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Emerson Fisher 2500 Instruction Manual

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1. 1 Consult your Emerson Process Management sales office about gauges in other units 2 Control and stability may be impaired if this pressure is exceeded 3 Atzero or maximum proportional band or specific gravity setting 4 Atsetting in middle of proportional band or specific gravity range 5 If air consumption is desired in normal m3 hr at 0 C and 1 01325 bar multiply scfh by 0 0258 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 2 Guidelines for Use of Optional Heat Insulator Assembly AMBIENT TEMPERATURE C 11 AMBIENT TEMPERATURE C Ap 19 0 iy kis E P i 70 593 18 10 0 10 20 30 40 50 60 70 80 90 100105 1100 593 T 500 S l TOO 500 T 800 Se l L 500 c X HEAT INSULATOR 400 80 HEAT INSULATOR HOT E REQUIRED soz E REQUIRED T z 400 200 s z T 4 300 E E 100 E aoo 200 Bo 18 Z T 2 NO INSULATOR NECESSARY i 5 E T NOINSULATOR NECESSARY OF 4 20 229 T 0 4 o 9 iu OO s O 4 40 0 S USEINSULATOR CAUTION IF AMBIENT DEWPOINT IS ABOVE PROCESS o E USE INSULATOR CAUTION IF AMBIENT DEWPOINT IS ABOVE E TEMPERATURE ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND T ra PROCESS TEMPERATURE ICE FORMATION MAY CAUSE INSTRUMENT a En js a MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS 20 p REDUCE INSULATOR EFFECTIVENESS rm 0 a aS ee 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180 200 220 AMBIENT TEM
2. 2 Disconnect the tubing key 10 or 11 from the relay 3 Remove both mounting screws relay and relay gasket keys 43 34 and 22 Replacement 1 Install a new gasket key 22 the replacement relay key 34 and secure with two mounting screws key 43 On a controller or transmitter with an indicator assembly slide the base plate under the two lower screws of the relay case align the plate so the pointer will read properly and tighten the screws 2 Connect the tubing key 10 or 11 to the relay 3 Testthe relay deadband according to the Relay Deadband Testing procedure in this section 4 If the deadband is within tolerance go to the Calibration section Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment use the controller transmitter type number and the serial number The serial number is found on the nameplate key 215 figure 16 When ordering replacement parts also state the complete 11 character part number of each part required as found in the following parts list 37 2500 and 2503 Controllers Transmitters April 2014 Instruction Manual D200124X012 A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the perf
3. 4 If the controller transmitter has a heat insulator remove the four button head cap screws and washers keys 40 and 53 figure 14 and remove the insulator assembly Changing Mounting Methods To avoid personal injury from contact with the process fluid lower the vessel fluid level below the torque tube arm before proceeding For closed vessels release any pressure that may be above the fluid Also be careful to avoid overloading a thin wall torque tube with an overweight displacer Refer to figure 16 for key number locations 33 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 1 Remove the controller transmitter as described previously 2 Acontroller transmitter is attached to the sensor in one of the mounting positions shown in figure 4 Right hand mounting is with the controller transmitter case key 1 to the right of the displacer FLOAT as you look at the front of the case left hand mounting is with with the case to the left of the displacer For a 249 sensor remove the torque tube arm from the sensor or vessel and reinstall the torque tube arm in the opposite position according to the appropriate instruction manual Note that the term FLOAT is marked on the RAISE LEVEL dial and the indicator plate if one is used 3 Check the desired control action If the control action is not correct refer to the changing action procedures to change it Mount the Bourdon tube in one of the positio
4. W2141 1B SCREWED CONNECTION AP CONNECTION DAMPING PLATE W0144 1 A cageless sensor comes with its displacer separated from the sensor assembly Displacers longer than 813 mm 32 inches come in a separate crate Shorter displacers come in the same crate as the sensor but are not attached to their displacer rods Inspect the displacer to ensure it is not dented A dent may reduce the pressure rating of the displacer If a displacer is dented replace it Controller Transmitter Orientation The controller transmitter attaches to the sensor in one of the mounting positions shown in figure 4 Right hand mounting is with the controller or transmitter case to the right of the displacer when you look at the front of the case left hand mounting is with the case to the left of the displacer The mounting position can be changed in the field Changing this mounting position changes the control action from direct to reverse or vice versa All caged sensors have a rotatable head That is the controller transmitter may be positioned at any of eight alternate positions around the cage as indicated by the numbers 1 through 8 in figure 4 To rotate the head remove the head flange bolts and nuts and position the head as desired 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 Figure 4 Cage Head Mounting Positions proteases beers t RIGHT HAND MOUNTING LEFT HAND MOUNTING TD 67C
5. Transmitters Only 04 20 Calibration 4 eese eere kr that es 20 Precalibration Requirements 20 Wet Calibration 00 eee eee 20 Dry Calibration 2 0 ce cece eee eee 21 Controller Transmitter and Torque Tube Arm Disassembly 0 0c ccc cece eens 21 Determining the Amount of Suspended Weight 06 21 Calibration Procedure Luuuus 22 2500 Controller and 2500T Transmitter 23 2500S and 2503 Controllers 25 Startup eiae a a o e a ee e a a ae e R A OR RES 27 2500 Controller 2 cece 27 2500T Transmitter er eee eee ee eee 27 2500S Controller 0 cece eee eee 27 2503 Controller eee eee eee 27 Figure 1 Fisher 2500 or 2503 Controller Transmitter on 249 Caged Sensor 2500 OR 2503 CONTROLLER TRANSMITTER de 249 SENSOR Principle of Operation sese 27 2500 Controller or 2500T Transmitter 28 Proportional Valve 00 e eee eee 28 2500S Controller eee ee eee eee 28 2503 Controller eee eee eee eee 29 Maintenance cee eee eee eee 30 Troubleshooting 0c cece cece eens 31 Removing Controller Transmitter from Sensor 32 Changing Mounting Methods 33 Installing Controller Transmitter on Sensor 34 Replacing the Bourdon Tube 35 Changing Action 0 cec
6. D200124X012 April 2014 If necessary you may use water for wet calibration in the shop You must compensate for the difference between the specific gravities of water and the process fluid however As an example assume the process fluid has a specific gravity of 0 7 The specific gravity of water is 1 0 To simulate a process level of 50 percent of the input span would require a water level of 35 percent 0 7 1 0 x 50 percent 35 percent Dry Calibration Remove the controller transmitter and torque tube arm as a single unit from the cage or vessel Then wherever the standard calibration procedures in this manual require a specific process variable input to the sensor simulate the process variable by suspending the proper weight such as a can of sand from the end of the displacer rod Complete the following procedures Controller Transmitter and Torque Tube Arm Disassembly and Determining the Amount of Suspended Weight before proceeding to the Calibrating Procedure Controller Transmitter and Torque Tube Arm Disassembly A WARNING To avoid personal injury from contact with the process fluid lower the vessel level below the sensor torque tube arm or shut off the cage equalizing valves and drain the cage before proceeding For closed vessels release any pressure that may be in the vessel before removing the sensor assembly When removing the displacer from the displacer rod or removing the controller transmitter and torque tube
7. Density From 0 to 100 of displacement force change obtained with given displacer volume Standard volume for displacers are listed in table 2 Output Signal 2500 Controller and 2500T Transmitter 0 2 to 1 bar 3 to 15 psig or 0 4 to 2 bar 6 to 30 psig 2500S and 2503 Differential Gap Controllers 0 bar 0 psig when switched off and full supply 1 4 or 2 4 bar 20 or 35 psig nominal depending on controller output pressure range when switched on Area Ratio of Relay Diaphragms 3 1 Supply Pressure Data See table 3 2 Supply Medium Air or natural gas Air Supply pressure must be clean dry air that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Natural Gas Natural gas must be clean dry oil free and noncorrosive H5S content should not exceed 20 ppm Maximum Supply Pressure 2 3 3 bar 45 psig to the controller or transmitter If controller or transmitter is equipped with an integrally mounted 67CFR filter regulator typical supply pressure to the requlator is from 2 5 bar 35 psig to 17 bar 250 psig maximum For supply pressures to the filter regulator refer to the appropriate regulator instruction manual Steady State Air Consumption
8. G A3891 1 e Sensor with Nonstandard Torque Tube and or Displacer with Other than Standard Volume If the construction does not have a standard wall torque tube or has a displacer volume that deviates significantly from the volume listed in table 2 or both the PROPORTIONAL BAND or SPECIFIC GRAVITY dial setting does not necessarily indicate the actual proportional band or specific gravity To determine the correct dial setting solve the following equation Corrected Dial Setting sea SP s v joo Required where L percentage of displacer length desired for full output pressure change e g if 80 of displacer is used L 80 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 SP GR 7 specific gravity of the process fluid for interface level control use the difference between the specific gravity of the two fluids for specific gravity control use the difference between the upper and lower range limits of specific gravity Va actual displacer volume cubic inches listed on the sensor nameplate V standard displacer volume cubic inches from table 2 X torque tube factor 1 0 for standard torque tubes 2 0 for thin wall torque tubes or 0 5 for heavy wall torque tubes 2500 Controller or 2500T Transmitter Note In the following steps the output pressure can go as high as the controller supply pressure 1 Turn on the supply pressure and check that the supply pressure gauge reads 1 4
