1/2-INCH NPT (2 PLACES)

51 (2.00)

19A7968−E B1910−4 / IL

(2.00)

BOTTOM VIEW

5/16-18UNC 13 DEEP (0.53)

CAP (2 PLACES)

6 (0.25) DIA.

END VIEW

Figure 3. Transmitter Dimensions

Installation

WARNING

Always wear protective clothing and eyewear when performing any installation operations to avoid personal injury.

Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual.

When the 4200 Series transmitters are ordered with an actuator, the factory mounts the transmitter and adjusts the zero and span for the travel specified on the order. Make field wiring connections as described in the electrical connections procedure and fine tune the transmitter to the application. Refer to the appropriate actuator and valve instruction manuals to install the attached assemblies.

If the transmitter has been ordered separately, or removed for maintenance, perform the appropriate portion of the Mechanical Connections, Electrical Connections, Potentiometer Alignment, and Calibration procedures.

The transmitter can be mounted in any of four positions. Mount the transmitter vertically or

102 (4.00)

67 (2.62)

TRANSMITTER COMPARTMENT

102 (4.00)

35 (1.38)

21 (0.81)

ALLOW 254 mm (10 INCHES) FOR MAINTENANCE (2 PLACES)

(3.00)

159 (6.25)

67 (2.62)

SIDE VIEW

FIELD WIRING COMPARTMENT

POTENTIOMETER SHAFT

mm (INCH)

horizontally depending on the application requirements. Refer to figures 15 through 23 for examples of typical actuator mounting assemblies.

As an aid to installation, and to understand the transmitter design in general, refer to figure 3 which shows the location of the transmitter compartment and the field wiring compartment. The transmitter compartment contains the transmitter and/or the position switch circuit on the printed wiring board, associated wiring assemblies, adjustment potentiometers, and the potentiometer that senses position. Remove the cover on the transmitter compartment to gain access to this compartment. The transmitter compartment is adjacent to the symbol on the housing.

Except for a Type 4211 or 4221 transmitter, the field wiring compartment contains a printed wiring board with the terminal blocks (figure 4) for connecting field wiring and associated cable assemblies. It also contains the position switch relays which are mounted on the printed wiring board. Remove the cap adjacent to the + and − symbols on the housing to access this compartment.

For a Type 4211 or 4221 transmitter without position switch circuits, the field wiring compartment contains a barrier strip for installation of the transmitter field wiring (figure 4).

Figure 3 shows the location of the ports into the field wiring compartment. Two ports are available for routing the transmitter and/or position switch wiring into the transmitter housing. After transmitter installation, install a plug in the unused port. When installing the transmitter, allow sufficient space for

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

removing the covers to perform maintenance and to make the wiring connections. Figure 3 also shows the basic transmitter outline dimensions.

Mechanical Connections

Sliding-Stem Actuator Mounting, Types 4210, 4211, 4212, and 4215

Use the following general procedures and figures 15, 16, 17, and 18 to mount the transmitter on sliding-stem actuators, standard stroke up to 105 mm (4.125 inches) travel.

Refer to figure 15 for key number locations for this example.

1. Install the transmitter on the mounting plate (key 21) with two cap screws (key 32).

2. Bolt the stem mounting bracket and spacer (keys 34 and 39) to the stem connector on the actuator stem. Replace the stem connector cap screws with the two cap screws (key 35) furnished with the stem mounting bracket.

3. If necessary, refer to the appropriate procedures in the actuator instruction manual to reconnect the actuator stem to the valve stem.

4. Fasten the stem bracket (key 33) to the stem mounting bracket (key 34) with two cap screws (key 37) centered in the slots of the stem bracket. Tighten the cap screws slightly.

5. On the transmitter, install the pickup pin into the lever assembly (key 30) in the position to match the application. Refer to table 3 and figure 15.

6. Temporarily connect the 24 volt dc power supply to the instrument as indicated in figure 4.

7. Perform the potentiometer alignment procedures before mounting the transmitter on the actuator. To simulate mid-stroke position in step 4 of the procedure, move the lever assembly (key 30) until its center line is parallel with the center line of the operating arm (key 25). After completing step 9 of the potentiometer alignment procedure, remove the 24 volts dc, and continue the actuator mounting procedure as described in the following steps.

8. Stroke the actuator to the mid position of the valve travel.

9. Fit the pickup pin, located in the lever assembly (key 30), into the horizontal slot in the stem bracket (key 33). Bolt the mounting plate (key 21) to the actuator with cap screws, washers, and spacers

(keys 23, 24, and 22) using the two tapped holes in the side of the actuator yoke.

10. Use the mounting plate slots, which allow the lever assembly (key 30) and the operating arm (key 25) to be nearly parallel, and position the long edge of the mounting plate parallel with the actuator stem. Tighten the bolts securely.

11. Loosen the two cap screws (key 37) connecting the stem bracket (key 33) to the stem mounting bracket (key 34). Manually move the lever assembly (key 30) until its center line is parallel with the center line of the operating arm (key 25).

12. Tighten the two cap screws (key 37) in the slotted holes.

13. Stroke the actuator to ensure that full travel is allowed.

14. Perform the electrical connection and direct and reverse action procedures.

15. Verify potentiometer alignment by performing the potentiometer alignment procedure.

Rotary-Shaft Actuator Mounting, Types 4210, 4211, 4212, and 4215

Use the following general procedures and figures 19, 20, and 21 to mount the transmitter on rotary-shaft actuators.

Refer to figure 19 for key number locations for this example.

1. Install the transmitter on the mounting plate (key 21) with two cap screws (key 32). The transmitter can be mounted in any of four positions on the bracket. Tighten the cap screws slightly.

2. On the actuator, attach the coupler plate assembly (key 57) and travel indicator to the actuator shaft. This is accomplished by removing two self-tapping screws and travel indicator and replacing them with the self-tapping screws and coupler plate assembly furnished with the transmitter for the mounting application.

3. Install the mounting plate (key 21) on the actuator using the four cap screws and washers (keys 23 and 24). The transmitter and bracket can be mounted in any of four positions by using the cap screws (key 23) on the face of the actuator hub.

4. Tighten the cap screws (key 23) slightly while aligning the potentiometer shaft on the transmitter with the coupler plate assembly pin (key 57). When aligned, tighten the four cap screws (key 23). Maintain this alignment while tightening the two cap

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

screws (key 32) holding the transmitter to the mounting plate (key 21).

5. Slide the coupler (key 52) over the potentiometer shaft and into the hole in the mounting plate (key 21). Slide the coupling (key 54) onto the plate assembly pin and attach the coupling to the plate assembly pin using the set screw.

6. Slide the coupler (key 52) into the coupling (key 54). The coupling should not be deflected in any direction when installed. Do not tighten the coupling set screw (key 53) as it will be tightened during the potentiometer alignment procedure.

7. Perform the electrical connections and potentiometer alignment procedures.

Long Stroke Sliding-Stem Type 585C and 470-16 Actuator Mounting, Types 4220, 4221, and 4222

Use the following general procedures and figure 22 to mount the transmitter on long stroke sliding-stem Type 585C and 470-16 actuators with 105 to 206 mm (4.125 to 8.125 inches) travel.

4. Attach the cable transducer housing (key 100A) to the mounting plate (key 63) using cap screws (key 103) and hex nuts (key 104).

5. Attach the mounting plate (key 63) to the actuator using hex head cap screws (key 32). Note: Some actuators may require spacers (key 101) between the mounting plate (key 63) and the actuator.

CAUTION

Free release of the cable (key 100B) will damage the transducer. Whenever the cable (key 100B) is extended, take steps to ensure that free release does not happen.

6. Carefully pull the cable (key 100B) down to the cable bracket (key 60) and attach it with the socket head cap screw (key 102), the lock washer (key 83) and the nut (key 72).

7. Remove the four cap screws (key 100D) and the mounting plate (key 100C) from the cable transducer.

8. Mount the mounting plate (key 100C) to the transmitter using cap screws (key 105).

CAUTION

To avoid damaging the potentiometer after the transmitter is mounted, do not stroke the actuator without first loosening the socket screw set (key 100F) that fastens the coupling (key 100E) to the potentiometer shaft (key 5).

1. Stroke the actuator to mid-stroke.

2. Bolt the cable bracket (key 60) to the stem connector on the actuator stem. To do this, first replace the existing stem connector cap screws with studs (key 78). Slide the cable bracket (key 60) over the studs (key 78) before installing the nuts (key 71). Tighten the nuts (key 71).

3. If necessary, refer to the appropriate actuator instruction manual for the procedure to reconnect the actuator stem to the valve stem.

9. Verify that the actuator is still in the mid-stroke position. Loosen the socket cap screws (key 100F) and rotate the coupling until the socket cap screws (key 100F) can be accessed with a hex wrench through one of the openings in the cable transducer housing (key 100A). Lock the coupling in place by tightening the inboard socket cap screw (key 100F).

10. Turn the potentiometer shaft (key 5) to the midpoint of it’s range.

11. Carefully install the transmitter to the cable transducer housing (key 100A) making sure that the potentiometer shaft (key 5) slides freely into the coupling (key 100E) and remains in the midpoint position. Reinstall the four cap screws (key 100D).

12. Lock the coupling (key 100E) to the potentiometer shaft (key 5) by tightening the outer socket cap screw (key 100F).

13. Install the cable cover assembly (key 64) on to the mounting plate (key 63) with the two machine screws (key 81). Attach the lower end of the cable cover assembly (key 64) to the actuator yoke with the cap screw (key 82). Note: Some actuators may require additional pieces to fully cover the yoke.

14. Perform the electrical connections.

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

Long Stroke Sliding-Stem Type 585CLS and 490 Actuator Mounting, Types 4220, 4221, and 4222

Use the following general procedures and figure 23 to mount the transmitter on long stroke sliding-stem Type 585CLS and 491 actuators with 229 to 610 mm (9 to 24 inches) travel.

CAUTION

1. Stroke the actuator to mid-stroke.

2. Bolt the cable clip (key 61) to the stem connector on the actuator stem. To do this, first replace the existing stem connector cap screws with a stud (key

35). Slide the cable clip (key 61) over the stud (key 35) before installing the nuts (key 73). Tighten the nuts.

3. If necessary, refer to the appropriate actuator instruction manual for the procedure to reconnect the actuator stem to the valve stem.

