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

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

R

, 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)

0

0

POWER SUPPLY VOLTAGE (VOLTS dc)

A6765/IL

10

11

Figure 2. Power Supply Requirements

24

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.

2

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)

(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)

(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

1

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

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)

3

4200 Series Transmitters

ELECTRICAL

POTENTIOMETER

CONNECTION

TYPE

CONNECTION

(1)

Zero

Zero

Zero

4211

0 to 90

15

90

4221

0 to 884

150

884

Enclosure

l

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

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: [e-mail]

4

Instruction Manual

ATEX

Form 5596
July 2005

CERTIFICATION

BODY

CSA

FM

MODEL/

TYPE

4211, 4221

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

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 − − −

V

= 40 Vdc

max

= 200 mA

I

max

= 5 nF

C

i

= 0 mH

L

i

− − −

− − −

− − −

TEMPERATURE

CODE

TC3 (T

T5 (T

T5 (T

T4A (T

T5 (T

T5 (T

T5 (T

amb

amb

amb

amb

amb

amb

amb

 71°C)

 71°C)

 71°C)

 71°C)

 71°C)

 71°C)

 71°C)

ENCLOSURE

RATING

4X

4X

4X

4X

4X

4X

4X

CERTIFICATE

(AGENCY)

ATEX

(LCIE)

MODEL/

TYPE

4211, 4221

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

i

P

= 1.0 W

i

= 5 nF

C

i

L

= 0 mH

i

(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

IP66

5

4200 Series Transmitters

Instruction Manual

Form 5596

July 2005

PORT
1/2-INCH NPT
(2 PLACES)

51

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)

75

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

6

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

7

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.

8

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

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 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).

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 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

9

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

10

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

1

FIELD WIRING
COMPARTMENT

R

3

3

TB3

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

FOR TYPE 4212 OR 4222 POSITION SWITCHES WITHOUT THE TRANSMITTER

4

EARTH
GROUND

+

POWER
SUPPLY

−

+

DEVICE
RECEIVING
4 TO 20 MA
DC SIGNAL

−

12

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:

1

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

THE ASSOCIATED WIRING.

2

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.

3

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.

4

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

−

2

Figure 4. Wiring Connections

11

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.

12

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

13

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:

1

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.

14