• Wide Range of Sensing Elements—A Bourdon tube is available for high pressures or bellows for vacuum and low pressures. Either kind of sensing element can be installed in the case with the controller or transmitter. Two interchangeable ranges of output bellows and gauges also are available.
• Sour Service Capability—Materials are available for applications handling sour process fluids. These constructions comply with the metallurgical requirements of NACE MR0175-2002. Environmental restrictions may apply.
• Mounting Versatility—Install the case on a panel, wall or pipestand, as well as directly on the control valve actuator.
• Reduced Maintenance Costs—A spring-out cleaning wire, shown in figure 5, provides for in-service cleaning of the relay orifice.
• Easy Conversion to Another Mode—Add reset action to a proportional controller by adding only one valve and three pieces of tubing, as shown in figure 6. The original case may be used in either instance.
• Easy Reversibility—Switch action from direct to reverse or vice versa without additional parts. As illustrated in figure 7, simply transfer the reversing block to the opposite side of the flapper and change the feedback bellows frame tubing connections.
• Easy, Accurate Adjustments—Make pressure setting, proportional band, and reset changes with simple dial-knob controls that help to assure positive settings.
• Sensitive Response—Area ratio of large relay diaphragm to small relay diaphragm permits small nozzle pressure changes to induce much greater output pressure changes.

Available Configurations

See table 1

Input Signal

Type: ■Gauge pressure, ■vacuum, ■compound pressure, or ■differential pressure of a liquid or gas
Limits: See table 2 or 3

Output Signal

Proportional or Proportional-Plus-Reset Controllers and Transmitters: ■0.2 to 1.0 bar (3 to 15 psig) or ■0.4 to 2.0 bar (6 to 30 psig) pneumatic pressure signal
Differential Gap Controllers: ■0 and 1.4 bar
(0 and 20 psig) or ■0 and 2.4 bar (0 and 35 psig) pneumatic pressure signal
Action: Control action is field reversible between ■direct (increasing sensed pressure produces increasing output signal) and ■reverse (increasing sensed pressure produces decreasing output signal). The suffix R is added to the type number of a construction specified for reverse action.

Supply Pressure Requirements(1)

See table 4

Supply Pressure Medium

Air or Natural Gas(2)

Steady-State Air Consumption

See figure 2

Supply and Output Connections

1/4 NPT internal

Supply and Output Pressure Gauge Ranges

See table 5

Proportional Band Adjustment

For Proportional and Proportional-Plus-Reset Controllers: 0.2 to 1.0 bar (3 to 15 psig) Output: Full output pressure change adjustable from 3 to 100% of the sensing element range.
0.4 to 2.0 bar (6 to 30 psig) Output: Full output pressure change adjustable from 6 to 100% of the sensing element range.

Differential Gap Adjustment

For Differential Gap Controllers: Full output pressure change adjustable from 15% to 100% of sensing element range

Reset Adjustment

For Proportional-Plus-Reset Controllers: Adjustable from 0.01 to 74 minutes per repeat (100 to 0.01 repeats per minute)

Zero Adjustment (Transmitters Only)

Continuously adjustable to position span of less than 100% anywhere within the sensing element range

Span Adjustment (Transmitters Only)

Full output pressure change adjustable from 6 to 100% of process sensing element range

Performance

Repeatability: 0.5% of sensing element range
Dead Band (Except Differential Gap Controllers(3)): 0.1% of output span
Typical Frequency Response at 100% Proportional Band:
Output to Actuator: 0.7 Hz and 110 degree phase shift with 1850 cm3 (113 inches3) volume actuator at mid-stroke
Output to Positioner Bellows: 9 Hz and 130 degree phase shift with 0.2 to 1.0 bar (3 to 15 psig) output to 33 cm3 ( 2 inches3 ) bellows

Ambient Operating Temperature Limits(1)

■Standard Construction: -40 to 93°C (-40 to 200°F)
■4160KF (w/Reset Relief): -40 to 71°C (-40 to 160°F)

Typical Ambient Temperature Operating Influence

Proportional Control only: Output pressure changes ±3.0% of sensing element rating for each 28°C (50°F) change in temperature between -40 and 71°C (-40 and 160°F) for a controller set at 100% proportional band
Reset Control only: Output pressure changes ±2.0% of sensing element rating for each 28°C (50°F) change in temperature between -40 and 71°C (-40 and 160°F) for a controller set at 100% proportional band
Transmitters only: Output pressure changes ±3.0% of sensing element rating for each 28°C (50°F) change in temperature between -40 and 71°C (-40 and 160°F) for a transmitter set at 100% span

Hazardous Area Classification

Complies with the requirements of ATEX Group II Category 2 Gas and Dust

Construction Materials

See tables 2, 3, and 6

Approximate Weight

8.2 kg (18 pounds)

Proportional-Only Controllers

The controller output pressure change feeds back to the proportional bellows, countering the pressure change in the nozzle and equalizing the relay diaphragm pressure differential. The relay valve maintains a new loading pressure according to the change in sensed pressure.
If the proportional valve is wide open (maximum dial setting), all of the controller output pressure change feeds back to the proportional bellows. The more the proportional valve is closed, the more the controller output pressure change bleeds out through the proportional valve exhaust and the less there is to feed back to the proportional bellows. A fully open proportional valve results in a proportional band of 100 percent; closing the proportional valve reduces the proportional band.