4. Attach the cable transducer housing (key 100A) to the mounting plate (key 63) using cap screws (key 103) and hex nuts (key 104).

5. Attach the mounting plate to the actuator using hex head cap screws (key 75). Note: Some actuators may require spacers (key 101) between the mounting plate (key 63) and the actuator.

8. Mount the mounting plate (key 100C) to the transmitter using cap screws (key 105).

10. Turn the potentiometer shaft (key 5) to the midpoint of it’s range.

12. Lock the coupling (key 100E) to the potentiometer shaft (key 5) by tightening the outer socket cap screw (key 100F).

13. Install the lower yoke cover (key 69) on to actuator yoke with pan head machine screws (key

77) and washers (key 86).

14. Perform the electrical connections.

Electrical Connections

Note

For intrinsically safe installations, refer to loop schematics or to instructions supplied by the barrier manufacturer for proper wiring and installation.

Conduit

Install conduit using local and national electrical codes which apply to the application.

CAUTION

Free release of the cable (key 100B) will damage the transducer. Whenever the cable (key 100B) is extended, take steps to ensure that free release does not happen.

6. Carefully pull the cable (key 100B) down to the cable clip (key 61) and attach it with the socket head cap screw (key 102), the lock washer (key 83) and the nut (key 72).

7. Remove the four cap screws (key 100D) and the mounting plate (key 100C) from the cable transducer.

WARNING

For explosion-proof applications, install a suitable conduit seal no more than 460 mm (18 inches) from the transmitter. Personal injury or property damage may result from fire and explosion if the seal is not installed.

Field Wiring

Figure 4 shows typical field wiring connections into the field wiring compartment. The transmitter is powered by 24 volts dc. Refer to table 1 to

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

determine the power supply requirements. For units without position switches, the 24 volts dc can be provided by the receiving device or an external supply.

For units with position switches, the power supply provides 24 volt dc power to the position switch circuit in units without the transmitter, or to both the position switch circuits and transmitter in units with the transmitter. A 24 volt dc power supply independent of the receiving device is recommended. A separate return is required for the relays. This prevents relay return currents from flowing in the transmitter 4 to 20 ma dc current loop.

For the position switch relay wiring, during normal operating conditions relays K1 and K2 are energized, which connects the common (C) terminal to the normally open (NO) terminal (TB1 and TB2, figure 4). During a tripped (or alarm) condition the relay is de-energized, which connects the C terminal to the normally closed (NC) terminal. If power is removed or lost from the power supply both relays are de-energized which connects the common (C) terminals to the normally closed terminals (NC).

CAUTION

Connect the transmitter grounding terminal (key 58) to an earth ground. Improper grounding of the position transmitter can cause erratic operation.

Before making transmitter or position switch connections, ensure that the power supply is turned off. Refer to figure 4 for location of connections.

1. Remove the cover from the field wiring compartment.

2. Bring the transmitter field wiring and/or position switch wiring into the housing through one or both of the ports.

3. Field wiring connections:

(−) terminal of the power supply to the (R) terminal on TB3. Also connect a wire from the (−) terminal on the power supply to the negative (−) terminal of the receiving device. Connect a wire from the receiving device positive (+) terminal to the (−) terminal on TB3. Connect a wire from the (+) terminal on the power supply to the (+) terminal on TB3. Provide wiring for the position switch indicating device to match the application.

b. For Type 4212 and 4222 position switches without a transmitter, connect a wire from the (+) terminal of the power supply to the (+) terminal on TB3. Connect a wire from the (−) terminal of the power supply to the (R) terminal on TB3. Provide wiring for the position switch indicating device to match the application.

c. For a Type 4211 or 4221 transmitter without position switches. Connect a wire from the (+) terminal of the power supply to the (+) terminal on the barrier strip (key 11). Connect a wire from the (−) terminal of the power supply to the negative (−) terminal of the receiving device. Connect a wire from the receiving device positive (+) terminal to the (−) terminal on the barrier strip.

4. Connect the grounding terminal (key 58) to an earth ground.

5. For a Type 4210, 4212, 4215, 4220, or 4222 instrument with position switches, perform the following steps to connect the position switch wiring:

a. Connect the high position switch field wiring from the high indicating device to TB1 on the field circuit printed wiring board.

Note

On transmitters with position switches, always make the connection between the power supply negative (−) terminal and the (R) terminal on TB3, even if the position switch outputs are not used.

a. For a Type 4210, 4215, or 4220 transmitter with position switches, connect a wire from the

b. Connect the low position switch field wiring from the low indicating device to TB2 on the field circuit printed wiring board.

6. If only one output port is used, screw the pipe plug (supplied with the transmitter) into the unused port.

7. Perform the potentiometer alignment and direct/reverse action procedures for all applications.

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

FIELD CIRCUIT PRINTED WIRING BOARD

TB1

GROUNDING TERMINAL UNDER PRINTED WIRING BOARD

TB2

TRANSMITTER FIELD WIRING

POSITION SWITCH FIELD WIRING

RELAY RETURN

FIELD WIRING COMPARTMENT

TB3

FOR TYPE 4210, 4215, OR 4220 TRANSMITTER WITH POSITION SWITCHES AND

FOR TYPE 4212 OR 4222 POSITION SWITCHES WITHOUT THE TRANSMITTER

EARTH GROUND

POWER SUPPLY

−

DEVICE RECEIVING 4 TO 20 MA DC SIGNAL

−

DEVICE RECEIVING LO POSITION SWITCH OUTPUT (CONTACT CLOSURE)

DEVICE RECEIVING HI POSITION SWITCH OUTPUT (CONTACT CLOSURE)

FIELD WIRING COMPARTMENT

TRANSMITTER FIELD WIRING

EARTH GROUND

GROUNDING TERMINAL

BARRIER STRIP (KEY 11)

SAFETY GROUND

FOR TYPE 4211 OR 4221 TRANSMITTER WITHOUT POSITION SWITCHES

NOTES:

TYPE 4212 AND 4222 POSITION SWITCHES WITHOUT THE TRANSMITTER CIRCUIT DO NOT REQUIRE A RECEIVING DEVICE OR

THE ASSOCIATED WIRING.

RECEIVING DEVICE MAY BE ANALOG CURRENT INPUT TO DISTRIBUTED CONTROL SYSTEM, PROGRAMMABLE LOGIC CONTROLLER OR INDICATING DEVICE. INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 OHM RESISTOR OR A CURRENT METER.

DURING NORMAL CONDITIONS, RELAYS K1 AND K2 ARE ENERGIZED, WHICH CONNECTS THE COMMON (C) TERMINAL TO THE NORMALLY OPEN (NO) TERMINAL. A TRIPPED (OR ALARM) CONDITION IS WITH THE RELAY(S) DE-ENERGIZED, WHICH CONNECTS THE COMMON (C) TERMINAL TO THE NORMALLY CLOSED (NC) TERMINAL.

SEPARATE RETURN REQUIRED FOR RELAYS. RETURN WIRE MUST BE CONNECTED EVEN IF RELAY OUTPUTS ARE NOT USED.

49A7894-D 49A7892-D C0601-4/IL

POWER SUPPLY

−

DEVICE

RECEIVING 4 TO 20 MA DC SIGNAL

−

Figure 4. Wiring Connections

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

Potentiometer Alignment

CAUTION

The following procedure must be performed prior to calibrating the transmitter or position switches. Failure to perform this procedure may result in erratic performance or unit failure.

This procedure adjusts the potentiometer to the center of its electrical travel when the control valve actuator or other device is at the center of its mechanical travel.

Refer to the Calibration section for the test equipment required in this section.

WARNING

3. Loosen the appropriate set screw connecting the potentiometer shaft to the linkage:

a. For sliding stem applications, loosen the set screw (key 26, figure 15) in the operating arm (key 30) on the potentiometer shaft.

b. For rotary actuator applications, loosen the set screw in the coupling (key 50, figure 19) on the potentiometer shaft.

c. For long stroke applications, leave the coupler (key 100E) rigidly attached to the potentiometer shaft. Loosen only the coupling screw (key 100F, figures 22 and 23) in the coupler (key 100E) on the transducer shaft.

4. Stroke the actuator or other device to the mid-stroke position.

Note

On units with position switches, the (R) terminal on TB3 must be connected to the power supply negative (−) terminal as shown in figure 9 to attain correct potentiometer alignment.

On an explosion-proof instrument, remove electrical power before removing the covers in a hazardous area. Personal injury or property damage may result from fire or explosion if power is applied to the instrument with the covers removed, in a hazardous area.

On an intrinsically safe instrument, current monitoring during operation must be with a meter approved for hazardous areas.

Refer to figure 5 for component locations.

1. Remove power from the instrument.

2. Connect the digital voltmeter (DVM) leads as follows:

a. For all transmitters (except a Type 4212 or

4222) connect between TP3 (+) and TP4 (−) on the printed wiring board.

b. For a Type 4212 or 4222 transmitter, connect the DVM between TP5 (+) and TP6 (−).

5. Apply power to the instrument.

6. While the device is in mid-stroke position, insert a screwdriver blade into the slot in the end of the potentiometer shaft (see figure 15), or turn the coupler (key 52, figure 19 or key 100E, figures 22 and 23) to turn the potentiometer shaft until the DVM reads 1.25 ±0.05 volts dc. This establishes the electrical center of the potentiometer.

7. Tighten the appropriate set screw. Check that the DVM reading has remained at 1.25 ±0.05 volts dc.

Note

For sliding stem applications, tighten the set screw (key 26, figure 15) in the operating arm (key 30) to a torque of

3.39 to 3.95 NSm (30 to 35 lbfSin).

