• Sensitive Response—A nozzle-flapper arrangement and a three-to-one relay allow small process temperature changes to induce large output pressure changes.
• Mounting Versatility—Install the controller on a panel, wall, or pipestand, as well as on an actuator (as shown in figure 1). The temperature element is adjustable for desired penetration into the process vessel.
• Easy Adjustments—Temperature set point, proportional band, and reset are adjustable with large, easy-to-read dial-knob controls.
• Continuous Indication of Process Temperature—A temperature gauge, calibrated for the specific measurement range, monitors the process temperature continuously.
• Easy Maintenance—Simple design of the controller allows fast, easy maintenance and minimum spare parts inventory.

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.

Available Configurations

See table 1

Input Signal(1)

Type: Temperature between 0°C and 500°C or 0°F and 1000°F; see table 2 for available ranges
Minimum Span(1): 100°C or 100°F
Maximum Span(1): 500°C or 1000°F

Output Signal(1)

Proportional-Only or Proportional-Plus-Reset Controllers: ■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 temperature produces increasing output signal) and ■reverse (increasing sensed temperature produces decreasing output signal). The suffix R is added to the type number of a construction specified for reverse action.

Supply Pressure(3)

See table 3

Steady-State Air Consumption(1)

See figure 2

Supply and Output Connections

1/4-inch NPT female

Maximum Allowable Pressure in Closed Vessel (For Temperature Bulb)

3/8-inch (10 mm) Temperature Bulb: 69 bar (1000 psig) at 38°C (100°F)
9/16-inch (14 mm) Temperature Bulb: 34.5 bar (500 psig) at 38°C (100°F)

Proportional Band(1) Adjustment

For Proportional-Only or Proportional-Plus-Reset Controllers
Full output pressure change adjustable over percent of sensing element temperature range as follows:
Proportional-Only Controllers: ■3% to 100% [0.2 to 1.0 bar (3 to 15 psig)] or
■6% to 100% [0.4 to 2.0 bar (6 to 30 psig)]
Proportional-Plus-Reset Controllers: ■6% to 200% [0.2 to 1.0 bar (3 to 15 psig)] or
■12% to 200% [0.4 to 2.0 bar (6 to 30 psig)]

Differential Gap Adjustment

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

Reset(1) Adjustment

For Proportional-Plus-Reset Controllers:
Adjustable from 0.01 minutes to more than 74 minutes per repeat (from 100 repeats per minute to less than 0.0135 repeats per minute)

Performance

Repeatability(1): 0.5% of sensing element temperature range
Dead Band(1) (Except Differential Gap Controllers(2)): 0.1% of output span
Time Constant of Temperature Bulb: 9 to 18 seconds (bare bulb in agitated liquid)

Ambient Operating Temperature Limits(3)

-40 to 71°C (-40 to 160°F)

Typical Ambient Temperature Operating Influence

Proportional Control Only: Output pressure changes ±3.0% of sensing element range for each 28°C (50°F) change in ambient temperature for a controller set at 100% proportional band
Reset Control Only: Output pressure changes ±2.0% of sensing element range for each 28°C (50°F) change in ambient temperature for a controller set at 100% proportional band

Process Temperature Indication

Standard on all controllers and calibrated for the temperature range ordered

Hazardous Area Classification

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

Capillary Lengths

Standard: 4.6 m (15 foot)
Optional: Consult your Emerson Process ManagementTM sales office for other lengths

Approximate Weight

8.2 kg (18 pounds)