9. after setting the pressure 2 Setthe process variable to its minimum value 3 Onacontroller with a mechanical indicator assembly the pointer should be over the LOW point on the indicator plate If a slight adjustment is necessary loosen the hex clamp nut key 40 figure 16 shift the pointer and retighten the nut Note Adjustment of the RAISE LEVEL control can set the switching points anywhere within the length of the displacer Be careful not to set the switching points so that one is off the displacer 4 Make sure that the PROPORTIONAL BAND control is at the setting determined in the previous procedures Set the RAISE LEVEL control to 0 then set it to 1 0 for a direct acting or 4 0 for a reverse acting controller 5 The OUTPUT gauge should read 0 bar 0 psig for direct or supply pressure for reverse action 6 Increase the process variable until the OUTPUT gauge changes to either supply pressure for direct or 0 bar 0 psig for reverse acting The process variable should be at the desired high trip value On a controller with an indicator assembly the pointer should be over the HIGH point on the indicator plate slight adjustment may be necessary as described at the end of step 3 7 Decrease the process variable until the OUTPUT gauge changes to 0 bar 0 psig for direct or supply pressure for reverse action depending on controller range The process variable should be at the desired low trip value 8 If all prestartup check
10. bar 20 psig for a 0 2 to 1 bar 3 to 15 psig or 2 4 bar 35 psig for a 0 4 to 2 bar 6 to 30 psig output pressure range If the pressure is incorrect loosen the locknut of the 67CFR filter regulator figure 9 turn the adjusting screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the locknut after setting the regulator pressure 2 Setthe process variable to its minimum value 3 Make sure that the PROPORTIONAL BAND or SPECIFIC GRAVITY control is at the setting determined earlier in this section Then set the RAISE LEVEL or ZERO ADJUSTMENT control at an appropriate value according to table 5 This table gives recommended settings based on maximum and minimum possible PROPORTIONAL BAND and SPECIFIC GRAVITY settings If an intermediate PROPORTIONAL BAND or SPECIFIC GRAVITY setting is necessary extrapolation may be used to determine an appropriate RAISE LEVEL or ZERO ADJUSTMENT setting Note The raise level dial does not reflect actual fluid level in the tank or fluid level position on the displacer 4 The OUTPUT gauge on a 0 2 to 1 bar 3 to 15 psig range should read 0 2 bar 3 psig for direct or 1 bar 15 psig for reverse action On a 0 4 to 2 bar 6 to 30 psig range the OUTPUT gauge should read 0 4 bar 6 psig for direct or 2 bar 30 psig for reverse action 5 On a controller or transmitter with a mechanical indicator assembly the pointer should be over the LOW point on the indicator pl
11. displacement force change Deadband except differential gap controllers gt 0 05 of proportional band or span Typical Frequency Response 4 Hz and 90 degree phase shift at 100 proportional band with output piped to typical instrument bellows using 6 1 meters 20 feet of 1 4 inch tubing Ambient Operating Temperature Limits For ambient temperature ranges and guidelines for use of the optional heat insulator assembly see figure 2 Relay temperature limits are Standard Construction 40 to 71 C 40 to 160 F High Temperature Construction 18 to 104 C 0 to 220 F Typical Ambient Temperature Operating Influence Output pressure changes 1 5 per 10 C 50 F change in temperature at 100 proportional band when using a standard wall torque tube with 249 sensors Hazardous Area Classification 2500 and 2503 controllers transmitters comply with the requirements of ATEX Group Il Category 2 Gas and Dust C x u2 ap Supply and Output Connections 1 4 NPT internal Maximum Working Pressure sensors only Refer to the appropriate sensor instruction manual NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminolog Kat the controller transmitter shipped from the factory set for reverse action see chang 1 Controllers are field adjustable between direct or reverse action The letter R in the type number indicates tl ing controller action procedures The le
12. in the following step changes the zero as well as the differential gap 11 If the flexure strip base has been moved as far as possible and the differential gap is still too large or too small adjust the PROPORTIONAL BAND as follows e f the differential gap is too large slightly decrease the PROPORTIONAL BAND setting e f the differential gap is too small slightly increase the PROPORTIONAL BAND setting 12 Repeat the procedure from step 4 until the required calibration points are obtained Note If you cannot calibrate the controller look for other problems as described in the Troubleshooting procedures such as a nozzle that is not perpendicular to the flapper leaky connections or a binding displacer rod If none of these troubles are apparent ensure the displacer is sized correctly for the application 26 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Startup Adjustment locations are shown in figure 10 The pre startup or calibration procedures must be completed prior to startup 2500 Controller 1 Slowly open the upstream and downstream manual control valves in the pipeline If the pipeline has a bypass valve close the valve 2 If desired adjust the proportional band to the narrowest lowest setting that maintains stable control Proportional band adjustments will affect the process level and may require a level adjustment If adjusting proportional band make the adjustments in
13. pressure to exhaust This relay valve action reduces the output pressure to the final control element and is the reverse of the previous explanation The proportional valve varies the reaction of the Bourdon tube to changes in the output pressure For additional information on the proportional valve action refer to the following proportional valve subsection Proportional Valve The three way proportional valve is adjustable to allow some or all of the output pressure change to feed back to the Bourdon tube outer channel providing proportional band control see figure 12 The Bourdon tube moves to counteract the pressure changes in the nozzle equaling the relay diaphragm pressure differential The relay valve maintains a new output pressure according to the change in the process variable A wide open proportional valve fully counterclockwise permits feedback of the output pressure signal change and produces 100 percent proportional response A closed fully clockwise proportional valve produces smaller proportional responses because part of the output pressure change vents through the proportional valve exhaust 2500S Controller This construction has the same flapper relay and proportional valve as the 2500 controller However the nozzle is connected figure 12 in such a way that output pressure feedback from the movement of the Bourdon tube moves the nozzle in the opposite direction of the flapper This action completely opens the rel
14. reposition the switching points by adjusting the RAISE LEVEL control For example if the differential gap is set for 102 mm 4 inches of level change this 102 mm 4 inches can be set anywhere within the length of the displacer After readjustment confirm the controller is still switching correctly at both switching points Principle of Operation The controller transmitter receives the change in fluid level fluid to fluid interface level or density from the change in the buoyant force the fluid exerts on the sensor displacer The displacer through a mechanical linkage imparts a rotary motion to the torque tube shaft This rotary motion positions the flapper according to the level position of the displacer the nozzle Bourdon tube arrangement sends a pneumatic signal to the relay valve 27 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 All 2500 and 2503 controller transmitters use the same basic pressure balanced relay assembly The following descriptions explain how the relay action produces the output signal with the various controller transmitter constructions 2500 Controller or 2500T Transmitter Full supply pressure comes to the relay from the regulator as shown in figure 12 The relay has a fixed restriction through which supply pressure bleeds before entering the large diaphragm area and the inner Bourdon tube channel In a steady state condition the process level holds the torque tube and at
15. rroo LII t C sPecIFIC GRAVITY 1E8731 1E8732 A1897 1 TRAVEL INDICATOR PLATE FOR LEFT HAND MOUNTING 15 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 Set the PROPORTIONAL BAND control on a 2500 or 2500S controller or the SPECIFIC GRAVITY control on a 2500T transmitter as follows e Sensor with Both Standard Torque Tube and Standard Volume Displacer If the torque tube is standard and the displacer volume is close to that listed in table 2 use figure 11 to find the PROPORTIONAL BAND or SPECIFIC GRAVITY setting Locate the specific gravity of the process fluid on fluid level applications or the difference between minimum and maximum specific gravity on interface level or density applications on the vertical axis of the chart From this location trace horizontally to the curve with the desired percentage of displacer used then trace vertically up or down to determine the proper dial setting on the horizontal axis Figure 11 Proportional Band and Specific Gravity Setting Chart chart assumes standard wall torque tube and displacer volume in table 2 TRANSMITTER SPECIFIC GRAVITY SETTING 0 01 02 03 04 05 06 07 08 09 10 HIDE THT VV VV IE EEE HUUVY AAT HUE ZZ ALL TI TTT ZZA TT TA T WA W AA 10 e N SPECIFIC GRAVITY OR SPECIFIC GRAVITY DIFFERENTIAL iore CONTROLLER PROPORTIONAL BAND SETTING EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED 1C9259
16. small increments 3 To confirm the optimum proportional band setting momentarily create a load upset If cycling occurs broaden increase the proportional band until process oscillations diminish rapidly In general the narrowest proportional band that does not produce cycling provides the best control 2500T Transmitter 1 Make sure that the SPECIFIC GRAVITY and ZERO ADJUSTMENT controls are set according to the 2500 Controller or 2500T Transmitter portion of the pre startup checks procedures 2 Slowly open the upstream and downstream manual control valves in the pipeline If the pipeline has a manual bypass valve close the valve 2500S Controller 1 Setthe switching points according to the 2500S Controller portion of the prestartup checks procedures 2 Slowly open the upstream and downstream manual control valves in the pipeline If the pipeline has a manual bypass valve close the valve 3 If necessary the proportional band may be adjusted to increase or decrease the differential gap Adjust the RAISE LEVEL adjustment to reposition the differential gap After readjustment confirm the controller is still switching correctly at both switching points 2503 Controller 1 Setthe switching points according to the 2503 Controller portion of the prestartup checks procedures 2 Slowly open the upstream and downstream manual control valves in the pipeline If the pipeline has a manual bypass valve close the valve 3 If necessary