8. Remove the power from the transmitter power supply.

9. Remove the DVM leads from TP3 and TP4 (transmitter signal) or TP5 and TP6 (position switch signal).

10. Refer to the direct or reverse action procedures.

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

SPAN ADJUSTMENT (R2)

ZERO ADJUSTMENT (R1)

TP1

TP4

TP2

HIGH POSITION SWITCH ADJUSTMENT (R3)

JUMPER W1 JUMPER W2

TP3

FOR TYPE 4210, 4215, OR 4220 TRANSMITTERS WITH POSITION SWITCHES

SPAN ADJUSTMENT (R16)

ZERO ADJUSTMENT (R15)

LOW POSITION SWITCH ADJUSTMENT (R6)

HIGH POSITION SWITCH DEADBAND ADJUSTMENT (R4)

JUMPER W3

LOW POSITION SWITCH DEADBAND ADJUSTMENT (R5)

TP6

TP5

39A6156-F 39A7238-E B1957-3 / IL

TP4

TP2TP3

FOR TYPE 4211 OR 4221 TRANSMITTER WITHOUT POSITION SWITCHES

HIGH POSITION SWITCH ADJUSTMENT (R3)

FOR TYPE 4212 OR 4222 POSITION SWITCHES WITHOUT TRANSMITTER

TP1

LOW POSITION SWITCH ADJUSTMENT (R6)

HIGH POSITION SWITCH DEADBAND ADJUSTMENT (R4)

JUMPER W3

LOW POSITION SWITCH DEADBAND ADJUSTMENT (R5)

TP6

TP5

Figure 5. Transmitter Printed Wiring Board Assemblies

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

TB1

BROWN

ORANGE

RED

FEEDTHROUGH TRANSMITTER

END VIEW CUTAWAY SIDE VIEW END VIEW

PRINTED WIRING BOARD

FOR TYPE 4210, 4215, OR 4220 TRANSMITTER WITH POSITION SWITCHES

AND FOR TYPE 4212 OR 4222 POSITION SWITCHES WITHOUT THE TRANSMITTER

PLUG

TB1

RFI FILTER

WIRES FROM RFI FILTER

CAP

O-RINGS

TRANSMITTER COMPARTMENT

RFI FILTER

PORT

POTENTIOMETER SHAFT

FIELD WIRING COMPARTMENT

TB2

TB1 TB3

GROUNDING TERMINALS

BARRIER STRIP (KEY 11)

FIELD CIRCUIT PRINTED WIRING BOARD

BROWN

ORANGE

RED

TRANSMITTER PRINTED WIRING BOARD

FOR TYPE 4211 OR 4221 TRANSMITTER WITHOUT POSITION SWITCHES

NOTES:

49A7894-C 49A7892-D C0602−4 / IL

WIRES CONNECTED TO TB1 ARE SHOWN IN THE COLOR SEQUENCE FOR DIRECT ACTION. FOR REVERSE ACTION, THE COLOR SEQUENCE IS RED, ORANGE, AND BROWN (FROM LEFT TO RIGHT).

Figure 6. Instrument Assembly Details

Direct or Reverse Action

Direct action means, when looking at the slotted end of the potentiometer shaft, a clockwise rotation of the shaft produces an increasing output signal from the transmitter.

Reverse action means, when looking at the slotted end of the potentiometer shaft, a clockwise rotation of the shaft produces a decreasing output signal from the transmitter.

GROUNDING TERMINALS

The transmitter produces a direct or reverse action output signal depending on the location of the potentiometer wires inserted in terminal block number 1 (TB1) mounted on the transmitter printed wiring board. Refer to figure 6 for the location of the wires and the wire color sequence for direct action.

For reverse action, exchange the positions of the brown and red wires.

Instruction Manual

A,D

Direct

B,C

4210

A,D

Reverse

B,C

A,D

Direct

N/A

4212

B,C

A,D

Direct

B,C

4215

A,D

Reverse

B,C

Direct

− − −

4210

4220

Reverse

− − −

Direct

− − −

4222

Direct

− − −

4215

Reverse

− − −

Form 5596 July 2005

FOR ROTARY ACTUATORS

Type

Transmitter

Action

Actuator Style

4212

Reverse Not available for position switches without transmitter

4211 Not required for transmitter without position switches

4210 4220

4212

Reverse Not available for position switches without transmitter

4211,4221 Not required for transmitter without position switches

1. Viewed from the potentiometer shaft end.

Actuator Stem

Travel

Down CW 20 Hi

Up CCW 4 Lo Up CW 20 Hi

Down CCW 4 Lo

Up CCW 20 Hi Down CW 4 Lo Down CCW 20 Hi

Up CW 4 Lo Down CW Hi

Up CCW

Up CW Down CCW Lo

Down CW 20 Hi

Up CCW 4 Lo

Up CW 20 Hi Down CCW 4 Lo Down CS 4 Hi

Up CCW 20 Lo

Up CW 4 Hi Down CCW 20 Lo

FOR SLIDING STEM ACTUATORS

Down CW 20 Hi

Up CCW 4 Lo

Up CCW 20 Hi Down CW 4 Lo Down CW N/A Hi

Up CCW N/A Lo

Down CW 20 Hi

Up CCW 4 Lo Down CW 20 Hi

Up CCW 4 Lo

4200 Series Transmitters

Input Potentiometer

Rotation

(1)

Transmitter

Current Output,

Milliampere

Set Position Switch

NOTES:

WHEN USING THE COMMON (C) AND THE NORMALLY CLOSED (NC) TERMINAL CONNECTIONS, THE CONTACTS WILL BE CLOSED WHEN THE RELAY COIL IS DE-ENERGIZED.

A3787 / IL

Figure 7. Transmitter and Position Switch Conditions

ACTUATOR TRAVEL UP OR DOWN

REFER TO TABLES ABOVE FOR CONDITIONS

ACTUATOR TRAVEL UP OR DOWN

HIGH ALARM RANGE

LOW ALARM RANGE

TERMINAL CONNECTIONS

HIGH ALARM SETPOINT (TRIPS ON)

0−10% FULL SPAN

(TRIPS OFF)

0−10% FULL SPAN

LOW ALARM SETPOINT (TRIPS ON)

CONTACT CLOSED

DESIRED DEADBAND

CONTACT OPEN

DESIRED DEADBAND

CONTACT CLOSED

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

Arrange wires on the terminal block (TB1) for either direct or reverse action to match the application requirements; then repeat the potentiometer alignment procedures.

Refer to the Calibration section to adjust the zero and span of the transmitter and/or position switch circuits.

Operating Information

Initial Considerations

If the transmitter is ordered with an actuator, the transmitter is factory calibrated to the length of travel specified on the order. If the transmitter is ordered separately, adjust the zero and span as described in the Calibration section so that the transmitter operates properly in your specific application.

If the transmitter is calibrated for a specific control valve actuator travel, perform the procedures in the Calibration section to fine tune the zero and span adjustments to the specific application.

from relays K1 and K2 (figures 4 and 9). The high position switch circuit output controls relay K1 mounted on the field circuit printed wiring board and, the relay contacts connect to TB1. The low position switch circuit output controls relay K2 and, the relay contacts connect to TB2. Deadband is the difference between trip and reset points of a relay.

D A Type 4215 transmitter obtains position information from a dual potentiometer on the same shaft, which allows for individual potentiometers for the transmitter circuit and the position switch circuits. The transmitter input is from one of the potentiometers and its output connects to TB3 (figure 6) mounted on the field circuit printed wiring board. The position switch input is obtained from the other potentiometer.

The high position switch circuit output controls relay K1 mounted on the field circuit printed wiring board and the relay contacts connect to TB1. The low position switch circuit output controls relay K2 and the relay contacts connect to TB2. The relationship between the transmitter output, relay position switch outputs, and deadband is shown in figure 7. Deadband is the difference between the trip and reset points of a relay.

Transmitter and Position Switch Conditions

D A Type 4210 or 4220 transmitter (with position switches) obtains stem position from the input potentiometer and circuit electronics to provide a 4 to 20 milliampere output. The transmitter output connects to a terminal block mounted in the field wiring compartment. The high position switch circuit output controls relay K1 mounted on the field circuit printed wiring board, and the relay contacts connect to TB1. The low position switch circuit output controls relay K2, and the relay contacts connect to TB2. The relationship between the transmitter output, relay position switch outputs, and deadband is shown in figure 7. Deadband is the difference between trip and reset points of a relay.

D A Type 4211 or 4221 transmitter (without position switches) obtains input information from the potentiometer and provides a 4 to 20 milliampere output. The transmitter output connects to the barrier strip (key 11, figure 4) mounted in the field wiring compartment.

D A Type 4212 or 4222 position switch (without the transmitter) obtains stem position from the input potentiometer and provides position switch outputs

Normal Operation

WARNING

On an explosion-proof instrument, remove electrical power before removing the instrument covers in a hazardous area. Personal injury or property damage may result from fire or explosion if power is applied to the instrument with the covers removed, in a hazardous area.

Once the instrument has been calibrated and placed in operation, further adjustments should not be necessary. The 4 to 20 milliampere output can be monitored during operation (in a non-hazardous environment) by removing the cover and connecting a milliammeter between TP1 (+) and TP2 (−) on the printed wiring board (figure 5) on Type 4210, 4211, 4215, 4220, or 4221 transmitter. On Type 4212 or 4222 connect a voltmeter between TP5 (+) and TP6 (−) to measure potentiometer position.

For position switch circuits, the switching condition can be monitored by observing the indicating device or using an ohmmeter connected to the terminal

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

blocks (TB1 and TB2) in the field wiring compartment. Refer to the Calibration section for the test setup.

Calibration

Note

The potentiometer alignment procedures, in the Installation section, must be completed before performing instrument calibration. Also, be sure the direct or reverse action is correct for the application.

Calibration of the instrument consists of adjusting the zero and span of the transmitter and/or adjusting the high and low position switches for a specific travel. The high and low position switches also have deadband adjustments that are made during the calibration procedures. Refer to figure 7 for transmitter and position switch conditions.

For a Type 4212 or 4222 instrument with position switch circuits only, refer to the high and low position switch adjustment procedures in this section. For a transmitter with or without position switch circuits, refer to the transmitter circuit zero and span adjustment procedures in this section.

Test Connections to the Field Wiring Compartment

During calibration setup the transmitter as shown in figure 8. Except for Type 4211 and 4221 transmitters, the field circuit printed wiring board is used. A Type 4211 or 4221 transmitter uses a barrier strip (key 11, figure 4) mounted in the field wiring compartment for field wiring connections. For calibration and bench check of the 4211 or 4221 transmitter, make connections to the barrier strip (key 11).

For a Type 4210, 4215, or 4220 transmitter with position switches, the transmitter can be calibrated with or without the position switch outputs being connected.

Note

On units with position switches, the (R) terminal on TB3 must be connected to the power supply negative (−) terminal for proper instrument operation, even if the position switch outputs are not used.