Proportional-Plus-Reset Controllers

Additionally, all 4160K Series controllers have a two-way reset restriction valve that channels proportional pressure into a reset bellows to oppose the proportional bellows action. The action of this reset pressure occurs on a delayed basis, and the reset valve can be adjusted to vary the time of delay.

Anti-Reset Windup

The Type 4160KF and 4162KF controllers have an adjustable and reversible differential relief valve to provide anti-reset windup. As shown in figure 4, the proportional pressure registers rapidly on the spring side of the relief valve diaphragm as well as in the proportional bellows. Reset pressure registers slowly on the opposite side of the relief valve diaphragm. As long as controller output pressure changes are slow enough for normal proportional and reset action, the relief valve spring keeps the relief valve diaphragm from opening. However, a large or rapid decrease in controller output pressure causes the relay to rapidly exhaust loading pressure from the control element, and also from the proportional system and spring side of the relief diaphragm. If this decrease on the spring side of the diaphragm is greater than the relief valve spring setting, the diaphragm will move off the relief valve orifice and permit the reset pressure on the opposite side of the relief valve diaphragm to bleed rapidly into the proportional system. The anti-reset windup action also can be reversed to relieve with an increasing proportional pressure.

Rugged Service Capability

The case and cover are made of weather resistant, die-cast aluminum. Stainless steel tubing and fitting materials provide the capability for operation in ammonia and similar corrosive service conditions. Optional materials for relay diaphragms and other soft parts permit operation at ambient temperatures up to 93°C (200°F).

Low-Pressure Precision

Bellows sensing constructions provide accuracy in low-pressure, vacuum, or compound ranges. Two sensing bellows are used where an important variable is the difference between two sensed pressures.

Easy Conversion From Proportional To On-Off Control

The Type 4150KS controller provides on-off rather than proportional control. This construction has the same parts as the comparable Type 4150K controller. However, the proportional bellows is connected so that feedback pressure pushes the beam and flapper in the same direction as caused by the sensed pressure change. This reinforcement completely opens the relay valve either to full supply pressure or to full exhaust, allowing no in-between throttling.
To change from a proportional to on-off controller, or vice versa, just reverse the tubing connection at the bellows frame on top of the beam and flapper as shown in figure 7.

Anti-Reset Windup

The anti-reset windup capability of the Type 4160KF and 4162KF controllers provides quick equalization of reset and proportional pressures. This capability reduces overshoot and the time required for a system to return to the pressure setting after large changes in sensed pressure. This feature is useful when slow reset and broad proportional band settings are used.
The differential relief valve has a range of 0.14 to 0.4 bar (2 to 7 psig) and, unless ordered otherwise, is set by the factory to relieve at a 0.3 bar (5 psi) difference between proportional and reset pressures.

Manual Backup

As shown in figure 8, a 670 or 671 Series panel-mounted loading regulator with changeover valve permits switching to an alternate loading pressure, if a Wizard II controller experiences supply pressure failure or other malfunction.

Continuous Indication of Process Pressure

Replacing the supply pressure gauge on a controller or transmitter by a process pressure gauge permits indicating process pressure in one of the ranges shown in table 7. To obtain a supply pressure indication, install a gauge on the supply regulator. The process pressure gauge must be specially ordered and comes with brass trim standard in all ranges and stainless steel trim optional in some ranges. Adding a process pressure gauge in the field also requires a special control pressure block. A process pressure gauge can not be added to controllers or transmitters that use a differential bellows for sensing process pressure.

Bourdon Tube Protection

All Bourdon tube constructions are available with one or both of the following protective devices:

• Barrier Protector for Corrosive or Clogging Process Fluids—A sealed and fluid-filled barrier (described in a separate bulletin) may be installed between the process and the Bourdon tube. The barrier fluid transmits sensed pressure on a one-to-one basis into the Bourdon tube.
• Travel Stop for Bourdon Tube—The stop limits Bourdon tube overtravel when momentary surges in the sensed pressure exceed the Bourdon tube rating. Although it does not permit accurate control or transmission of a pressure higher than the upper range limit listed in table 2, this stop does permit Bourdon tube overpressuring to the maximum static pressure shown in table 2 without damage.

Application

When ordering, specify:
1. Type of service, such as pressure reduction or pressure relief, throttling or on-off.
2. Composition, pressure, and temperature of measured variable(s).
3. Type number, orientation, and other applicable descriptions of control or indicating device(s).

Construction

Refer to the Specifications and the Construction Features sections. Review the description for each specification, construction feature, and in the referenced tables. Specify the desired selection whenever there is a choice.
Always specify the complete type number (including the R suffix for reverse action) of the Wizard II controller or transmitter, supply pressure regulator, and other desired equipment. On controllers with anti-reset windup, specify whether the differential relief valve is to relieve with falling or rising output.

Note
Neither Emerson, Emerson Process Management, 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