17. supply pressure is within limits Reset the supply regulator pressure If the condition occurs again rebuild or replace regulator Provide a regulator input pressure within regulator limits 2 2 Leak in the controller transmitter loop Use soap and water to check for internal and external leaks Replace or repair leaking parts as necessary 2 3 Leaking displacer Ensure the displacer is not filling with process fluid Refer to sensor maintenance procedures in the appropriate sensor instruction manual 2 4 Flapper adjustment Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle Replace or tighten flapper assembly as necessary and or center flapper on nozzle 2 5 Process variable changed Ensure the process variable has not changed from original calibration settings or displacer not designed for specific gravity of process Change process variable back to original specification or recalibrate If necessary provide replacement displacer of correct size and recalibrate 3 Controller transmitter cannot attain full output range 3 1 Supply pressure not set correctly Make sure supply pressure is set correctly Make sure regulator IN supply pressure is within limits Reset the regulator pressure If problem reoccurs replace or rebuild the regulator Ensure regulator IN supply pressure is within limits at all operating levels 3 2 Flapper adjus
18. the fluid level the level of interface between two fluids or the density specific gravity Each unit consists of a 249 displacer type fluid level sensor and a 2500 or 2503 pneumatic controller or transmitter Figure 1 shows a typical controller sensor combination Specifications Refer to table 1 for specifications Educational Services For information on available courses for 2500 or 2503 controller transmitter as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 Marshalltown IA 50158 2823 Phone 800 338 8158 or 641 754 3771 FAX 641 754 3431 e mail education emerson com Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 Table 1 Specifications Available Configurations 2500 Proportional only controller 2500C Proportional only controller with indicator see figure 10 2500R Reverse acting proportional only controller 2500S Differential gap snap acting controller See changing controller action procedure and figure 15 2500T Transmitter 2503 Differential gap controller without proportional valve for applications requiring very little adjustment Input Signal Fluid Level or Fluid to Fluid Interface Level From 0 to 100 of displacer length standard lengths for all sensors are 356 mm or 812 mm 14 inches or 32 inches Other lengths available depending on sensor construction Fluid
19. tuned control loop Ensure the prestartup procedures are completed correctly Tune control loop If stable control cannot be attained and all other elements are functionally correct examine other possible causes related to the controller transmitter 1 2 Supply pressure varying or incorrect supply pressure setting Use input pressure gauge to monitor stability Make sure regulator IN supply pressure is within limits Apply correct supply pressure Use one regulator per instrument 1 3 Sensor not plumb and is in contact with sidewall or leak in displacer Check cage vessel and stillwell installation or for leaking displacer Make sure the displacer and displacer rod hangs freely Make sure linkage is tight Replace displacer if leaking 1 4 Relay malfunction Check for relay malfunction by using the testing relay deadband procedure Depress plunger to clean out the fixed restriction Replace relay using the procedure in the Maintenance section continued 31 2500 and 2503 Controllers Transmitters April 2014 Instruction Manual D200124X012 Table 7 Troubleshooting Chart for Fisher 2500 Controller Transmitters continued Fault Possible Cause Check Correction 2 Controller transmitter controlling off set point or switching point 2 1 Supply pressure not set correctly Make sure regulator supply pressure is set correctly Make sure regulator IN
20. 2 1E5914X0062 Key 40 41 42 43 44 45 46 47 49 50 51 52 53 73 90 215 Description Hex nut pl steel 2 req d for C versions 1 req d for all others Screw pl steel 2 req d for C versions only Machine screw pl steel Machine screw pl steel Machine screw pl steel 6 req d Machine Screw pl steel 2 req d Machine Screw pl steel 4 req d Spring not shown stainless steel Cap screw pl steel 4 req d Machine screw pl steel 13 req d Screen N04400 Pointer assembly C versions only Stainless steel brass pl 8 req d 2 req d annann Washer C versions only steel 2 req d Base plate C versions only aluminum Front plate C versions only aluminum Pipe plug 2503 only brass not shown Specific gravity adjustment assembly Standard and high temperature Corrosive service Nameplate Heat Insulator figure 14 Note All Heat Insulator parts are included in the Heat Insulator Parts Kit 35 36 38 39 40 53 Heat Insulator Assembly stainless steel Shaft Coupling stainless steel Shaft extension N05500 Set screw stainless steel 2 req d Cap screw pl steel 4 req d Cap screw pl steel 4 req d Washer carbon steel pl 4 req d Recommended spare parts Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection us
21. 2500 Controllers and Transmitters 2500 2500C 2500R 2500S and 2500T See table 3 2503 Controller Vents only when relay is exhausting Proportional Band Adjustment Proportional Only Controllers Full output pressure ene adjustable over 10 to 100 of displacer length 4 Differential Gap Adjustment Differential Gap Controllers 2500S Controller Full output pressure change adjustable from 20 to 100 of displacer length 4 2503 Controller Full output pressure change adjustable over approximately 25 to 40 of displacer length Span Adjustment 2500T Transmitter Full output pressure emange adjustable from 20 to 100 of displacer length Set Point controllers only or Zero transmitters only Adjustment For proportional only controllers or transmitters level adjustment positions the set point or zero for the fluid level interface level or displacer force change density within the displacer length For differential gap controllers level adjustment simultaneously positions both ends of the gap within the displacer length continued 2500 and 2503 Controllers Transmitters April 2014 Instruction Manual D200124X012 Table 1 Specifications Continued Performance Independent Linearity transmitters only 1 of output pressure change for 100 span Hysteresis 0 625 of output pressure change at 10025 proportional band differential gap or span Repeatability 0 2 of displacer length or
22. 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 To determine the total weight that must be suspended from the displacer rod to simulate a certain condition of fluid level or specific gravity solve the following equation W W 0 0361 V SP GR where W Total suspended weight in pounds should never be less than 0 5 pounds For a unit with a horizontal displacer make sure the center of gravity of the substitute weight is where it would be on the actual displacer Note For liquid level control only simulate the lower range limit of the input span by suspending the displacer from the displacer rod For other values of input span remove the displacer and suspend the appropriate weight as determined in the equation above Wa Weight of the displacer in pounds determine by weighing displacer 0 0361 Weight of one cubic inch of water specific gravity 1 0 in pounds V 7 Volume in cubic inches of the portion of the displacer submerged Or V n4 displacer diameter length of displacer submerged SP GR Specific gravity of the process fluid at operating temperature For interface level measurement the equation becomes W W 0 0361 V SP GR 0 0361 V SP GR SP GRjJ where Vc Total volume in cubic inches of the displacer SP GR Specific gravity of the lighter of the fluids at operating temperature Vp Volume in cubic inches of the portion of the displacer s
23. FR FILTER REGULATOR AH9150 A A2613 2 Mounting Caged Sensor Note Install the cage so that it is plumb the displacer must not touch the cage wall If the displacer touches the cage wall the unit will transmit an erroneous output signal Note If the controller transmitter is not mounted on the sensor refer to the Installing Controller Transmitter on Sensor procedures in the Maintenance section This section also provides instructions for adding a heat insulator to a unit Cage connections normally are either NPS 1 1 2 or 2 screwed or flanged Figure 5 shows the combinations With flanged connections use standard gaskets or other flat sheet gaskets compatible with the process fluid Spiral wound gaskets without compression controlling centering rings cannot be used for flange connections Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 5 Cage Connection Styles STYLE 1 TOP STYLE 2 TOP STYLE 3 UPPER AND BOTTOM AND LOWER SIDE STYLE 4 UPPER AND LOWER SIDE SIDE AND BOTTOM oes a SCREWED S1 SCREWED S2 SCREWED S3 SCREWED S4 FLANGED F1 FLANGED F2 FLANGED F3 FLANGED F4 A1271 2 As shown in figure 6 mount the cage by running equalizing lines between the cage connections and the vessel A shutoff or hand valve with a 1 1 2 inch diameter or larger port should be installed in each of the equalizing lines Also install a drain between the cage and shutoff or hand valv
24. Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 Fisher 2500 and 2503 Controllers and Transmitters Contents Introduction cece eee eee ee eee ene ee eee 2 Scope of Manual 2 eee eee eee eee 2 DescrptlOni ertet ette cr ERIGI 2 Specifications cee e eee eee eee 2 Educational Services 0 e eee eee 2 Installation e cocer eme teen a ahah es 5 Sensor Assembly 00 0c eee ee eens 6 Unerating et ER ERRREPRIU PER elena eles 6 Controller Transmitter Orientation 7 Mounting Caged Sensor llslslsss 8 Mounting Cageless Sensor eeees 10 Side Mounted Sensor 05 10 Top Mounted Sensor sss 12 Supply and Output Pressure Connection 12 Supply Pressure eee eee ee eee 12 Controller Transmitter Output Connection 13 Vent Assembly 000 eee cece eee eee 13 Prestartup Checks 1 0 0 0 cc cece eee eee eee 14 2500 Controller or 2500T Transmitter 17 2500S Controller 2 eee eee eee eee 18 2503 Controller torre Derek 18 Adjustments ccc e eee e cece eee eee 19 Control Action s esee le red is 19 Level Adjustment Controllers Only 19 Zero Adjustment Transmitters Only 20 Proportional Band Adjustment Except Transmitters and 2503 Controllers 0 ccc cece eee ees 20 Specific Gravity Adjustment
25. PERATURE F AMBIENT TEMPERATURE F STANDARD CONTROLLER OR TRANSMITTER HIGH TEMPERATURE CONTROLLER OR TRANSMITTER NOTE FOR APPLICATIONS BELOW 29 C 20 F BE SURE THE SENSOR MATERIALS OF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE CV6190 E B1413 3 Table 4 Displacer and Torque Tube Materials Part Standard Material Other Materials Displacer 304 Stainless Steel 316 Stainless Steel N10276 N04400 Plastic and Special Alloys Displacer Stem Driver Bearing Displacer Rod and Driver 316 Stainless Steel N10276 N04400 other Austenitic Stainless Steels and Special Alloys N05500 1 Torque Tube 316 Stainless Steel N06600 N10276 limit are required 1 N05500 is not recommended for spring applications above 232 C 450 F Contact your Emerson Process Management sales office or application engineer if temperatures exceeding this Installation 2500 and 2503 controller transmitters work in combination with 249 displacer type sensors The factory attaches the controller transmitter to the sensor unless it is ordered separately If using natural gas as the pneumatic supply medium natural gas will be used in the pressure connections of the unit to any connected equipment The unit will vent natural gas into the surrounding atmosphere A WARNING Always wear protective clothing gloves and eyewear when performing any installation operations to avoid personal inju