For a Type 4211 or 4221 transmitter without position switches, use a two wire system with the indicating device installed as shown in figure 8.

If satisfactory results cannot be obtained during calibration, refer to the appropriate procedures in the Maintenance section.

Test Equipment Required

The following test equipment is used in the calibration and maintenance of the instrument:

D Digital voltmeter (DVM) that measures voltages in the range of 0 to 30 volts dc with an accuracy of ±0.25 percent.

D Power supply capable of supplying 20 to 30 volts dc at 100 milliamperes.

D Resistor, 250 ohms, 0.1%, 0.5 watt or greater.

Transmitter Circuit Zero and Span Adjustment

WARNING

On an intrinsically safe instrument, the current monitoring across TP1 and TP2 during operation must be with an approved meter. Personal injury or property damage may result from fire or explosion if an approved meter is not used in a hazardous area.

Calibration of the transmitter consists of adjusting the zero and span for a 1 to 5 volt dc output across a 250 ohm resistor, or a 4 to 20 milliampere output

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

TO RFI FILTERS

J1 FROM RFI FILTERS

TRANSMITTER COMPARTMENT

NOTES:

CONNECT DVM TO TEST POINTS AS DIRECTED BY CALIBRATION AND

MAINTENANCE PROCEDURES.

INSURE THAT THE CONNECTOR ATTACHED TO J1 (VIEW A) IS NOT

REVERSED WHEN INSTALLING IT ON THE PRINTED WIRING BOARD.

THE INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 OHM

49A7894-B 39A6156-F B1948-4 / IL

RESISTOR OR A CURRENT METER.

SEPARATE RETURN LEAD REQUIRED FOR RELAYS. RETURN WIRE

MUST BE CONNECTED EVEN IF RELAY OUTPUTS ARE NOT USED.

Figure 8. Calibration and Bench Check Test Setup

current for a specific travel. If necessary refer to the type number on the nameplate to determine the configuration of the transmitter.

1. Remove power from the instrument.

2. Connect the transmitter as shown in figure 8.

3. Remove the transmitter covers.

4. Stroke the valve or device to the mid-stroke position

5. Check the potentiometer alignment by connecting a digital voltmeter (DVM) as follows:

FIELD WIRING

COMPARTMENT

J1 (SEE VIEW A)

VIEW A

+ 24 VOLT DC POWER SUPPLY

8. Stroke the valve or device to the point of travel where the transmitter output is to be 4 milliamperes dc.

9. Adjust the zero potentiometer (R1 or R15, figure 5) until the output is 4 milliamperes dc (1.00 volt across 250 ohms).

10. Stroke the valve or device to the point of travel where the transmitter output is to be 20 milliamperes dc.

11. Adjust the span potentiometer (R2 or R16, figure 5) until the output is 20 milliamperes dc (5.00 volts across 250 ohms).

a. For all transmitters (except a Type 4212 or

4222) connect between TP3 (+) and TP4 (−) on the printed wiring board.

b. For a Type 4212 or 4222 transmitter, connect the DVM between TP5 (+) and TP6 (−).

6. Apply power to the instrument.

7. The DVM should read 1.25 ±0.05 volts dc. If not, perform the potentiometer alignment procedures in the Installation section.

12. Some small interaction between the two adjustments may occur. Repeat steps 8 through 11 until the error is within the application requirements.

13. For a Type 4211 or 4221 transmitter without position switches, calibration is complete. Refer to the installation and/or operating information to place the transmitter in service.

14. If calibration is complete, replace the transmitter covers. For transmitters with position switches, refer to the high and low position switch adjustment procedure below.

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

High and Low Position Switch Adjustment

Note

The “high” and “low” designations refer to the voltage output of the position potentiometer. See figure 7 for relationship to valve or actuator travel.

The high position switch must be adjusted before the low position switch. If the deadband of either the high or low position switches exceeds the difference between the set points of the high and low position switches, both position switches may be on at the same time.

The following procedure sets the high and low position switches, and the deadband for each of them. The high position switch must be adjusted before the low position switch. Use an ohmmeter connected between the normally closed (NC) and common (C) connections on terminal block TB1 (high switch) or TB2 (low switch) to observe relay switching action as directed by the procedures.

The potentiometer alignment procedures must be performed before calibrating the position switch circuits. For transmitter and position switch switch conditions, refer to figure 7 while performing the following calibration:

1. If necessary, perform the potentiometer alignment procedure.

2. Remove power from the instrument.

3. Remove the transmitter covers.

Note

The potentiometers are 25 turn trimpots with a slip clutch. To set these potentiometers at their maximum counterclockwise position, turn them 25 or more turns in the counterclockwise direction.

Setting the High Position Switch

For Type 4210, 4220, 4212, 4222, and 4215 direct acting transmitters, refer to figure 5 for location of adjustments.

1. Turn the high position switch potentiometer (HIGH, R3) fully clockwise.

2. Stroke the valve or device to the point of travel where the high position switch is to operate (see figure 7).

3. Apply power to the instrument.

4. Turn the high position switch potentiometer (R3) slowly counterclockwise until the high position switch trips, the ohmmeter changes from a high resistance to a low resistance reading.

5. The high position switch is now set.

Setting the High Position Switch Deadband

1. Slowly stroke the actuator or device between the tripped and reset point of the high position switch. Observe this by the changing readings of the ohmmeter. Note the differences in travel between the trip point and reset points. This is the deadband of the switch.

2. If necessary, increase the deadband by turning the potentiometer (DBH, R4), clockwise.

3. Repeat steps 1 and 2 until the desired deadband setting is obtained.

Setting the Low Position Switch

4. To provide an indication of switch conditions, remove power from the instrument. Disconnect the position switch field wiring from TB1 and TB2, and connect an ohmmeter to TB1 between the (NC) and (C) terminals (figure 4).

Turn both the high and low deadband potentiometers (DBH, R4, and DBL, R5) fully counterclockwise to set the deadbands to minimum and set the low position switch potentiometer (LOW, R6) fully counterclockwise.

Note

Perform the high position switch adjustment procedures before adjusting the low position switch.

1. To provide an indication of switch condition, remove power from the instrument. Connect an ohmmeter to TB2 between the (NC) and (C) terminals (figure 4).

2. Stroke the device to the point of travel where the low position switch is to operate (See figure 7).

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

MECHANICAL CONNECTION TO DEVICE

B1946-4/IL

TRANSMITTER

TRANSMITTER PRINTED WIRING BOARD

TRANSMITTER CIRCUIT

SWITCHING CIRCUIT

NOTES:

THIS EQUIVALENT CIRCUIT IS TYPICAL FOR ALL TYPES OF TRANSMITTERS.

GENERALLY, IF A PORTION OF THE CIRCUIT IS NOT USED, IT IS OMITTED.

RECEIVING DEVICE MAY BE ANALOG CURRENT INPUT TO DISTRIBUTED CONTROL SYSTEM, PROGRAMMABLE LOGIC CONTROLLER OR INDICATING DEVICE. INDICATING DEVICE CAN BE A VOLTMETER ACROSS 250 OHM RESISTOR OR A CURRENT METER.

FIELD WIRING FOR POSITION SWITCHING CIRCUITS CAN BE A TWO OR THREE WIRE SYSTEM DEPENDING ON THE APPLICATION REQUIREMENTS.

SEPARATE RETURN REQUIRED FOR RELAYS. RETURN WIRE MUST BE CONNECTED EVEN IF RELAY OUTPUTS ARE NOT USED.

FIELD CIRCUIT PRINTED WIRING BOARD

K1 RELAY

K2 RELAY

24 VOLT DC POWER SUPPLY

−

DEVICE RECEIVING 4 TO 20 MA DC SIGNAL

−

DEVICE RECEIVING HI POSITION SWITCH OUTPUT (CONTACT CLOSURE)

DEVICE RECEIVING LO POSITION SWITCH OUTPUT (CONTACT CLOSURE)

Figure 9. Transmitter Operation

3. Apply power to the instrument.

4. Ensure that the low position switch potentiometer (LOW, R6, figure 5) is fully counterclockwise as previously instructed.

5. Turn the low position switch potentiometer (R6) slowly clockwise until the low position switch trips, the ohmmeter changes from a high to a low resistance reading.

6. The low position switch is now set.

Setting the Low Position Switch Deadband

1. Slowly stroke the actuator or device between the tripped and reset point of the low position switch. Observe this by the changing readings on the

ohmmeter. Note the differences in travel between the trip point and reset points. This is the deadband of the low position switch.

2. If necessary, increase the deadband, by turning potentiometer (DBL, R5, figure 5) clockwise.

3. Repeat steps 1 and 2 until the desired deadband setting is obtained.

4. If adjustments are complete, remove power from the instrument and disconnect the ohmmeter.

5. Perform the installation and/or operating procedures to place the transmitter in service and replace the transmitter covers.

Position Switch Circuit Shutoff

Refer to figure 5 for location of adjustments. Certain conditions may require the position switch

circuit capabilities to be shut off. To shut off the

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

position switches, turn the high position switch potentiometer (HIGH, R3) fully clockwise, and turn the low position switch potentiometer (LOW, R6) fully counterclockwise. To restore the position switch circuits to operation, follow the high and low position switch adjustment procedures described in this section.

Note

Both position switch relays are energized in this condition. The trip points cannot be adjusted to prevent the relays from energizing.

Principle of Operation

The basic concept of the electronic position transmitter can be understood by visualizing the entire transmitter as a variable resistor in series with a load and connected to a power supply as shown in figure 9. A linkage or cable/pulley assembly transmits linear motion of the device into rotary motion of the potentiometer. The potentiometer is connected to the input of the transmitter circuit. The voltage present at the wiper of the potentiometer supplies input voltage to the electronic circuitry in the transmitter to produce a current output.

The position switch circuit is driven by the same input system as the transmitter (except for the Type 4215 transmitter). The position switch circuit acts as an electronic switch that controls two relays. The voltage present at the wiper of the potentiometer is compared to the settings of the high and low position switch set points and provides an on or off condition for the relays. Instruments that use a single element potentiometer use the same element for both the transmitter input and the input to the position switch circuits. A Type 4215 transmitter with dual element potentiometers uses one element of the potentiometer for the transmitter input and the other

element for the position switch circuit input. On an instrument with position switches only, the single element potentiometer is used for the position switch circuit input. Each of the position switch circuit outputs is connected to a relay on the field circuit printed wiring board, and depending on the potentiometer position, the relays are energized or de-energized.