Construction Materials

See table 4

Output Pressure Gauge Indications

See table 5

Options

■Stainless steel bellows and ■stainless steel relay

Proportional-Only Controllers

Refer to figures 3 and 4.
As the process temperature increases, pressure increases within the Bourdon tube extending its radius of arc. This moves the flapper toward the nozzle (in a direct-acting controller) restricting flow through the nozzle and increasing nozzle pressure. When this occurs, relay action increases the output pressure of the controller.
With a Type 4156K proportional-only controller, a portion of the output pressure is fed back to the proportional bellows. The action of the proportional bellows counters the flapper movement that resulted from the process temperature change and backs the flapper away from the nozzle until equilibrium is attained. The proportional band adjustment determines the amount of output pressure that is fed back to the proportional bellows. Adjusting the proportional band changes the gain of the controller.
The set point adjustment changes the proximity of the nozzle and flapper as does a change in process temperature. When the set point is changed, however, the nozzle moves with respect to the flapper.
As shown in figure 6, moving the reversing block and bellows connection changes the controller action from direct to reverse, and vice versa. With reverse-acting controllers, an increase in process temperature causes a decrease in output pressure.

Proportional-Plus-Reset Controllers

Refer to figures 3 and 5.
Operation of the Type 4166K Proportional-plus-reset controller is similar to that of the proportional-only controller except that output pressure is fed back to the reset bellows, through a reset restriction valve, as well as to the proportional bellows. The action of the reset bellows opposes that of the proportional bellows. However, because of the reset restriction valve, the action of the reset pressure is delayed. The reset valve can be adjusted to vary the delay time. In operation, proportional-plus-reset controllers minimize the offset between the process temperature and set point.

Anti-Reset Windup

The Type 4166KF controller has an adjustable and reversible differential relief valve to provide anti-reset windup. As shown in figure 3, 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 the 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 decreases the pressure in the proportional system, and on the spring side of the relief diaphragm. If the 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 differential relief valve can also be reversed to relieve with an increasing output pressure.

Differential Gap Controllers

In the Type 4156KS controllers, feedback pressure does not counteract the change in flapper position. Instead, the output pressure is piped to the bellows located on the side of the beam and flapper opposite the nozzle. Feedback pressure now reinforces the flapper movement by the sensed temperature change. This construction causes the controller output to switch from full supply pressure to zero pressure or vice versa. The difference between the process temperature when the controller output switches to zero and the process temperature
when the controller switches to maximum is the differential gap. Adjusting the proportional band adjustment adjusts the width of the gap; adjusting the set point positions the gap within the temperature element range.

Easy Relay Maintenance

A clean-out wire provides a fast, easy means of cleaning the primary orifice of the relay during service.

Rugged Service Capability

The case and cover are made of weather resistant die-cast aluminum. Internal constructions are available to resist corrosive supply pressure media such as sour gas.

Easy Conversion from Proportional to Differential Gap

When the application requires differential gap control, the Type 4156KS controller is available. Or, a proportional-only controller can be easily converted to differential gap operation by reversing the tubing connection at the bellows frame on top of the beam and flapper.

Easy Direct/Reverse Conversion

Switching the action from direct to reverse or vice versa is done by simply moving the reversing block and feedback bellows connection as shown in
figure 6.

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 in the event of a supply pressure failure or other malfunction.

Anti-Reset Windup

The anti-reset windup capability of the Type 4166KF controller provides quick equalization of reset and proportional pressures. This capability reduces overshoot of the process temperature that can result from large or prolonged deviation from set point.
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. The valve can be positioned to relieve on either increasing or decreasing output pressure.

Application

1. Description of the service
2. Temperature range of the process
3. Ambient temperature
4. Velocity of process fluid (if measuring the temperature of a process fluid flowing through a pipe)
5. Pressure in process vessel (if closed)
6. Bushing or thermowell (when the temperature bulb is to be used in a closed vessel). Refer to figure 8 for available sizes. Specify straight shank or tapered shank thermowell. (Tapered-shank thermowells, with their high strength-to-weight ratio, permit operation in higher process fluid velocities than do straight-shank thermowells.)

Construction

Refer to the specifications and the Construction Features section. Review each specification and feature, specifying your choice whenever a selection is offered. A panel mounting bracket is supplied unless some other mounting method is specified.
Specify the quantity and the complete type number (including the R suffix for reverse action) for the Wizard II controller.

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.