26. Sensor Mounting W9517 1 SIDE VIEW SHOWING STILLWELL Figure 8 Displacer and Displacer Rod Connections COTTER SPRING NI X DISPLACER ROD ja NUTS a DISPLACER SPUD DISPLACER STEM EXTENSION B sem 249VS 3 CF5380 A A3893 SIDE VIEW WITHOUT STILLWELL DISPLACER COTTER SPRING id DISPLACER ROD WO0228 1A ALL OTHER TYPES 11 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 Top Mounted Sensor CAUTION If inserting the displacer into the vessel before attaching to the displacer rod provide a means of supporting the displacer to prevent it from dropping into the vessel and suffering damage Figure 7 shows an example of a top mounted cageless sensor You may attach the displacer to the displacer rod before installing the sensor on the vessel If the displacer diameter is small enough you may install a long or sectionalized displacer through the sensor head access hole after the sensor is installed on the vessel Connect the displacer as shown in figure 8 locking the assembly with the cotter springs provided If a stem extension is used between the displacer spud and the stem end piece make sure the nuts are tight at each end of the stem Install and tighten suitable cap screws in the flanged connection to complete the installation A special travel stop m
27. an is too large slightly increase the PROPORTIONAL BAND or SPECIFIC GRAVITY setting If the output pressure span is too small slightly decrease the PROPORTIONAL BAND or SPECIFIC GRAVITY setting Repeat the procedure from step 4 until the required calibration points are obtained Note If you cannot calibrate the controller or transmitter look for other problems as described in the Troubleshooting procedures such as leaking connections or a binding displacer rod If none of these troubles are apparent ensure that the displacer is sized correctly for the application 2500S and 2503 Controllers 1 2 Turn on the supply pressure and check that it is set according to the appropriate prestartup checks procedure Make sure that the PROPORTIONAL BAND adjustment 2500S only is at the setting determined according to the appropriate prestartup check procedure Perform one orthe other of the following For direct acting controllers set the RAISE LEVEL adjustment between 1 0 and 1 5 For reverse acting controllers set the RAISE LEVEL adjustment between 3 5 and 4 0 Set the process variable at the minimum value of the input range as shown in table 6 For constructions with an indicator assembly make sure that the pointer is over the LOW mark Note In the following step the alignment screw key 33 figure 16 must always remain screwed in far enough to provide spring tension on the underside of the alignment screw head Bes
28. anges and record the value of the process variable at the detection point 4 Change the process variable in the opposite direction until the output pressure just changes and again record the value of the process variable If the difference between the two recorded values the deadband is more than 0 2 of the maximum displacer length the relay must be replaced or repaired according to the Changing Relay section 5 Turn off the supply pressure remove the pipe plug and install the appropriate adjustment assembly 36 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Replacing the Proportional Valve Note The following procedure to convert to or from the pipe plug or the desired adjustment assembly can be used for any type number covered in this manual 1 Remove the tubing key 10 from the proportional band valve assembly 2 Unscrew the base of the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment assembly key 36 or 90 figure 16 orthe 1 8 NPT pipe plug key 73 not shown from the relay base key 23 figure 16 3 Install the pipe plug or the desired adjustment assembly into the relay base 4 Replace the tubing key 10 to the proportional band valve assembly Changing Relay The relay may be removed for cleaning or replacement Removal 1 Fora controller or transmitter with indicator assembly loosen the two lower relay screws key 96 and slide out the indicator base plate key 53
29. ansmitter is not mounted on the sensor refer to the Installing Controller Transmitter on Sensor procedures in the Maintenance section This section also provides instructions for adding a heat insulator to a unit Attach a cageless sensor to a flanged connection on the vessel as shown in figure 7 For interface or fluid level applications install a gauge glass on the vessel Side Mounted Sensor If a stillwell is required see figure 7 attach the displacer to the displacer rod from inside the vessel Connect the displacer as shown in figure 8 locking the assembly with the cotter spring provided If a stillwell is not required attach the displacer rod before mounting the sensor on the vessel Then you can swing the displacer out horizontally for insertion into the vessel However once the sensor is installed and the displacer drops to a vertical position the displacer may not be capable of being withdrawn for servicing later Be sure there is another access to the displacer to permit swinging it to a horizontal position or to permit disconnecting it from the displacer rod If an extension is used between the displacer spud and the displacer stem end piece make sure the nuts are tight at each end of the displacer stem extension Install and tighten suitable bolting or cap screws in the flanged connection to complete the installation Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 Figure 7 Cageless
30. arm from the cage or vessel refer to the appropriate 249 instruction manual for assistance The method of removing the displacer or torque tube arm and attached controller transmitter varies with the type of sensor For a caged sensor with top equalizing connection it may be appropriate to remove the entire cage from the vessel before disassembling CAUTION If the displacer is to be disconnected from the displacer rod before the sensor assembly is removed from the cage or vessel provide a means of supporting the displacer to prevent it from dropping and suffering damage The spuds or stem end pieces on all displacers have holes suitable for inserting rods or other supports Additionally a threaded rod may be installed into the 1 4 inch 28 UNF threaded hole in the displacer spud or stem end piece of top mounted cageless and all caged sensors For some top mounted sensors with long displacers the sensor may be removed through the access hole in the sensor head For 249BP sensors with travel stop the stem end piece pins will secure the displacer on the travel stop as long as the travel stop plate is installed and the sensor head is in position Determining the Amount of Suspended Weight CAUTION Avoid overloading a torque tube sized for interface or density applications Consult your Emerson Process Management sales office for the maximum allowable substitute weight Ws that may be used with your particular construction 21 2500 and
31. assembly see figure 9 or the end of a remote vent pipe must be protected against the entrance of all foreign matter that could plug the vent Use 13 mm 1 2 inch pipe for the remote vent pipe if one is required Check the vent periodically to be certain it has not become plugged Prestartup Checks Adjustments are shown in figure 10 unless otherwise indicated Open loop conditions must exist when performing the prestartup checks To obtain open loop conditions e make sure there is no process flow through the final control element or e disconnect the controller transmitter output signal line and connect it to a pressure gauge During prestartup the displacer must be positioned from its maximum to its minimum range of operation Provide a means to change the process variable the process level or interface If the process variable cannot be varied sufficiently use the precalibration procedures in the Calibration section to simulate the process variable changes required for these checks Make sure the RAISE LEVEL dial on the controller is mounted with the correct side facing out The dial is marked on both sides with an arrow The arrow points to the left on one side and to the right on the other When the sensor is mounted to the left of the controller transmitter the arrow on the raise level dial should point to the left as shown in figure 10 If the sensor is to the right the arrow should point to the right If necessary remove the two mou
32. assembly or removing the displacer Before disassembling the sensor or removing the displacer observe the more specific warning provided in the sensor instruction manual Uncrating Unless ordered separately the controller transmitter is attached to the sensor when shipped Carefully uncrate the assembly CAUTION Sensors used for interface or density control may be so large and heavy that the torque tube cannot fully support their weight in air On the 249VS a travel stop is used to prevent damage Do not remove this travel stop assembly without first removing the displacer from the displacer rod Refer to the appropriate instruction manual for 249 cageless sensors Note Caged sensors have rods and blocks installed at each end of the displacers to protect the displacers in shipping Remove these parts before you install the sensor to allow the displacer to function properly Caged sensors come with the displacer installed in the cage If a tubular gauge glass is ordered with the sensor the gauge glass is crated separately and must be installed at the site A damping plate is installed in the lower screwed or flanged connection see figure 3 to provide more stable operation Be certain that the cage equalizing connections and the damping plate are not plugged by foreign material Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 3 Damping Plate Location DISPLACER CAGE l Vs
33. ate If a slight adjustment is necessary loosen the side hex clamp nut key 40 figure 16 shift the pointer and retighten the nut 6 Increase the process variable to the level desired for full output change The OUTPUT gauge on a 0 2 to 1 bar 3 to 15 psig range should read 1 bar 15 psig for direct or 0 2 bar 3 psig for reverse action On a 0 4 to 2 bar 6 to 30 psig range the OUTPUT gauge should read 2 bar 30 psig for direct or 0 4 bar 6 psig for reverse action On a controller or transmitter with an indicator assembly the pointer should be over the HIGH point on the indicator plate slight plate adjustment may be necessary as described at the end of step 5 7 If all prestartup checks are satisfactory go to the startup procedure If performance is unsatisfactory proceed to the Calibration section 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 2500S Controller Note In the following steps the output pressure can go as high as the controller supply pressure 1 Turn on the supply pressure and check that the SUPPLY pressure gauge reads 1 4 bar 20 psig for a 0 to 1 4 bar 0 to 20 psig output pressure range or 2 4 bar 35 psig for a 0 to 2 4 bar 0 to 35 psig output pressure range If the pressure is incorrect loosen the locknut of the 67CFR filter regulator figure 9 turn the adjusting screw clockwise to increase the pressure or counterclockwise to decrease pressure Tighten the locknut