Transmitter Circuit

At all times, the current flow into the transmitter equals the current flow out of the transmitter. The current flowing into the transmitter divides between a regulator circuit and transistor Q1.The regulator circuit establishes two voltages one of which is (VREF). This voltage is applied across the input potentiometer. The other voltage, (VREG) powers the hybrid circuit.

On units with position switches, the transmitter voltage regulator, 4 to 20 mA signal, and relay coil currents flow in the wire between the power supply (+) terminal and the (+) terminal on TB3. The transmitter voltage regulator, switching, and relay coil currents are returned to the power supply common from the (R) terminal on TB3. The 4 to 20 mA output signal flows between the (−) terminal on TB3 and the power supply common. This prevents the relay coil switching currents from appearing on the 4 to 20 mA output.

Position Switch Circuit

A regulated voltage is setup to power the position switch circuit. The position switch circuit senses the position of the potentiometer and triggers the appropriate position switch relay (K1 or K2, figure

10) when travel reaches the trip points established by the adjustments. The Type 4215 transmitter uses dual potentiometers which allows individual potentiometers for the transmitter circuit and the position switch circuit.

4200 Series Transmitters

29A6206-C / DOC

Figure 10. Schematic Diagram for the Field Printed Wiring Board

Instruction Manual

NOTES:

RELAYS K1 AND K2 ARE SHOWN IN THE DE-ENERGIZED POSITION.

(TRIPPED POSITION)

Form 5596

July 2005

Maintenance

WARNING

To avoid personal injury or property damage from the sudden release of pressure:

D Always wear protective clothing and eyewear when performing any maintenance operations.

D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve.

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure on both sides of the valve.

D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

WARNING

On an explosion-proof instrument, remove the electrical power before removing the instrument covers in a hazardous area. Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed, in a hazardous area.

Test equipment for the following procedure is listed in the Calibration section. Voltage references in this procedure may vary depending on the temperature of the instrument. The voltages below are taken at approximately 22_C (72_F) ambient temperature.

CAUTION

Electrostatic voltages present in the environment may be transferred to the transmitter printed wiring board which may cause failure or degraded performance. Use appropriate antistatic procedures when working with the printed wiring board to protect the electronic circuits.

The following procedures consider the instrument assembled with all components installed according to the type number description. The following procedures can be used in the field or for a bench check. Connect the instrument as shown in figure 8 for bench check.

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

Troubleshooting Procedures

Transmitter Circuit

Note

On transmitters with position switches, the (R) terminal on the field circuit printed wiring board must be connected to the power supply negative (−) terminal for proper transmitter operation, even though the position switch outputs are not used.

1. Verify that the instrument is receiving power, and verify that the receiving device(s) are operating correctly.

2. If the transmitter is the problem, maintenance can be performed by either sending the entire instrument to the factory for repair, by replacing the printed wiring board(s), or by replacing the pot/bushing assembly (key 3, figures 13 and 14) depending on which is defective.

3. Troubleshoot the transmitter circuit by measuring the voltages.

4. Locations of test voltages designated by V1 and V2 (table 7) are shown on the printed wiring board assembly (figure 11).

5. Check the voltages V1 and V2 as described in table 7.

6. If either or both of the voltages are not present, field repair of the instrument is not recommended. Either replace the printed wiring board or return the instrument to the factory for repair.

7. If these voltages are present, the potentiometer may be the source of trouble.

c. If the potentiometer voltage is present but the transmitter output current does not change linearly as the position of the potentiometer changes, replace the transmitter printed wiring board, or return the transmitter to the factory for repair.

Position Switch Circuit

1. Ensure that the position switch circuit is connected correctly, and that the terminal marked (R) on the field circuit printed wiring board is returned to the negative terminal of the supply. Refer to figure 4 for wiring connections.

2. Ensure that the power supply voltage is between 20 and 30 volts dc.

3. Check the voltages V3 and V4 as described in table 7:

a. If either or both of the voltages are not present, field repair of the instrument is not recommended. Return the instrument to the factory for repair.

b. If V3 and V4 are correct, continue with the following steps:

4. Perform the high and low position switch calibration procedures in the Calibration section.

5. If the position switches cannot be set, replace the field circuit printed wiring board (figure 13) or return the instrument to the factory for repair.

Printed Wiring Board Removal and Replacement

8. Check the voltage between TP3 (+) and TP4 (−) as the position of the potentiometer is varied. For Type 4212 and 4222 transmitters, check the voltage between TP5 and TP6 as the position of the potentiometer is varied.

a. If the voltage does not vary with position, perform the potentiometer alignment. If the problem remains, replace the pot/bushing assembly (key 3, figure 13 or 14).

b. If the potentiometer wiper voltage checks good, but the transmitter output is constant or non-linear, the problem may be due to improper potentiometer alignment. Perform the potentiometer alignment procedures; then repeat step 8 above.

WARNING

Refer to the Maintenance WARNING at the beginning of this section.

CAUTION

4200 Series Transmitters

STEP

DVM READS

Instruction Manual

Form 5596

July 2005

39A6156-F A3497-2 / IL

FOR TYPE 4210, 4215, OR 4220 TRANSMITTER

WITH POSITION SWITCHES

39A7236-E 39A6156-F A3504-2 / IL

Figure 11. Transmitter Printed Wiring Boards

FOR TYPE 4211 OR 4221 TRANSMITTER

WITHOUT POSITION SWITCHES

FOR TYPE 4212 OR 4222 POSITION SWITCHES

WITHOUT TRANSMITTER

Table 7. Test Procedure (also refer to figure 11)

CONNECT DVM TO

(+) Lead (−) Lead

1 V1 TP4 5.9 to 6.3 V dc (VREG) 2 V2 TP4 2.46 to 2.54 V dc (VREF) 3 V3 TP6 14.1 to 16.1 V dc (+15)

4 V4 TP6

2.46 to 2.54 V dc (VREF2)

Instruction Manual

Form 5596 July 2005

Table 8. Jumper Selection

JUMPER*

W1 Not Installed Installed Not Installed W2 Not Installed Installed Not Installed W3 Installed Not Installed Installed

* See figure 5 for jumper locations on the printed wiring boards. NOTES:

1. The three wire cable assembly connected to J3 provides the position switch circuit output to relays K1 and K2 on the field circuit printed wiring board.

2. Terminal block number 1 (TB1) provides the connections for the three wire cable assembly from the potentiometer. On a dual potentiometer system, it provides the transmitter input only.

3. Connector J2 is only used with a dual potentiometer or for position switches without transmitter circuit. It provides the position switch circuit input to the printed wiring board.

4. The two wire cable assembly connected to J1 is used for the transmitter output signal, (4 to 20 milliamperes), and is connected to the RFI filter.

POSITION

SWITCH

4212

TRANSMITTER WITH SWITCHES AND SINGLE

POTENTIOMETER 4210, 4220

4200 Series Transmitters

TRANSMITTER WITH SWITCHES AND

DUAL POTENTIOMETER 4215

Transmitter Printed Wiring Board

Refer to figure 11 for component locations.

Removal:

1. Remove power from the transmitter.

2. With the transmitter compartment covers removed, disconnect the connectors from J1, J2, and J3 if they are used.

3. Note the locations of the wires, then disconnect the wires from TB1.

4. Remove the three screws that hold the board in place.

5. Grasp one of the components that protrudes from the board, and gently lift the board from the transmitter compartment.

6. Place the board on an anti-static surface for repair or replacement.

Replacement:

Note

When replacing connectors J1, J2, and J3 do not reverse the connector. The connector can be forced on in the opposite direction. Reversing any connector can cause incorrect operation of the transmitter. Refer to figure 8, view A, for proper insertion of the connectors.

5. Connect the red and black wires to the printed wiring board according to the transmitter type.

6. Perform the potentiometer alignment and calibration procedures.

Field Circuit Printed Wiring Board

Refer to figure 12 for component locations.

Removal:

1. Note the locations of the field wires then disconnect the wires from TB1, TB2, and TB3 (if they are all used).

2. Remove the three screws that hold the board in place.

3. Grasp one of the components that protrudes from the board and gently lift the board from the field wiring compartment.

4. Place the board on an anti-static surface for repair or replacement.

Replacement:

1. When the replacement board is ready, lower the board into the transmitter compartment.

2. Insert and tighten the three screws and, install the wiring connections that were removed.

3. The red and black power wires must be connected to TB3 according to the transmitter type.

1. Check the printed wiring board for correct jumper configuration. Refer to table 8.

2. When the replacement board is ready, lower the board into the transmitter compartment.

3. Insert and tighten the three screws.

4. Install the plug connections that were removed.

Pot/Bushing Assembly Replacement

WARNING

Refer to the Maintenance WARNING at the beginning of this section.

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

39A6195-C / DOC

CAUTION

Remove the wiring assembly or assemblies connected between the potentiometer and the transmitter printed wiring board before removing the pot/bushing assembly (key 3) from the transmitter housing (key 1). Failure to disconnect the wiring assembly(ies) may result in damage to the wiring.

1. Remove power from the instrument.

Figure 12. Field Circuit Printed Wiring Board

10. Perform the installation, potentiometer alignment, and calibration procedures to return the transmitter to service.

Parts Ordering

When corresponding with the Fisher sales office about this equipment, always mention the transmitter serial number. When ordering replacement parts, refer to the part number of each required part as found in the following parts lists.

2. Remove the covers (key 2, figure 13 or 14) from the transmitter housing.

3. Note the location of the field wiring, and disconnect the wiring from the field circuit printed wiring board, or from the barrier strip (key 11, figure

14), mounted in the field wiring compartment.

4. Remove the transmitter from its mounting.

5. Perform the transmitter printed wiring board removal procedure.

6. Remove the pot/bushing assembly (key 3) from the housing (key 1).

7. When installing the pot/bushing assembly (key 3) in the transmitter housing, apply lubricant (key 50) to the bushing threads.

8. Install the pot/bushing assembly in the transmitter housing and tighten. Ensure free rotation of the potentiometer shaft.

9. Perform the printed wiring board replacement procedure.

Note

Use only genuine Fisher replacement parts. Components that are not supplied by Fisher should not, under any circumstances, be used in any Fisher instrument. Use of components not supplied by Fisher will void your warranty, might adversely affect the performance of the instrument, and might jeopardize worker and workplace safety.

Note

Neither Emerson, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user

Instruction Manual

Form 5596 July 2005

APPLY LUBRICANT OR SEALANT

NOTES:

ON 4212, 4222, USE KEY 35 INSTEAD OF KEY 19 AT THE “−”FEEDTHROUGH POSITION,

OMIT KEY 10

49A7893-L / IL

4200 Series Transmitters

Figure 13. Housing Assembly for Type 4210, 4215, or 4220 Transmitter with Position Switches

and for Type 4212 or 4222 Position Switches without Transmitter

Parts List

Transmitter Common Parts (Figures 13 and 14)

Key Description Part Number

1 Housing, aluminum 49A5654X012 2 Cap, aluminum (2 req’d) 38A5251X012 3* Pot/bushing Assembly

Type 4210, 4211 27B6208X012 Type 4212 27B6208X042 Type 4215 27B6208X022 Type 4220, 4221 27B6208X032

Type 4222 27B6208X052 4 Wire Assembly (not Type 4211, 4221) 29A7257X012 6 Machine Screw, SST

Type 4211, 4221 (3 req’d) 18A5263X012

Type 4210, 4212, 4215, 4220, 4222 (6 req’d) 18A5263X012 7 Split Washer, (Type 4211, 4221 only),

stainless steel (2 req’d) 61000580X12 8 Spacer, plastic

Type 4211, 4221 (3 req’d) 18A5265X012

Type 4210, 4212, 4215, 4220, 4222 (6 req’d) 18A5265X012 9 Wire (red), 18 AWG

50.8 mm (2 inches) Type 4211, 4221 17B0682X012

146 mm (5.75 inches) Type 4210, 4220,

4215, 4212, and 4222, 17B0682X032

10 Wire (black), 18 AWG (Not used on 4212, 4222)

50.8 mm (2 inches) Type 4211, 4221 17B0682X022

146 mm (5.75 inches) Type 4210,

4220, 4215, 17B0682X042

11 Barrier Strip (Type 4211, 4221 only), plastic 1H290406992

Key Description Part Number

12 Machine Screw (Type 4211, 4221 only),

stainless steel (2 req’d) 1B9925X0012 13 Barrier Marker Strip (Type 4211, 4221 only) 15A4793X012 14* O-Ring, nitrile (2 req’d) T1205106562 15* O-Ring Bushing, Nitrile 10A8931X012 16 Solder Lug, (Type 4211, 4221 only)

Tin pl brass (2 req’d) 15A6903X012 17 Insulating Washer, PTFE (2 req’d) (not shown) 14A7983X012

18 Self Tapping Screw, pl steel (2 req’d) 1P426928982 19 RFI Filter

Type 4212, 4222 (1 req’d) 11A7793X012

4210, 4211, 4215, 4220, 4221 (2 req’d) 11A7793X012 20 Pipe Plug (Type 4211, 4221 only), steel 0Z020128992 35 Machine Screw, pl steel (Type 4212, 4222 only) 17A3109X012 43 Field Circuit Printed Wiring Board Assembly 39A6195X012

45 Transmitter Printed Wiring Board Assembly

Type 4210, 4220 39A6156X022 Type 4211, 4221 39A7236X012 Type 4212, 4222 39A6156X032 Type 4215 39A6156X012

48 Lubricant (not furnished with transmitter) 49 Threadlock − medium strength (not furnished with transmitter) 50 Anti-seize (not furnished with transmitter) 55 Pipe Plug (not shown), pl steel 1A3619X0012 56 Machine Screw (not shown), pl steel

Type 4212, 4222 only 17A3109X012 58 Wire Retainer, pl steel, (2 req’d) 16A2821X012 65 Nameplate − − − 67 2-Wire Connector 19A3898X012

*Recommended spare parts

4200 Series Transmitters

APPLY LUBRICANT OR SEALANT

49A7891-K / IL

Instruction Manual

Form 5596

July 2005

Figure 14. Housing Assembly for Type 4211 or 4221 Transmitter without Position Switches

Key Description Part Number

Mounting Parts for Sliding Stem Actuators

Parts for Mounting the Transmitter on Type 470 and 471 (585C size 60 thru 130) Actuator (figure 15)

21 Mounting plate, steel

Size 130 37A7900X012 All other sizes 37A5448X012

22 Yoke Spacer, steel (2 req’d)

Size 30, 45 only 1F9067X0012

23 Cap Screw, zn pl steel (2 req’d)

Size 30, 45 1A352624052

Size 40, 46 thru 130 1A381624052 24 Washer, pl steel (2 req’d) 1B865928982 25 Operating Arm, pl steel 19A3811X012 26 Cap Screw, pl steel 1H3284X0012 27 Square Nut, pl steel 16A6711X022 29 Torsional Spring, zn pl steel 19A3812X012

30 Lever Assembly

Size 30 thru 130

w/ 54 mm (2.125 inch) max travel 16A6705X012

Size 80 thru 130 w/ 54 thru 105 mm

(2.125 thru 4.125 inch) max travel 16A6706X012 31 Shoulder Screw, stainless steel 10B5722X012 32 Cap Screw, pl steel (2 req’d) 1C631224052 33 Stem Bracket, zn pl steel

Size 30 thru 130

with 54 mm (2.125 inch) max travel l6A6709X012

Size 80 thru 130 w/ 54 thru 105 mm

(2.125 thru 4.125 inch) max travel 16A8277X012

Key Description Part Number

34 Stem Mounting Bracket, zn pl steel

Size 30, 40, 45, 63, 64 16A0430X012 Size 46, 60, 68, 80, 86, 130 27A5447X012 Size 100 21B5965X012

35 Cap Screw, zn pl steel (2 req’d)

Size 30, 45 1A352524052 Size 40 1A553424052 Size 64 1A375124052 Size 68, 80 10A5001X012

Size 100 1U625631192 36 Sleeve, acetal 16A0428X012 37 Cap Screw, steel (2 req’d) 16A0429X012 38 Stem Washer (2 req’d)

Size 30 thru 46, pl steel 1B865928982

Size 60 thru 64, zn pl steel 1H723125072

Size 68 thru 130, zn pl steel 1K899525072 39 Stem Spacer (2 req’d)

Size 30, 45, steel 1F9067X0012

Size 40, steel 1J830724092

Size 64, steel 1J830724092

Size 68, 80, zn pl steel 16A1367X012

Size 100, steel 1V683324092 48 Lubricant (not furnished with transmitter) 49 Threadlock − medium strength (not furnished with transmitter) 51 Threadlock − mild strength (not furnished with mounting)

Parts for Mounting the Transmitter on Type 470-7 and 471-7 (585C, size 60 thru

130) Actuator (figure 15)

21 Mounting plate, steel 37A5448X012 23 Cap Screw, zn pl steel (2 req’d) 1A381624052 24 Washer, pl steel (2 req’d) 1B865928982 25 Operating Arm, pl steel 19A3811X012

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

TRAVEL,

mm (Inch)

Up to 54 (2.125) max

Up to 105 (4.125) max

PICKUP PIN CONNECTION NUMBER 2

PICKUP PIN CONNECTION NUMBER 1

PICK-UP PIN

CONNECTION

NUMBER

ACTUATOR STEM CONNECTION

TRANSFER PIN

HEX CAP SCREW

OPERATING ARM

HEX NUT

PICK-UP PIN

LEVER

ASSEMBLY

1 2

ACTUATOR YOKE

PICK-UP PIN IN

CONNECTION NUMBER 2

PICK-UP PIN

LEVER ASSEMBLY

PICK-UP PIN IN

TRANSFER PIN

OPERATING ARM

CONNECTION NUMBER 1

V APPLY LUBRICANT NOTES:

PICK-UP PIN AND TRANSFER PIN ARE PART OF LEVER ASSEMBLY PART NUMBER 16A6705X012 PICK-UP PIN, TRANSFER PIN, HEX NUT, AND HEX CAP SCREW ARE PART OF LEVER ASSEMBLY PART NUMBER 16A6706X012

39A7768-B / IL

Figure 15. Typical Transmitter Mounting on Type 470, 471, 470-7, 471-7 (585C Size 60 Thru 130), 657, or 667 Actuator

Key Description Part Number

26 Cap Screw, pl steel 1H3284X0012 27 Square Nut, pl steel 16A6711X022 29 Torsional Spring, zn pl steel 19A3812X012 30 Lever Assembly 16A6706X012

31 Shoulder Screw, heat treated stainless steel 10B5722X012 32 Cap Screw, pl steel (2 req’d) 1C631224052 33 Stem Bracket, zn pl steel 16A8277X012 34 Stem Mounting Bracket, zn pl steel

Size 40 thru 45, 64 16A0430X012

Size 60 27A5447X012

35 Cap Screw, zn pl steel (2 req’d)

Size 40 1A553424052 Size 45 1A352524052

Size 64 1A375124052 36 Sleeve, acetal 16A0428X012 37 Cap Screw, steel (2 req’d) 16A0429X012 38 Stem Washer (2 req’d)

Size 40, 45, pl steel 1B865928982

Size 60, 64, zn pl steel 1H723125072

39 Stem Spacer, steel (2 req’d)

Size 40 & 64 1J830724092

Size 45 1F9067X0012

Key Description Part Number

48 Lubricant (not furnished with transmitter) 49 Threadlock − medium strength (not furnished with transmitter) 51 Threadlock − mild strength (not furnished with mounting)

Parts for Mounting the Transmitter on Type 657 or 667 Actuator (figure 15)

21 Mounting plate, steel 37A5448X012

Type 657 size 70 w/ or w/o positioner 27A7509X012 Type 657 & 667 Size 70 thru 87 w/MO and

w/3582, 3590, or DVC5010 39A2249X012

22 Yoke Spacer, steel (2 req’d)

Size 30 thru 40 1V102624092 Size 45, 46 1R7939X0012 Size 50, 60 1L8872X0012 Type 657 Size 70 W/ or W/o MO 1N822924092 Type 667 Size 70 W/o MO 1J830724092 Type 667 Size 70 W/MO 102 mm