34. ay be provided on top mounted sensors to aid in servicing of the sensor This option prevents dropping the displacer and stem when the displacer rod is disconnected Supply and Output Pressure Connections A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install any system component where service conditions could exceed the limits given in this manual Use pressure relieving devices as required by government or accepted industry codes and good engineering practices Figure 9 shows dimensions locations and connections for controller transmitter installation All pressure connections to the controller transmitter are 1 4 NPT internal Supply Pressure A WARNING Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean dry oil free air or noncorrosive gas While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications check with an Emerson Process Management field office and industry instrument air quality standards for use with corrosive air or if you are unsure about the proper amount or method of air filtration or filter maintenance Supply pressure must be clean dry air or noncorrosive gas that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer par
35. ay valve for full output pressure or completely closes the relay valve for full exhaust of the output pressure allowing no in between throttling 28 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 12 Direct Acting Right Hand Mounted Fisher 2500 249 Controller Transmitter OUTER BOURDON INNER BOURDON TUBE TUBE CHANNEL CHANNEL LEVEL SET ADJUSTMENT AS CAM fA a MOVABLE ARM NOZZLE N 2 EXHAUSTEND VE FLAPPE VA a EXHAUST OF RELAY VALVE Gi D FIXED wht LARGE DIAPHRAGM H RESTRICTION OF ASSEMBLY j eo PROPORTIONAL VALVE TO OTHER PNEUMATIC TRANSMITTER CONSTRUCTION INLET END OF em RELAY VALVE f SMALL FEN DIAPHRAGM OF ASSEMBLY SUPPLY SUPPLY PRESSURE SOURCE OUTPUT PRESSURE 67CFR FILTER T REGULATOR DIRECT ACTING NOZZLE PRESSURE DIAPHRAGM VESSEL INFLOW CONTROL VALVE P BN PROPORTIONAL PRESSURE EXHAUST CD2114 E BO998 1 2503 Controller This construction has the same flapper and sensor arrangement as the 2500 controller but its Bourdon tube has a three way valve operated by a plunger see figure 13 Note that the switch point adjustment changes the position of the moveable arm and attached Bourdon tube assembly this in turn changes the switch point in relationship to the process level The differential gap of the 2503 either completely opens the relay valve for full output pressure or completely closes
36. e and maintenance of any product remains solely with the purchaser and end user Fisher is a mark owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management 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 All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com a es EMERSON 1977 2014 Fisher Controls International LLC All rights reserved Dr 1cc gt arn Process Management
37. e eee eee 35 Relay Deadband Testing 2500 Controller or 2500T Transmitter Only 36 Replacing the Proportional Valve 37 Changing Relay cee ee eee e eee 37 Parts Ordering ccc cece cece eee eeees 37 Parts List iles stanton ee E aA eed 38 s EMERSON www Fisher com Process Management 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 Introduction Scope of Manual This manual provides installation operating calibration maintenance and parts ordering information for 2500 and 2503 pneumatic controllers and transmitters used in combination with 249 displacer sensors Note This manual does not include installation or maintenance procedures for the supply pressure regulator sensor or other devices For that information refer to the appropriate instruction manual for the other device Do not install operate or maintain a 2500 or 2503 pneumatic controller transmitter without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all contents of this quick start guide including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Description These instruments control or transmit
38. e whenever the bottom cage line has a fluid trapping low point Figure 6 Caged Sensor Mounting SHUTOFF CENTER OF LIQUID VALVES OR INTERFACE LEVEL mw ra DRAIN VALVE I N EQUALIZING LINE DF5379 A A1883 2 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 On fluid or interface level applications position the sensor so that the center line on the cage see figure 6 is as close as possible to the center of the fluid level or interface level range being measured Also consider installing a gauge glass on the vessel or on the sensor cage if the cage is tapped for a gauge Mounting Cageless Sensor Note If a stillwell is used install it plumb so that the displacer does not touch the wall of the stillwell If the displacer touches the wall the unit will transmit an erroneous output signal Since the displacer hangs inside the vessel provide a stillwell around the displacer if the fluid is in a state of continuous agitation to avoid excessive turbulence around the displacer Note Displacers used in an interface level application must be completely submerged during operation If displacers aren t completely submerged they will not calibrate or perform properly To obtain the desired controller or transmitter sensitivity may require using either a thin wall torque tube an oversized displacer or both Note If the controller tr
39. en mount the insulator assembly key 35 on the controller transmitter case with four button head cap screws and washers keys 40 and 53 Tighten the screws CAUTION In the following step avoid bending the rotary shaft of the torque tube assembly Bending or side loading of this shaft could cause erroneous readings Additionally make sure the ball bearing assembly key 12 figure 16 is removed from the case key 1 figure 16 to provide clearance when installing the case on the sensor 2 Remove the bearing assembly key 12 figure 16 from the case key 1 figure 16 3 Carefully slide the controller transmitter case straight in Secure the case on the torque arm or insulator with the four cap screws key 39 Note If a heat insulator is used do not insulate its exterior 34 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 4 Slide the bearing assembly key 12 figure 16 onto the shaft or shaft extension of the insulator and install the bearing assembly key 12 figure 16 into the case key 1 figure 16 5 Install the flapper base key 30 figure 16 on the torque tube rotary shaft making sure the flapper is centered over the nozzle or Bourdon tube valve Secure the base with the hex nut key 40 figure 16 For a controller transmitter with an indicator assembly install the pointer assembly according to the Replacing the Bourdon Tube section 6 Connect the supply and output pressure tub
40. ess variable until the output pressure switches to 0 bar 0 psig The process variable should be at the maximum value of input range as shown in table 6 If the process variable agrees with table 6 proceed with step 8 If the process variable does not agree with table 6 proceed to step 9 8 If the unit does not contain an indicator assembly go to the startup section If the unit contains an indicator assembly change the pointer span by loosening the indicator plate screws key 41 figure 16 indicator assembly detail slide the plate until the HIGH mark is under the pointer Tighten the plate screws and go to the startup section Note Any sliding of the level set arm key 28 figure 16 in the following step changes the zero as well as the differential gap 9 To adjust the differential gap loosen the two level set mounting screws see figure 16 and slide the flexure strip base key 27 right or left along the elongated slotted hole as follows To decrease the differential gap slide the flexure strip base away from the torque tube shaft e To increase the differential gap slide the flexure strip base toward the torque tube shaft Retighten the screws For the 2500S only if the flexure strip base has been moved as far as possible and the differential gap is still too low proceed to step 11 10 Repeat the procedure from step 4 until the required calibration points are obtained Note Any change in the PROPORTIONAL BAND adjustment
41. g to steps 1 through 4 of the Replacing the Bourdon Tube section 2 Loosen the hex nut key 40 and remove the flapper base key 30 from the torque tube rotary shaft Turn the flapper base over and install it on the rotary shaft using the proper orientation as shown in figure 15 and making sure the flapper is centered over the nozzle or Bourdon tube valve 3 Perform the calibration procedure 35 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 Figure 15 Bourdon Tube Flapper Arrangements for Various Actions and Mountings CONSTRUCTION D RECTACTING RIGHT HAND MOUNTING REVERSE ACTING RIGHT HAND MOUNTING REVERSE ACTING LEFT HAND MOUNTING DIRECT ACTING LEFT HAND MOUNTING 2500 OR2500T INCLUDING C VERSIONS 2500S INCLUDING C VERSIONS AC9554 AR8148 BO996 1 Relay Deadband Testing 2500 Controller or 2500T Transmitter Only 1 Replace the appropriate proportional or specific gravity adjustment assembly with the 1 8 NPT pipe plug according to the Replacing the Proportional Valve section 2 Turnon the supply pressure and set it to 1 4 to 2 4 bar 20 or 35 psig depending on the controller transmitter operating range 3 By changing the process variable and adjusting the RAISE LEVEL or ZERO ADJUSTMENT control set the output pressure to 1 0 or 2 0 bar 15 or 30 psig While monitoring the output pressure slowly change the process variable until the output pressure just ch
42. ing and perform the calibration procedure Replacing the Bourdon Tube Refer to figure 16 for key number locations 1 Disconnect the tubing key 10 for 2503 and key 11 for 2500 from the Bourdon tube base For a controller transmitter with indicator assembly loosen the side hex clamp nut key 40 and remove the pointer assembly key 51 from the torque tube rotary shaft 2 Remove the mounting screws key 45 and Bourdon tube assembly key 16 3 Inspect the Bourdon tube Replace it if necessary using a tube with a black color code for a 0 2 to 1 bar or 0 to 1 4 bar 3 to 15 psig or 0 to 20 psig range Use a tube with a red color code for a 0 4 to 2 bar or 0 to 2 4 bar 6 to 30 psig or 0 to 35 psig range The range is stamped at the Bourdon tube base 4 Mountthe Bourdon tube on the level set arm key 28 Secure it with the mounting screws using the proper orientation as shown in figure 15 Connect the tubing to the tube base with tubing from the R connection on the relay key 34 going to the marked base connection The other tubing goes to the unmarked base connection With an indicator assembly install the pointer assembly on the rotary shaft and tighten the hex nut 5 Perform the calibration procedure Changing Action Note The following procedure is necessary to restore previous action if the mounting method has been changed Figure 16 shows key numbers 1 Reposition the Bourdon tube and indicator assembly if used accordin
43. ng the indicator plate screws key 41 figure 16 detail of indicator assembly slide the plate until the HIGH mark is under the pointer Tighten the plate screws and go to the Startup section Note Any sliding of the level set arm key 28 figure 16 in the following step changes the zero as well as the output pressure span 11 To adjust the output pressure span loosen the two level set mounting screws see figure 16 and slide the flexure strip base key 27 right or left along the elongated slotted hole as follows e To increase the output pressure span slide the flexure strip base away from the torque tube shaft To decrease the output pressure span slide the flexure strip base toward the torque tube shaft Retighten the screws If the flexure strip base has been moved as far as possible and the output pressure span is still too large or too small proceed to step 13 12 Repeat the procedure from step 4 until the required calibration points are obtained Note Any change of the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment in the following step changes the zero as well as the output pressure span 24 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 13 14 If the flexure strip base has been moved as far as possible and the output pressure span is still too large or too small slightly adjust the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment as follows If the output pressure sp
44. nge To perform this adjustment open the controller cover and turn the PROPORTIONAL BAND adjustment see figure 10 Refer to the prestartup check procedures to determine the proper setting Specific Gravity Adjustment Transmitters Only This adjustment also varies the amount of process variable change required to obtain a full output pressure change To perform this adjustment open the transmitter cover and turn the SPECIFIC GRAVITY adjustment see figure 10 Refer to the prestartup check procedures to determine the proper setting Calibration Precalibration Requirements The controller transmitter can be calibrated in the field mounted on the vessel containing the process fluid It may also be done in the shop but other means of obtaining a displacement force change must be provided There are wet and dry methods of adapting the calibrating procedure Note Contact your Emerson Process Management sales office for information on obtaining Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters Supplement to 249 Sensor Instruction Manuals D103066X012 Wet Calibration Remove the entire controller transmitter and sensor assembly from the vessel For caged sensors pour the fluid into the cage For cageless sensors suspend the displacer to an appropriate depth in a fluid having a specific gravity equal to that of the process fluid 20 Instruction Manual 2500 and 2503 Controllers Transmitters
45. ns shown in figure 15 4 The arrow on the RAISE LEVEL dial under the word FLOAT should point toward the displacer If not remove the dial from the controller turn it over and install it in the correct position 5 Fora controller transmitter with an indicator assembly the arrow near the word FLOAT on the indicator plate should point toward the displacer If it does not remove the two screws key 41 see detail of indicator assembly in figure 16 turn the front plate key 54 to the side with the FLOAT arrow pointing toward the displacer and secure the plate with the screws 6 Install the controller transmitter according to the next section Installing Controller Transmitter on Sensor Note If the installation is in a location that is not readily accessible and shop calibration is required remove the torque tube arm from the cage or vessel before installing the controller or transmitter to the sensor Install the controller transmitter on the torque tube arm in the shop then calibrate and return the controller transmitter with the torque tube arm assembly attached for installation Perform step 1 only if adding a heat insulator to a unit that does not have one Key numbers in this step are shown in figure 14 1 To install the heat insulator secure the shaft extension key 37 to the torque tube assembly rotary shaft with the shaft coupling key 36 Tighten both set screws key 38 with the coupling centered as shown in figure 14 Th
46. nting screws turn the dial over so the arrow points correctly and reinstall the mounting screws The level directions shown on the dial will be correct for both direct acting and reverse acting controllers For a transmitter use the same side of the ZERO ADJUSTMENT dial for both right and left hand sensor mountings On acontroller or transmitter with an optional mechanical indicator assembly the travel indicator plate is also marked with an arrow on both sides If the sensor is to the left of the controller transmitter the arrow on the plate should point to the left If the sensor is to the right the arrow should point to the right If necessary reinstall the plate so that the arrow points in the correct direction Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 Figure 10 Adjustment Locations W0641 1B BOURDON TUBE DETAIL OF 2500S ON OFF CONTROLLER LEVEL SET ARM E 3 WAY VALVE M deed FLAPPER ALIGNMENT SCREW ARN SHAFT CLAMP NUT W0671 1 RIGHT HAND MOUNTED 2503R ON OFF CONTROLLER SPECIFIC GRAVITY ADJUSTMENT ZERO ADJUSTMENT W0647 2B W0648 1B DETAIL OF TRANSMITTER ADJUSTMENTS W0656 1 POINTER ASSEMBLY INDICATOR ASSEMBLY WITH RIGHT HAND MOUNTING 1C9283 B RAISE LEVEL DIAL FOR LEFT HAND MOUNTING LEVEL ADJUSTMENT PROPORTIONAL RELAY FLAPPER SPAN ADJUSTMENT RIGHT HAND MOUNTED 2500 PROPORTIONAL CONTROLLER FLOAT QO qoen
47. o Reverse 6 5 to 7 0 0 5 to 1 0 1 5to 2 0 to right 4 0 to 4 5 to left 1 For proportional band dial settings between 10 and 0 or for specific gravity dial settings between 1 0 and 0 interpolate the value 4 Setthe process variable to the minimum value of the input range as shown in table 6 For constructions with an indicator assembly make sure that the pointer is over the LOW mark Note In the following step the alignment screw key 33 figure 16 must always remain screwed in far enough to provide spring tension on the underside of the alignment screw head 5 Adjustthe flapper key 32 figure 16 to obtain the appropriate pressure listed below For coarse flapper adjustment loosen the hex nut key 40 figure 16 and rotate the flapper assembly about the torque tube shaft For fine flapper adjustment turn the flapper alignment screw key 33 figure 16 23 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 e For Direct Acting 2500 2500T 0 2 bar 3 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 0 4 bar 6 psig for a 0 4 to 2 0 bar 6 to 30 psig output e For Reverse Acting 2500 2500T 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output 6 Visually examine the nozzle and flapper to ensure the nozzle is as square as possible with the flapper The nozzle can be realigned by loosening the Bourdon tube mounting scre
48. ormance of the instrument and could cause personal injury and property damage Parts List Description Controller Parts Kits 2500 Controller Repair Kits Contains keys 12 15 21 24 38 and the flapper assembly Standard temperature High temperature 2503 Controller Repair Kit Standard temperature only The kit contains keys 12 21 22 24 38 and the flapper assembly Relay Replacement Kit Contains keys 22 43 and the relay assembly Standard temperature High temperature Heat Insulator Retrofit Kit Contains the heat insulator parts shown in figure 14 and listed under Heat Insulator in this parts list 2500 Controller Cover Gasket Kit Contains qty 5 cover gaskets key 21 Part Number R2500X00L32 R2500X00H32 R2503X00022 RRELAYXOL22 RRELAYXOH22 R2500XH0012 R2500CVRO12 Common Controller Transmitter Parts figure 16 Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Key Description 1 Case back 2 Case cover aluminum 3 Door handle pl steel 38 Key Description Door handle shaft not shown brass Machine screw steel Spring washer stainless steel Door hook pl steel Stop nut pl steel Drive lock pin 2 req d 0 Tubing assembly stainless steel uoDoo oc uL For all 2500 controllers transmitters except 2503 For 2503 only 11 Relay tubing stainless steel 12 Ball bearing assembly Bras
49. placer Be careful not to set the switching points so that one is off the displacer 3 Set the RAISE LEVEL control to 0 and then reset it as follows a For direct acting controllers set it between 1 0 and 1 5 b For reverse acting controllers set it between 3 5 and 4 0 4 The OUTPUT gauge should read 0 bar 0 psig for direct or full supply pressure for reverse action 5 Increase the process variable until the OUTPUT gauge changes to full supply pressure for direct or 0 bar 0 psig for reverse action The process variable should be at the desired high trip value 6 Decrease the process variable until the OUTPUT gauge changes to 0 bar 0 psig for direct or full supply pressure for reverse action The process variable should be at the desired low trip value 7 If all prestartup checks are satisfactory proceed to the Startup section If performance is unsatisfactory proceed to the Calibration section Adjustments This section explains controller transmitter action and adjustments Figure 10 shows adjustment locations Control Action The following is a definition of control action e Direct Action Increasing fluid level interface level or density increases the output signal Reverse Action Increasing fluid level interface level or density decreases the output signal Controller transmitters factory set for reverse acting have the suffix letter R added to their type number The control action is determined by
50. r 1367 system installation adjustment and maintenance information see the separate instruction manual Controller Transmitter Output Connection As shown in figure 9 the output pressure connection is on the back of the controller transmitter case After connecting the output pressure line turn on the supply pressure adjust the filter regulator to the appropriate supply pressure required for the controller transmitter and check all connections for leaks Vent Assembly Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the supply pressure medium Because the instrument case and cover assembly do not form a gas tight seal when the assembly is enclosed a remote vent line adequate ventilation and necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas However a remote vent pipe alone cannot be relied upon to remove all flammable and hazardous gas Vent line piping should comply with 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 local and regional codes and should be be as short as possible with adequate inside diameter and few bends to reduce case pressure buildup CAUTION When installing a remote vent pipe take care not to overtighten the pipe in the vent connection Excessive torque will damage the threads in the connection The vent
51. ry 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 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 A WARNING Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 13 Sensor Assembly Table 2 lists sensors recommended for use with controller transmitters Table 4 contains displacer and torque tube materials For sensor installation and maintenance refer to the appropriate sensor instruction manual A WARNING When replacing the sensor assembly the displacer may retain process fluid or pressure Personal injury or property damage may occur due to sudden release of the pressure Contact with hazardous fluid fire or explosion can be caused by puncturing heating or repairing a displacer retaining process pressure or fluid This danger may not be readily apparent when disassembling the sensor
52. s pl 13 Retaining ring pl steel 2 req d 14 Gauge glass 2 req d 15 Gauge glass gasket chloroprene 2 req d 16 Bourdon tube assembly Brass 2500 and 2500T 3to 15 psig 6to 30 psig 2500S Oto 20 psig Oto 35 psig 2503 Oto 20 psig 0 to 35 psig Stainless steel 2500 and 2500T 3 to 15 psig 6 to 30 psig 19 Triple scale gauge 2 req d Brass 0 to 30 psig 0 to 0 2 MPa 0 to 2 bar 0 to 60 psig 0 to 0 4 MPa 0 to 4 bar Stainless steel 0 to 30 psig 0 to 0 2 MPa 0 to 2 bar 0 to 60 psig 0 to 0 4 MPa 0 to 4 bar 19 Dual scale gauge 2 req d Brass 0 to 30 psig 0 to 2 kg cm2 0 to 60 psig 0 to 4 kg cm2 Stainless steel 0 to 30 psig 0 to 2 kg cm2 Recommended spare parts 1C8983000A2 01019206042 01019104082 32B1231X012 32B1231X022 32B1233X012 32B1233X022 32B1234X012 32B1234X022 32B1232X032 32B1232X042 11B8577X012 11B8577X022 11B8583X012 11B8583X022 11B8577X042 11B8577X052 11B8583X032 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 16 Fisher 2500 Controller Transmitter Constructions 09 2 Als 63 8 OBES Xt su e5 i C 9 S 9 3 96 9 69 D 6 a 3 60 6263 63 30A8865 TYPICAL CONTROLLER EE 2503 CONNECTION DETAIL VIEW A 2503R CONTROLLER CONSTRUCTION NOTE PARTS NOT SHOWN 4 24 38 39 47 AND 48 DETAIL OF INDICATOR ASSEMBLY ON C VERSIONS 2500 and 2503 Controllers Tran
53. s are satisfactory proceed to the Startup section If performance is unsatisfactory proceed to the Calibration section 2503 Controller Note In the following steps the output pressure can go as high as the controller supply pressure Note Since the 2503 controller has no proportional valve the differential gap between switching points is adjusted by varying the supply pressure This gap can be varied from approximately a 89 mm 3 5 inch level change at 1 bar 15 psig to a 152 mm 6 0 inch level change at 1 7 bar 25 psig with a standard volume displacer and a fluid with a specific gravity of 1 0 The gap also varies inversely according to density a fluid with 0 8 specific gravity produces a 112 mm 4 4 inch level change at 1 bar 15 psig to a Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 191 mm 7 5 inch change at 1 7 bar 25 psig Set the gap at a pressure low enough to be compatible with the limitations of the diaphragm control valve or other final control element 1 Turn on the supply pressure If necessary adjust the 67CFR regulator to produce the desired differential gap by loosening the locknut figure 9 and turning the adjusting screw clockwise to increase or counterclockwise to decrease pressure Tighten the locknut 2 Locate the process variable at its minimum value Note Adjustment of the RAISE LEVEL control can set the switching points anywhere within the length of the dis
54. s for 2500 Controller or 2500T Transmitter 2500S Controller or 2503 Controller 2500 Controller and 2500T Transmitter 1 Turn on the supply pressure and check that it is set according to the appropriate prestartup checks procedure 2 Make sure that the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment is at the setting determined according to the appropriate prestartup check procedure 3 Adjust the RAISE LEVEL 2500 or ZERO ADJUSTMENT 25007 to the appropriate value per table 5 This table gives recommended settings based on maximum and minimum possible PROPORTIONAL BAND 2500 or SPECIFIC GRAVITY 25007 settings If an intermediate PROPORTIONAL BAND or SPECIFIC GRAVITY setting is necessary extrapolation may be used to determine a new RAISE LEVEL or SPECIFIC GRAVITY setting Table 5 Recommended Settings For Pre Startup Checks RECOMMENDED RAISE LEVEL SETTING RECOMMENDED ZERO ADJUSTMENT SETTING FOR 2500T FOR 2500 CONTROLLER TRANSMITTER MOUNTING ACTION For Predetermined For Predetermined For Predetermined For Predetermined PROPORTIONAL BAND Dial PROPORTIONAL BAND Dial SPECIFIC GRAVITY Dial SPECIFIC GRAVITY Dial Setting of 10 1 Setting of 0 1 Setting of 1 0 1 Setting of 0 1 rahika Direct 3 0 to 3 5 4 0 to 4 5 1 5 to 2 0 to right 0 5 to 1 0 to right adi Reverse 6 5 to 7 0 0 5 to 1 0 1 5 to 2 0 to left 4 0 to 4 5 to right Lafehand Direct 3 0 to 3 5 4 0 to 4 5 1 5 to 2 0 to left 0 5 to 1 0 to left ib
55. smitters April 2014 Instruction Manual D200124X012 Key Description 21 Cover gasket chloroprene 22 Relay gasket Standard temperature chloroprene High temperature silicon 23 Relay base 24 Relay base gasket not shown Standard temperature chloroprene High temperature silicon 25 Flexure strip stainless steel 26 Flexure strip nut pl steel 2 req d 27 Flexure strip base pl steel 28 Level set arm pl steel 29 Drivelok pin pl steel 30 Flapper base brass pl 31 Shaft clamp screw SST 2 req d for C version only 1 req d for all others 32 Flapper stainless steel 33 Alignment screw brass pl 34 Relay assembly Part Number 10919806432 1C897403012 1N873804142 1C897303012 1N873904142 For all 2500 controllers transmitters except 2503 Standard temperature High temperature Corrosive service 2503 only Standard temperature High temperature 35 Level adjustment assembly controllers only 35 Zero adjustment assembly transmitters only 36 Proportional band adjustment assembly except transmitters and 2503 controllers see key 90 Standard and high temperature Corrosive service 37 67CFR regulator 38A Filter gasket not shown Standard temperature chloroprene High temperature silicon 38B Spacer aluminum not shown 38C O ring not shown Standard temperature nitrile High temperature fluoroelastomer 39 Cap screw not shown pl steel 2 req d 1C898603012 1N874004142 1E59140699
56. steps turn off the supply pressure and carefully release any pressure trapped in the controller transmitter before breaking any pressure connection Provide a bypass for the control device if continuous operation is required during maintenance 1 Disconnect the supply and output pressure tubing from the controller or transmitter For a controller transmitter with an indicator remove the pointer assembly by referring to the Replacing the Bourdon Tube section 2 Loosen the top hex clamp nut key 40 figure 16 and remove the flapper base key 30 figure 16 from the torque tube rotary shaft 32 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 CAUTION If the hex clamp nut has not been loosened or the pointer removed according to step 2 attempting to remove the controller transmitter from the sensor may bend the flapper or rotary shaft Be careful that the back of the controller transmitter case or the heat insulator does not drop down and bend the rotary shaft or shaft extension 3 Remove any insulating tape from the joint between the controller transmitter case and the torque tube arm Remove the four cap screws key 39 figure 14 that hold the controller transmitter or heat insulator to the torque tube arm Pull the case straight out from the torque tube arm easing it over the shaft coupling key 36 figure 14 if one is installed Figure 14 Heat Insulator for Fisher 249 Sensor 20A7423 C
57. tached flapper steady in relation to the nozzle This allows pressure to escape between the nozzle and flapper at the same rate it bleeds into the large diaphragm area The large diaphragm holds the inlet end of the relay valve slightly open to compensate for the venting of output pressure through the proportional valve as it maintains a steady state position of the final control element The output pressure through the three way proportional valve affects the Bourdon tube outer channel holding the Bourdon tube in a steady state position A process level change raises or lowers the displacer moving the flapper with respect to the nozzle If the process level change increases nozzle pressure the large diaphragm moves down this closes the exhaust end and opens the inlet end of the relay valve see figure 12 This action of the relay valve increases the output pressure to the final control element Since the area ratio of the large diaphragm to the small diaphragm is three to one the small diaphragm action amplifies the output pressure change The three way proportional valve lets the increase in output pressure apply to the Bourdon tube outer channel The expansion of the Bourdon tube moves the nozzle away from the flapper slowing the response of the pneumatic circuit If the process level change decreases the nozzle pressure the large diaphragm moves up This action closes the inlet end and opens the exhaust end of the relay valve which allows output
58. the cage head mounting position and by the Bourdon tube flapper arrangement in the controller transmitter Refer to figure 4 for mounting positions and to figure 15 for Bourdon tube flapper arrangements To change the action refer to the changing action procedure in the Maintenance section Level Adjustment Controllers Only To make a level adjustment open the controller cover loosen the knurled adjustment screw and rotate the adjustment lever around the RAISE LEVEL dial To raise the fluid or interface level or increase density rotate this knob 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 in the direction of the arrows To lower the level or decrease density rotate the knob in the opposite direction This procedure is the same for either direct or reverse action Tighten the knurled screw Note The RAISE LEVEL dial does not reflect actual fluid level in the tank or fluid level position on the displacer Zero Adjustment Transmitters Only To make a zero adjustment open the transmitter cover loosen the adjustment screw and rotate the adjustment lever around the ZERO ADJUSTMENT dial This adjustment sets the output pressure to correspond to a specific level on the displacer Tighten the knurled screw Proportional Band Adjustment Except Transmitters and 2503 Controllers The proportional band adjustment varies the amount of process variable change required to obtain a full output pressure cha
59. the relay valve for full exhaust of the output pressure allowing no in between throttling For a direct acting controller as long as the process variable remains above the switch point the flapper does not depress the plunger of the Bourdon tube valve In this condition the Bourdon tube valve remains closed providing full 29 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 loading pressure to the Bourdon tube This loading pressure moves the Bourdon tube away from the flapper Also in this condition full loading pressure is on the upper diaphragm of the relay The loading pressure moves the diaphragm down closing the exhaust end and opening the inlet end of the relay valve allowing full output pressure When the process level sufficiently decreases the flapper pushes in the plunger of the Bourdon tube valve enough to release the loading pressure and seal the inner Bourdon tube channel see figure 13 This decrease in the loading pressure moves the Bourdon tube toward the flapper producing the snap action Also this decrease in loading pressure allows relay spring pressure to move the large diaphragm up closing the inlet end and opening the exhaust end of the relay valve allowing full exhaust of the output pressure This control action continues until a sensor level change moves the flapper away from the plunger permitting the Bourdon tube valve to close restoring loading pressure to the pneumatic circ
60. ticle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Alternatively natural gas may be used as the supply pressure medium Gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 ppm 12 Instruction Manual 2500 and 2503 Controllers Transmitters D200124X012 April 2014 Figure 9 Controller Transmitter Dimensions and Connections ooo o OPTIONAL HEAT INSULATOR EXTENSION 5 6 18 UNC 2B 4 MOUNTING HOLES ON 95 3 3 75 DBC 231 6 9 12 1 4 18 NPT VENT OUTPUT CONN 1 4 18 NPT 67CFR OUTLET CONN 1 4 18 NPT PLUGGED SUPPLY CONN BACK VIEW FRONT VIEW mm Use a suitable supply pressure regulator to reduce the supply pressure to the normal operating supply pressure shown in table 3 As shown in figure 9 a 67CFR filter regulator mounts on the back of the controller transmitter case and mates with the supply pressure connection on the controller transmitter case Pipe the supply pressure to the IN connection of the regulator Typically the 67CFR filter regulator accepts supply pressures between 2 5 and 17 bar 35 and 250 psig For specific regulator limits refer to the appropriate regulator instruction manual If operating the controller or transmitter from a high pressure source up to 138 bar 2000 psig use a high pressure regulator system such as the 1367 High Pressure Instrument Supply System Fo
61. tment Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle Replace or tighten flapper assembly as necessary and or center flapper on nozzle 3 3 Process variable changed Ensure the process variable has not changed from original calibration settings or from displacers designed specific gravity Change process variable back to original specification or recalibrate If necessary provide replacement displacer of correct size and recalibrate 3 4 Relay malfunction Check for relay malfunction by using the testing relay deadband procedure Depress plunger to clean out the fixed restriction Replace relay using the procedure in the Maintenance section 3 5 Leak in the controller transmitter loop Use soap and water to check for internal and external leaks Replace or repair leaking parts as necessary 4 Controller transmitter remains at full or zero output pressure 4 1 Supply or output pressure gauge malfunction Ensure the pressure gauges are registering correctly Replace pressure gauges Use corrective action given in section 3 of this table 4 2 Flapper adjustment Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle Replace or tighten flapper assembly as necessary and or center flapper on nozzle Removing Controller Transmitter from Sensor A WARNING To avoid injury in the following
62. tter C in the type number indicates that a pointer is attac 2 Control and stability may be impaired if the maximum pressures are exceeded hed to the torque tube shaft providing visual monitoring of torque tube motion 3 The pressure temperature limits in this document and any applicable standard or code limitation should not be exceeded 4 These statements apply only to units sized to produce a full output change for a 100 level change at the maximum proportional band dial setting 5 Adjusting the span of the differential gap controller is equivalent to adjusting the deadband Table 2 Standard Displacer Volumes Sensor Standard Volume Standard Volume Liters Cubic Inches 249 249B 249BF 249BP 249K 249P 249W 1 6 1000 249C 249CP 249W 1 0 602 249L 1 9 120 249VS 1 38 80 3 1 For 249W with standard 812 mm 32 inch displacer 2 For 249W with standard 356 mm 14 inch displacer 3 With standard 305 mm 12 inch flange face to displacer centerline dimension only Table 3 Supply Pressure Data STANDARD SUPPLY AND NORMAL OPERATING AR COMSTMETION AT OUTPUT SUPPLY PRESSURE 2 NORMAL OPERATING MAXIMUM QUIEUIGIGIAERANOE PRESSURE GAUGE SUPPLY PRESSURE SUPPLY PRESSURE INDICATIONS Bar Psig MinimumG Maximum 4 0 2 to 1 bar 3 to 15 psig 0 to 30 psig 14 20 4 2 scfh 27 scfh gt 3 bar 45 psig 0 4 to 2 bar 6 to 30 psig 0 to 60 psig 24 35 7 scfh gt 42 scfh gt 3 bar 45 psig
63. ubmerged in the heavier of the fluids V n 4 displacer diameter length of the displacer submerged SP GR Specific gravity of the heavier of the fluids at operating temperature Calibration Procedure A WARNING The following calibration procedures require taking the controller transmitter out of service To avoid personal injury and property damage caused by an uncontrolled process provide some temporary means of control for the process before taking the controller transmitter out of service 22 Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 Figure 10 shows adjustment locations except as otherwise indicated In order to calibrate open loop conditions must exist One way to obtain an open loop is to ensure that there is no flow through the final control element Another way to obtain an open loop is to disconnect the controller transmitter output signal line and plug the output connection with a test pressure gauge Several steps in these calibrating procedures require setting the process variable at its minimum and maximum limits according to table 6 Note If the process cannot be varied readily or the Wet Calibration method cannot be used in the following steps be sure to use the proper sequence of correct weights as found in the Determining Amount of Suspended Weight procedure Whenever the following steps require particular prestartup checks refer to the appropriate procedure
64. uit Reverse acting controllers produce the opposite effect Figure 13 Direct Acting Left Hand Mounted Fisher 2503 Controller INNER BOURDON TUBE CHANNEL OUTER BOURDON MOVABLE ARM TUBE CHANNEL SWITCH POINT ADJUSTMENT THREE WAY BOURDON TUBE VALVE OPEN FOR RELEASE OF AFER p LOADING PRESSURE fr NA AA l T ZEN c FLAPPER Y o FIXED PIVOT X 7 VLL Epe LARGE DIAPHRAGM EXHAUST END OF RELAY VALVE PLY SUPPLY PRESSURE LOADING PRESSURE INLET END OF OUTPUT PRESSURE RELAY VALVE i SMALL DIAPHRAGM BD4466 A CD2114 E A1890 1 2500 and 2503 controllers transmitters work in combination with 249 displacers Refer to figure 16 for key number locations unless otherwise indicated A WARNING Always wear protective clothing gloves and eyewear when performing any maintenance operations to avoid personal injury 30 Instruction Manual D200124X012 2500 and 2503 Controllers Transmitters April 2014 When replacing the sensor assembly the displacer may retain process fluid or pressure Personal injury or property damage may occur due to sudden release of the pressure Contact with hazardous fluid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or fluid This danger may not be readily apparent when disassembling the sensor assembly or removing the displacer Before disassembling the sensor or removing the displacer obser
65. urethe flapper is centered over the nozzle If not loosen the hex nut key 40 figure 16 and reposition the flapper tighten the hex nut Adjust the flapper key 32 figure 16 as described below For coarse flapper adjustment loosen the hex nut key 40 figure 16 and rotate the flapper assembly about the torque tube shaft For fine flapper adjustment turn the flapper alignment screw key 33 figure 16 For Direct Acting Controllers move the flapper toward the nozzle until the output pressure switches to full supply pressure then carefully adjust the flapper away from the nozzle until the output pressure switches to 0 bar 0 psig For Reverse Acting Controllers move the flapper away from the nozzle until the output pressure switches to 0 bar 0 psig then carefully adjust the flapper toward the nozzle until the output pressure switches to full supply pressure 25 2500 and 2503 Controllers Transmitters Instruction Manual April 2014 D200124X012 7 Slowly increase the process variable until the output pressure switches e For Direct Acting Controllers slowly increase the process variable until the output pressure switches to full supply pressure The process variable should be at the maximum value of input range as shown in table 6 If the process variable agrees with table 6 proceed with step 8 If the process variable does not agree with table 6 proceed to step 9 e For Reverse Acting Controllers slowly increase the proc
66. ve the more specific warning provided in the sensor instruction manual When disconnecting any of the pneumatic connections natural gas if used as the supply medium will seep from the unit and any connected equipment into the surrounding atmosphere Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following e remote venting of the unit e re evaluating the hazardous area classification e the removal of any ignition sources and e ensuring adequate ventilation For information on remote venting of this controller refer to page 13 Check with your process or safety engineer for any additional measures that must be taken to protect against process media Troubleshooting When troubleshooting open loop conditions must exist unless otherwise stated When monitoring the process variable use the most accurate level indicating device available The output signal measuring device should have corresponding accuracy Table 7 lists some common operating faults their probable causes and corrective action Table 7 Troubleshooting Chart for Fisher 2500 Controller Transmitters Fault Possible Cause Check Correction 1 Process wanders or cycles around set point 1 1 Proportional band or specific gravity adjustment incorrect or improperly
67. ws key 45 figure 16 and rotating the Bourdon tube Slightly If the nozzle is realigned tighten the mounting screws and repeat step 5 7 Set the process variable to the maximum value of the input range as shown in table 6 Table 6 Minimum and Maximum Limits for Setting Process Variables Application Minimum Limit Maximum Limit Liquid Level Displacer must be completely out of liquid Displacer must be completely submerged in liquid Interface Displacer must be completely submerged in lighter of two Displacer must be completely submerged in process liquids heavier of two process liquids Density Displacer must be completely submerged in liquid having Displacer must be completely submerged in liquid having specific gravity of lowest range point specific gravity of highest range point 8 The output pressure should be e For Direct Acting 2500 2500T 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output e For Reverse Acting 2500 2500T 0 2 bar 3 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 0 4 bar 6 psig for a 0 4 to 2 0 bar 6 to 30 psig output 9 If the output pressure agrees with that shown in step 8 proceed to step 10 If the output pressure does not agree go to step 11 10 If the unit does not contain an indicator assembly go to the Startup section If the unit contains an indicator assembly change the pointer span by looseni

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