(4 inch) travel 1N822924092

23 Cap Screw, zn pl steel (2 req’d)

Size 30 thru 40 1C870224052 Size 45, 46 1F960324052 Size 50, 60 1B762424052 Size 70 1A352524052 Size 80 thru 100 1A352624052

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

Key Description Part Number

24 Washer, pl steel (2 req’d)

Size 30 thru 40 1D716228982

Size 45 thru 100 1B865928982 25 Operating Arm, pl steel 19A3811X012 26 Cap Screw, pl steel 1H3284X0012 27 Square Nut, pl steel 16A6711X022 29 Torsional Spring, zn pl steel 19A3812X012 30 Lever Assembly

Size 30 thru 100

w/ 54 mm (2.125 inch) max travel 16A6705X012

Size 70 thru 100 w/ 54 thru 105 mm

(2.125 thru 4.125 inch) max travel 16A6706X012 31 Shoulder Screw, stainless steel 10B5722X012 32 Cap Screw, pl steel (2 req’d) 1C631224052 33 Stem Bracket, zn pl steel

Size 30 thru 100

w/ 54 mm (2.125 inch) max travel 16A6709X012

Size 70 thru 100 w/ 54 thru 105 mm

(2.125 thru 4.125 inch) max travel 16A8277X012 34 Stem Mounting Bracket, zn pl steel

Size 30 thru 87 w/ 54 thru 76 mm

(2.125 thru 3 inch) max travel 16A0430X012

Size 80, 100 and

Size 70 w/ 102 mm (4 inch) travel 27A5447X012 35 Cap Screw, zn pl steel (2 req’d)

Type 657 or 667

Size 30, 34, 40 w/o positioner 17A8302X012

Size 30, 34, 40 w/3582, 3590 12A3218X012

Size 30, 34, 40 w/DVC5010 14B5001X012

Size 45, 46, 50, 60 w/o positioner 1A935924052

Size 45, 46, 50, 60 w/3582, 3590, DVC5010 1V6023X0012

Size 70 w/ or w/o 3582,3590 12A1492X012

Size 70, 87 w/MO, w/3582, up to 3 inch travel 1U9597X0032

Size 80, 87 w/o positioner 18A6422X022

Size 80 w/3582, 3590, DVC5010 1R125931032

Size 70 thru 87 w/MO, w/DVC5010

up to 76 mm (3 inch) travel 18A6422X022

Size 70 w/MO, w/DVC5010

102 mm (4 inch) travel 1D864531012

Size 100 1A344524052

Hex nut (not shown)

Size 30, 34, 40

w/3582, 3590, DVC5010 (4 reg’d) 1E944024112

Size 45, 46, 50, 60

w/3582, 3590, DVC5010 (4 req’d) 1A375324122

Size 70 w/o MO

w/ or w/o 3582, 3590, DVC5010 (4 req’d) 1A375324122

Size 80, 87 w/o MO (4 req’d) 1A341224122 Size 70 thru 87

w/MO w/3582, DVC5010 (2 req’d) 1A341224122

Size 70 w/MO,

w/3582 102 mm (4 inch) travel (4 req’d) 1A375324122

Size 70 w/MO,

w/DVC5010 102 mm (4 inch) travel (4 req’d) 1A341224122 36 Sleeve, acetal 16A0428X012 37 Cap Screw, steel (2 req’d) 16A0429X012 38 Stem Washer, pl steel (2 req’d)

Size 30, 34, 40, 1B865928982 Size 45 thru 60 1A375624022 Size 70 and 100, w/o MO 1H723125072 Size 70 thru 87 w/MO

up to 76 mm (3 inch) travel 1A518925092

Key Description Part Number

38 Stem Washer, pl steel (2 req’d) (cont’d)

Size 70 thru 87 w/MO

76 mm (4 inch) travel 1H723125072

Size 80 and 87 1A518925072

39 Stem Spacer, steel (2 req’d)

Size 30, 34, 40 1N822924092 Size 45 thru 60 17A8301X012 Size 70 w/o MO

Type 657 13A8282X012 Type 667 17A8301X012

Size 70 thru 87 w/MO

up to 76 mm (3 inch) travel 1U866024092

Size 100 13A8282X012 48 Lubricant (not furnished with transmitter) 49 Threadlock − medium strength (not furnished with transmitter) 51 Threadlock − mild strength (not furnished with mounting)

Parts for Mounting the Transmitter on Type 585 or 585C Actuators (figures 16 and 17)

12 Machine Screw, pl steel (2 req’d)

Type 585 & 585R only 1A331928982

21 Mounting Plate, steel

Type 585C and 585CR 24B6336X012

Type 585 and 585R

Size 25, 50 38A0649X012 Size 100 30B7649X012

23 Cap Screw, zn pl steel

Type 585 and 585R (4 req’d) 1C473224052

Type 585C and 585CR (2 req’d) 1A352624052

24 Washer, (2 req’d)

Type 585C and 585CR only 1B865928982 25 Operating Arm, pl steel 19A3811X012

26 Cap Screw, pl steel 1H3284X0012 27 Square Nut, pl steel 16A6711X022 29 Torsional Spring, zn pl steel 19A3812X012 30 Lever Assembly

Size 100 w/ 0.75 thru 2.125 inch travel 16A6705X012

Size 100 w/ 2.5 thru 4 inch travel 16A6706X012

Note

The lever assembly, key 30, is not used with size 25 and 50 actuators. Order the individual parts below (key 30A through 30C).

30A Lever/Bearing Assembly 18A0645X012 30B Transfer Pin, stainless steel 16A6707X012 30C Pickup Pin, stainless steel 16A6701X012 31 Shoulder Screw, stainless steel 10B5722X012

32 Hex Cap Screw, pl steel (2 req’d) 1C631224052

33 Stem Bracket

Type 585C and 585CR only

Size 25 24B6333X012

Size 50 24B6334X012 36 Sleeve, acetal 16A0428X012 40 Positioner Bracket, zn pl steel

Type 585 and 585R only

Size 25, 50 28A0646X012

Size 100 30B7617X012

83 Lockwasher (2 req’d)

Type 585C and 585CR only 1C225728982

Instruction Manual

Form 5596 July 2005

STEM BRACKET VIEW

4200 Series Transmitters

INDENT 1

INDENT 2

INDENT 3

INDENT 4

INDENT MARK

NUMBER

39A7636-D / DOC

STEM BRACKET VIEW

INDENT

1 2 3 4

TRAVEL

19 29 38 51

INDENT 1

INDENT 2

INDENT 3

INDENT 4

INDENT 5

INDENT 6

INDENT 7

INDENT 8

INDENT MARK

INCHES

0.75

1.125

1.5 2

FOR SIZES 25 AND 50

40B9854-D / DOC

INDENT

NUMBER

1 2 3 4 5 6 7 8

19 29 38 51 64 76 89

102

TRAVEL

INCHES

0.75

1.125

1.5 2

2.5 3

3.5 4

FOR SIZES 100

Figure 16. Typical Transmitter Mounting on Type 585 or 585R Actuator

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

37B4775-A / DOC

Figure 17. Typical Transmitter Mounting on Type 585C or 585CR Actuator

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

APPL Y LUBRICANT

40B7441−A / DOC

Figure 18. Typical Transmitter Mounting on Type 1250 or 1250R Actuator

Key Description Part Number

Parts for Mounting the Transmitter on Type 1250 or 1250R Actuator (figure 18)

21 Mounting Plate, steel 49A7856X012 25 Operating Arm, zn pl steel 19A3811X012 26 Cap Screw, pl steel 1H3284X0012 27 Square Nut, pl steel 16A6711X022 29 Torsional Spring, zn pl steel 19A3812X012 30A Lever/Bearing Assembly, steel 18A0645X012 30B Transfer Pin, stainless steel 16A6707X012 30C Pickup Pin, stainless steel 16A6701X012 31 Shoulder Screw, stainless steel 10B5722X012 32 Hex Cap Screw, pl steel (2 req’d) 1C631224052

Key Description Part Number

33 Stem Bracket, steel

Size 225, 450 30B6736X012 Size 675 30B7385X012

36 Sleeve, acetal 16A0428X012

49 Threadlock − medium strength (not furnished with transmitter) 51 Threadlock − mild strength (not furnished with mounting) 91 Cap Screw, pl steel (2 req’d)

W/positioner 10B6606X012

W/o positioner 10B6605X012 92 Washer, pl steel (2 req’d) 10B6609X012 93 U-Bolt, pl steel (2 req’d) 19A7930X012 94 Hex Nut, pl steel (4 req’d) 19A4838X022 95 Washer, pl steel (4 req’d) 10B6610X012

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

APPL Y LUBRICANT

49A7766-B / DOC

Figure 19. Typical Transmitter Mounting on Type 1051, 1052, or 1061 Actuator

Key Description Part Number

Mounting Parts for Rotary Actuators

Parts for Mounting the Transmitter on Type 1051, 1052, or 1061 Actuator (figure 19)

21 Mounting Plate, steel

W/o tandem linkage

Types 1051 & 1052, Size 33 38A4476X012 Types 1051 & 1052, Size 30 thru 70 and

Type 1061 Size 30 thru 68 36A5913X012

Type 1061 Size 80 and 100 38A5864X012

W/tandem linkage

Types 1051 & 1052, Size 30 & 40 and

Type 1061 Size 30 31B2903X012

Types 1051 & 1052, Size 60 & 70 and

Type 1061 Size 40 thru 68 30B1492X012

Key Description Part Number

32 Cap Screw, pl steel (2 req’d) 1C631224052 50 Anti-seize (not furnished with transmitter)

52 Coupler, stainless steel

Types 1051, 1052, & 1061 all sizes except 33 10B7304X012

Types 1051 & 1052, Size 33 10B7305X012 53 Socket Set Screw, stainless steel 1B8568X0022 54 Coupling, aluminum 17A8307X012

57 Coupling Plate Assembly

Types 1051 & 1052, Size 33 GE08705X012

Types 1051 & 1052, Size 30 &40 and

Type 1061 Size 30 17A8310X012 Type 1051 Size 60 17A9006X012 Type 1052 Size 60, 70 17A9006X012 Type 1061 Size 40, 60, 68 17A9006X012 Type 1061 Size 80 & 100 17A9825X012

Instruction Manual

Form 5596 July 2005

NOTE:

FIELD MOUNTING PARTS

APPL Y LUBRICANT

34A8843-B / DOC

4200 Series Transmitters

APPL Y LUBRICANT

34A8841-A / DOC

Figure 21. Typical Transmitter Mounting on Type 1063,

1064, 1065, 1066, or 1066SR Actuator

Figure 20. Typical Transmitter Mounting on Type 1052,

Size 20 Only Actuator

Parts for Mounting the Transmitter on Type 1052, Size 20 Only Actuator (figure 20)

21 Mounting Plate, steel 39A2482X012 32 Cap Screw, pl steel (2 req’d) 1C631224052 50 Anti-seize (not furnished with transmitter) 52 Coupler, stainless steel 10B7304X012 53 Socket Set Screw, stainless steel 1B8568X0022 54 Coupling, aluminum 17A8307X012 57 Coupling Plate Assembly GE08680X012

Parts for Mounting the Transmitter on Type 1063, 1064, 1065, 1066, or 1066R Actuator without Tandem Linkage (figure 21)

Key Description Part Number

21 Mounting Plate, steel

Types 1063 & 1066 Size 20, 27 and

Types 1064 & 1065, Size 20 38A4476X012 Types 1063, 1064, 1065, & 1066, Size 75 38A4477X012

32 Cap Screw, pl steel (2 req’d) 1C631224052 50 Anti-seize (not furnished with transmitter) 52 Coupler, stainless steel 10B7305X012 53 Socket Set Screw, stainless steel 1B8568X0022 54 Coupling, aluminum 17A8307X012 57 Coupling Plate Assembly

Types 1063 & 1066, Size 20, 27 and

Types 1064 & 1065 Size 20 GE08680X012 Types 1063, 1064, 1065, & 1066, Size 75 17A9147X012

4200 Series Transmitters

TRANSDUCER ASSEMBLY

Instruction Manual

Form 5596

July 2005

SECTION A−A

GE13433

GE16564

Figure 22. Typical Transmitter Mounting on a Type 470-16 Actuator (585C with Travel Greater than 4-inches)

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

Mounting Parts for Long Stroke Sliding Stem Actuators

Parts for Mounting the Transmitter on Type 470-16 Actuator (585C with travel greater than 4-inches) (figure 22)

Key Description Part Number

32 Hex Cap Screw, zn pl steel (2 req’d) 1C631224052 60 Cable Bracket, stainless steel

Size 60 GE13639X012 Size 68 GE13432X012 Size 80 &100 GE13621X012

Size 130 GE13762X012 63 Mounting Plate, stainless steel GE13431X012 64 Cable Cover Assembly, carbon steel

Size 60 GE13640X012

Size 68 GE13522X012

Size 80 &100 GE13622X012

Size 130 GE13763X012 71 Hex Nut, stainless steel (4 req’d)

Size 60, 68 1A3753X0042

Size 80, 100, 130 only 1A3412K0022 72 Hex Nut, stainless steel 1A4188X0012 78 Stud, stainless steel (2 req’d)

Size 60, 68 12A1493X052 Size 80, 100, 130 18A6422X092

81 Machine Screw, pl steel (2 req’d) 14B3887X012 82 Cap Screw, zn pl steel 1C275224052 83 Lockwasher, stainless steel 1A3291X0012

100 Transducer Assy GE13424X012 102 Cap Screw, stainless steel 1R450028982 103 Cap Screw, stainless steel (4 req’d) 1V154238982 104 Hex Nut, stainless steel (4 req’d) 1A3527K0032 105 Cap Screw, stainless steel (2 req’d) 1C631238982

Parts for Mounting the Transmitter on a Type 585CLS or 490 Actuator (figure 23)

35 Stud, zn pl steel 1H9892X0012 49 Threadlock − medium strength (not furnished with transmitter) 61 Cable Clip, , stainless steel

Yoke boss 5H,

Cylinder size 127 to 254 mm (5 to 10 inches), Max travel

305 mm (12 inches) and

406 mm (16 inches) GE13428X012

Key Description Part Number

63 Mounting Plate, stainless steel

Yoke boss 5H,

Cylinder size 127 to 254 mm (5 to 10 inches), Max travel

305 mm (12 inches) and

406 mm (16 inches) GE13427X012

Yoke Boss 5H

Cylinder size 305 & 356 mm (12 & 14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 7 IN

Cylinder size 127 to 356 mm (5 to14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 5H & 7 IN

Cylinder size 127 to 356 mm (5 to 14 inches),

Max travel 508 mm (20 inches) and

610 mm (24 inches) GE13425X012

69 Lower Yoke Cover, polycarbonate

Yoke Boss 5H

Cylinder size 127 to 254 mm (5 to 10 inches),

Max travel 305 mm (12 inches) 28A8147X012

Yoke Boss 5H

Cylinder size 127 to 254 mm (5 to 10 inches),

Max travel 406 mm (16 inches) 28A8147X022

Yoke Boss 5H

Cylinder size 305 & 356 mm (12 & 14 inches),

Max travel 305 mm (12 inches)

Yoke Boss 7 IN

Cylinder size 127 to 356 mm (5 to14 inches),

Max travel 305 mm (12 inches) 28A8147X032

Yoke Boss 5H

Cylinder size 305 & 356 mm (12 & 14 inches),

Max travel 406 mm (16 inches)

Yoke Boss 7 IN

Cylinder size 127 to 356 mm (5 to14 inches),

Max travel 406 mm (16 inches) 28A8147X042

Yoke Boss 5H & 7 IN

Cylinder size 127 to 356 mm (5 to 14 inches),

Max travel 508 mm (20 inches) 28A8147X052

Yoke Boss 5H & 7 IN

Cylinder size 127 to 356 mm (5 to 14 inches),

Max travel 610 mm (24 inches) 28A8147X062

Yoke Boss 5H

Cylinder size 305 & 356 mm (12 & 14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 7 IN

Cylinder size 127 to 356 mm (5 to14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 5H & 7 IN

Cylinder size 127 to 356 mm (5 to 14 inches),

Max travel 508 mm (20 inches) and

610 mm (24 inches) GE13426X012

72 Hex Nut, stainless steel 1A4188X0012 73 Hex Nut, zn pl steel (2 req’d) 1A341224112

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

Key Description Part Number

75 Cap Screw, stainless steel, (4 req’d)

Yoke boss 5H,

Cylinder size 127 to 254 mm (5 to 10 inches), Max travel

305 mm (12 inches) and

406 mm (16 inches) 1A352638982

Yoke Boss 5H

Cylinder size 305 & 356 mm (12 & 14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 7 IN

Cylinder size 127 to 356 mm (5 to14 inches),

Max travel 305 mm (12 inches) and 406 mm (16 inches)

Yoke Boss 5H & 7 IN

Cylinder size 127 to 356 mm (5 to 14 inches),

Max travel 508 mm (20 inches) and

610 mm (24 inches) 1A3816K0012

77 Machine Screw, pl steel (6 req’d), (not shown) 16A5763X012

Key Description Part Number

83 Lockwasher, stainless steel 1A3291X0012 86 Washer, pl steel (6 req’d), (not shown) 1F230328992

100 Transducer Assy

Max travel 305 mm (12 inches) GE13424X012

Max travel 406 mm (16 inches),

508 mm (20 inches) and

610 mm (24 inches) GE13424X022

101 Spacer, stainless steel (4 req’d)

Yoke Boss 5H

Cylinder Size 5 to 10 and 12 & 14

Max travel 305 mm (12 inches) and 406 mm

(16 inches) only 18B6031X012

102 Cap Screw, stainless steel 1R450028982 103 Cap Screw, stainless steel (4 req’d) 1V154238982 104 Hex Nut, stainless steel (4 req’d) 1A3527K0032 105 Cap Screw, stainless steel (2 req’d) 1C631238982

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

SECTION A−A

GE13430

TRANSDUCER ASSEMBLY

GE16563

Figure 23. Typical Transmitter Mounting on a Type 490 (585CLS) Actuator

4200 Series Transmitters

Loop Schematics and Nameplates

This section includes loop schematics required for wiring of intrinsically safe installations. It also contains the approvals nameplates. If you have any questions, contact your Fisher sales office.

Instruction Manual

Form 5596

July 2005

20B6503-A Sheet 1 of 2

Figure 24. CSA Schematics (continued on next page)

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

20B6503-A Sheet 2 of 2

Figure 24. CSA Schematics (continued)

TYPES 4211 AND 4221

INTRINSICALLY SAFE

Figure 25. CSA Approval Nameplates

TYPES 4210, 4212, 4215, 4220, AND 4222

EXPLOSION PROOF

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

20B6408-E

Figure 26. FM Schematics

TYPES 4211 AND 4221

INTRINSICALLY SAFE

TYPES 4210, 4211, 4212, 4215, 4220,

4221 AND 4222

EXPLOSION PROOF

Figure 27. FM Approval Nameplates

Instruction Manual

Form 5596 July 2005

4200 Series Transmitters

SPECIFIC CONDITIONS FOR SAFE USE STHIS EQUIPMENT IS INTRINSICALLY SAFE AND CAN BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES. STHE APPARATUS MUST ONLY BE CONNECTED TO A CERTIFIED ASSOCIATED INTRINSICALLY SAFE EQUIPMENT AND THIS COMBINATION MUST BE COMPATIBLE AS REGARDS INTRINSIC SAFETY RULES. STHE ELECTRICAL PARAMETERS OF THE ASSOCIATED INTRINSICALLY SAFE EQUIPMENT MUST NOT EXCEED ANY OF THE FOLLOWING VALUES:

Uov30 V, lov150mA, Pov1W

SMAXIMAL AMBIENT TEMPERATURE: −40_C to +71_C. STEMPERATURE CLASSIFICATION IS AS FOLLOWS:

T5 at Tav + 40_C T4 at Tav + 71_C

TYPES 4211 AND 4221

INTRINSICALLY SAFE AND DUST

Figure 28. ATEX (LCIE) Approvals Nameplates

TYPES 4211 AND 4221

TYPE n AND DUST

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

Fisher is a mark owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

Emerson Process Management

Fisher

Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461

www.Fisher.com

Emerson Fisher 4200 Series, Fisher 4211, Fisher 4212, Fisher 4215, Fisher 4220 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual