2500 and 2503 Series Level-Trol Controllers and Transmitters · 2013-07-15 · 2500 and 2503 Series Level-Trol Controllers and Transmitters 1013 March 2005 This errata sheet provides

Errata Sheetfor

The following Instruction Manuals

Instruction Manual Title Form Number Date

Caged 249 Series Displacer Sensors 1802 May 2003

Cageless 249 Series Displacer Sensors 1803 September 2004

Type 249W Cageless Wafer Style Level Sensor 5729 March 2005

2500 and 2503 Series Level-Trol� Controllers and Transmitters 1013 March 2005

This errata sheet provides updated information (refer to table 1) on displacer and torque tubematerials and information regarding simulation ofprocess conditions for calibration of Level-Trol�

controllers and transmitters.

Table 1. Displacer and Torque Tube MaterialsPart Standard Material Other Materials

Displacer 304 Stainless Steel

316 Stainless Steel,Hastelloy B, Monel,Plastic, and SpecialAlloys

Displacer Rod,Driver Bearing,Displacer RodDriver

316 Stainless Steel

Hastelloy B and C,Monel, Nickel, otherAustenitic StainlessSteels, and SpecialAlloys

Torque Tube N05500 (K Monel)(1)316 and 304LStainless Steels,Inconel, Hastelloy C

1. K-Monel is not recommended for spring applications above232�C (450�F). Contact your Fisher sales office or applicationengineer if temperatures exceeding this limit are required.

Simulation of Process Conditions for Calibrationof Level-Trol� Controllers and Transmitters

Contact your Fisher� sales office for information onobtaining the Supplement to 249 Series SensorsInstruction Manual: Simulation of Process Conditionsfor Calibration of Level-Trols - Form 5767 (part number D103066X012).

Note

Neither Emerson�, Emerson ProcessManagement nor Fisher assumeresponsibility for the selection, use, ormaintenance of any product.Responsibility for the selection, use,and maintenance of any Fisherproduct remains solely with thepurchaser and end-user.

Errata SheetApril 2005 2500-249 Series

2500-249 SeriesErrata Sheet

April 2005

2

Fisher Marshalltown, Iowa 50158 USACernay 68700 France Sao Paulo 05424 BrazilSingapore 128461

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 useor applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

Emerson Process Management does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection,use and maintenance of any Fisher product remains solely with the purchaser and end user.

�Fisher Controls International LLC 2005; All Rights Reserved Printed in USA

Level-Trol and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division ofEmerson Electric Co. Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the propertyof their respective owners.

Emerson Process Management

www.Fisher.com

www.Fisher.com

D20

0124

X01

2

2500 and 2503 Series Level-Trol� Controllersand TransmittersContents

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of Manual 2. . . . . . . . . . . . . . . . . . . . . . . . . . Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . Educational Services 2. . . . . . . . . . . . . . . . . . . . . .

Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Assembly 5. . . . . . . . . . . . . . . . . . . . . . . . . Uncrating 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller/Transmitter Orientation 6. . . . . . . . . . . Mounting Caged Sensor 6. . . . . . . . . . . . . . . . . . . Mounting Cageless Sensor 7. . . . . . . . . . . . . . . . .

Side-Mounted Sensor 8. . . . . . . . . . . . . . . . . . . . Top-Mounted Sensor 9. . . . . . . . . . . . . . . . . . . . .

Supply and Output Pressure Connection 9. . . . . Supply Pressure 10. . . . . . . . . . . . . . . . . . . . . . . . Controller/Transmitter Output Connection 10. .

Prestartup Checks 10. . . . . . . . . . . . . . . . . . . . . . . . Type 2500 Controller or Type 2500T

Transmitter 13. . . . . . . . . . . . . . . . . . . . . . . . . . . Type 2500S Controller 13. . . . . . . . . . . . . . . . . . . . Type 2503 Controller 14. . . . . . . . . . . . . . . . . . . . . Adjustments 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Action 15. . . . . . . . . . . . . . . . . . . . . . . . . . Level Adjustment

(Controllers Only) 15. . . . . . . . . . . . . . . . . . . . Zero Adjustment

(Transmitters Only) 15. . . . . . . . . . . . . . . . . . . Proportional Band Adjustment

(Except Transmitters and 2503Series Controllers) 15. . . . . . . . . . . . . . . . . . . .

Specific Gravity Adjustment (Transmitters Only) 15. . . . . . . . . . . . . . . . . . .

Calibration 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precalibration Requirements 15. . . . . . . . . . . . . . .

Wet Calibration 15. . . . . . . . . . . . . . . . . . . . . . . . . Dry Calibration 16. . . . . . . . . . . . . . . . . . . . . . . . . Controller/Transmitter and Torque Tube Arm

Disassembly 16. . . . . . . . . . . . . . . . . . . . . . . . . Determining the Amount of

Suspended Weight 16. . . . . . . . . . . . . . . . . . . Calibration Procedure 17. . . . . . . . . . . . . . . . . . . .

Type 2500 Controller and2500T Transmitter 17. . . . . . . . . . . . . . . . . . . .

Type 2500S and 2503 Controllers 19. . . . . . . . .

Figure 1. 2500 or 2503 Series Level-Trol� Controller/Transmitter on Caged 249 Series Sensor

2500 OR 2503 SERIESCONTROLLER/TRANSMITTER

249 SERIES SENSOR

W8334

Startup 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 2500 Controller 20. . . . . . . . . . . . . . . . . . . . . Type 2500T Transmitter 20. . . . . . . . . . . . . . . . . . Type 2500S Controller 20. . . . . . . . . . . . . . . . . . . . Type 2503 Controller 20. . . . . . . . . . . . . . . . . . . . .

Principle of Operation 21. . . . . . . . . . . . . . . . . . . . . . Type 2500 Controller or Type 2500T

Transmitter 21. . . . . . . . . . . . . . . . . . . . . . . . . . . Proportional Valve 21. . . . . . . . . . . . . . . . . . . . . . . Type 2500S Controller 21. . . . . . . . . . . . . . . . . . . . Type 2503 Controller 22. . . . . . . . . . . . . . . . . . . . .

Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . Removing Controller/Transmitter from

Sensor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Mounting Methods 24. . . . . . . . . . . . . . Installing Controller/Transmitter on Sensor 26. . .

(continued on page 2)

Instruction ManualForm 1013March 2005 Type 2500

Type 2500Instruction Manual

Form 1013March 2005

2

Contents (Continued)Replacing the Bourdon Tube 27. . . . . . . . . . . . . . Changing Action 27. . . . . . . . . . . . . . . . . . . . . . . . . Relay Deadband Testing (Type 2500 Controller

or 2500T Transmitter Only) 27. . . . . . . . . . . . . . . Replacing the Proportional Valve 28. . . . . . . . . . . Changing Relay 28. . . . . . . . . . . . . . . . . . . . . . . . .

Parts Ordering 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Scope of ManualThis manual provides installation, operating,calibration, maintenance, and parts orderinginformation for the 2500 and 2503 Series pneumaticcontrollers and transmitters used in combination with249 Series displacer sensors.

Note

This manual does not includeinstallation or maintenanceprocedures for the supply pressureregulator, sensor, or other devices. Forthat information, refer to theappropriate instruction manual for theother device.

No person may install, operate or maintain a 2500 or2503 Series pneumatic controller/transmitter withoutfirst � being fully trained and qualified in valve,actuator and accessory installation, operation andmaintenance, and � carefully reading andunderstanding the contents of this manual. If youhave any questions about these instructions, contactyour Fisher sales office.

Note

Neither Emerson, Emerson ProcessManagement, nor Fisher assumeresponsibility for the selection, use, ormaintenance of any product.Responsibility for the selection, use,and maintenance of any Fisherproduct remains with the purchaserand end-user.

DescriptionThese instruments control or transmit the fluid level,the level of interface between two fluids, or thedensity (specific gravity). Each unit consists of a 249Series displacer-type fluid level sensor and a 2500or 2503 Series pneumatic controller or transmitter.Figure 1 shows a typical controller-sensorcombination.

SpecificationsRefer to table 1 for specifications.

Educational ServicesFor information on available courses for 2500 or2503 Series pneumatic controllers and transmitters,as well as a variety of other products, contact:

Emerson Process ManagementEducational Services, RegistrationP.O. Box 190; 301 S. 1st Ave.Marshalltown, IA 50158-2823Phone: 800-338-8158 orPhone: 641-754-3771 FAX: 641-754-3431e-mail: [email protected]

InstallationThe 2500 and 2503 Series controller/transmitterswork in combination with 249 Series displacer-typesensors. The factory attaches thecontroller/transmitter to the sensor, unless it isordered separately.

WARNING

Always wear protective clothing andeyewear when performing anyinstallation operations to avoidpersonal injury.

Check with your process or safetyengineer for any additional measuresthat must be taken to protect againstprocess media.

Type 2500Instruction ManualForm 1013March 2005

3

Table 1. Specifications

Available Configurations(1)

Type 2500—Proportional-Only controllerType 2500C—Proportional-Only controller withindicator (see figure 10)Type 2500R—Reverse acting proportional-onlycontrollerType 2500S—Differential gap (snap acting)controller. See changing controller actionprocedure and figure 15.Type 2500T—TransmitterType 2503—Differential gap controller withoutproportional valve; for applications requiring verylittle adjustment.

Input Signal(2)

Fluid Level or Fluid-to-Fluid Interface Level:From 0 to 100% of displacer length—standardlengths for all sensors are 356 mm or 812 mm (14inches or 32 inches). Other lengths availabledepending on sensor construction.Fluid Density: From 0 to 100% of displacementforce change obtained with given displacervolume. Standard volume for displacers are listedin table 2.

Output Signal(2)

Type 2500 Controller and 2500T Transmitter:0.2 to 1 bar (3 to 15 psig) or 0.4 to 2 bar (6 to 30psig)Type 2500S and 2503 Differential GapControllers: 0 bar (0 psig) when switched off andfull supply [1.4 or 2.4 bar (20 or 35 psig) nominaldepending on controller output pressure range]when switched on.

Area Ratio of Relay Diaphragms

3:1

Supply Pressure Data

See table 3(3)

Maximum Supply Pressure(3,6)

3 bar (45 psig) to the controller or transmitter. Ifcontroller or transmitter is equipped with anintegrally mounted Type 67FR filter/regulator,typical supply pressure to the regulator is from 2.5bar (35 psig) to 17 bar (250 psig), maximum. Forsupply pressures to the filter/regulator, refer to theappropriate regulator instruction manual.

Steady-State Air Consumption

2500 Series Controllers and Transmitters(2500, 2500C, 2500R, 2500S, and 2500T): Seetable 3.Type 2503 Controller: Vents only when relay isexhausting.

Proportional Band(2) Adjustment(Proportional-Only Controllers)

Full output pressure change adjustable over 10 to100% of displacer length.(5)

Differential Gap(2) Adjustment (Differential GapControllers)

Type 2500S Controller: Full output pressurechange adjustable from 20 to 100% of displacerlength.(5)

Type 2503 Controller: Full output pressurechange adjustable over approximately 25 to 40%of displacer length.(5)

Span(2) Adjustment (Type 2500T Transmitter)

Full output pressure change adjustable from 20 to100% of displacer length.(5)

Set Point(2) (controllers only) or Zero(2)

(transmitters only) Adjustment

For proportional-only controllers or transmitters,level adjustment positions the set point or zero forthe fluid level, interface level, or displacer forcechange (density) within the displacer length.For differential gap controllers, level adjustmentsimultaneously positions both ends of the gapwithin the displacer length.

Performance

Independent Linearity(2) (transmitters only):1% of output pressure change for 100% span.Hysteresis: 0.6% of output pressure change at100% proportional band, differential gap, or span.Repeatability(2): 0.2% of displacer length ordisplacement force change.Deadband(2) (except differential gapcontrollers(4)): 0.05% of proportional band orspan.Typical Frequency Response(2): 4 Hz and 90degree phase shift at 100% proportional bandwith output piped to typical instrument bellowsusing 6.1 meters (20 feet) of 1/4-inch tubing.

(continued)


Form 1013March 2005

4

Table 1. Specifications (Continued)

Ambient Operating Temperature Limits(6)

For ambient temperature ranges and guidelinesfor use of the optional heat insulator assembly,see figure 2. Relay temperature limits are:Standard Construction: -40 to 71�C (-40 to160�F)High-Temperature Construction: -18 to 104�C(0 to 220�F)

Typical Ambient Temperature OperatingInfluence

Output pressure changes �1.5% per 10�C(50�F) change in temperature at 100%proportional band when using a standard walltorque tube with 249 Series sensors.

Hazardous Area Classification

2500 and 2503 Series controllers/transmitterscomply with the requirements of ATEX Group IICategory 2 Gas and Dust

Supply and Output Connections

1/4-inch NPT female

Maximum Working Pressure (sensors only)

Refer to the appropriate sensor instructionmanual.

1. Controllers are field adjustable between direct or reverse action. The letter R in the type number indicates that the controller/transmitter shipped from the factory set for reverse action (seechanging controller action procedures). The letter C in the type number indicates that a pointer is attached to the torque tube shaft providing visual monitoring of torque tube motion.2. This term is defined in ISA Standard S51.1.3. Control and stability may be impaired if the maximum pressures are exceeded.4. Adjusting the span of the differential gap controller is equivalent to adjusting the deadband.5. 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.6. The pressure/temperature limits in this manual, and any applicable standard or code limitation should not be exceeded.

Table 2. Standard Displacer Volumes

SENSOR TYPE STANDARD VOLUME, Liters

STANDARD VOLUME,Cubic Inches

249, 249B, 249BP, 249K, 249W249C, 249CP, 249W249L249V

1.61.01.91.3(3)

100(1)

60(2)

12080(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

OUTPUT SIGNAL RANGE

STANDARD SUPPLYAND OUTPUT

PRESSURE GAUGE

NORMAL OPERATINGSUPPLY PRESSURE(2)

AIR CONSUMPTION ATNORMAL OPERATINGSUPPLY PRESSURE

MAXIMUMSUPPLY PRESSUREPRESSURE GAUGE

INDICATIONS(1) Psig Bar Minimum(3) Maximum(4)SUPPLY PRESSURE

0.2 to 1 bar (3 to 15 psig) 0 to 30 psig 20 1.4 4.2 scfh(5) 27 scfh(5) 3 bar (45 psig)

0.4 to 2 bar (6 to 30 psig) 0 to 60 psig 35 2.4 7 scfh(5) 42 scfh(5) 3 bar (45 psig)1. Consult your Fisher sales office about gauges in other units.2. Control and stability may be impaired if this pressure is exceeded.3. At zero or maximum proportional band or specific gravity setting.4. At setting 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.


5

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

0 20 40 60 80 100 120 140 160

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENTMALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)

0 10 20-18 -10 30 40 50 60 7071

593

500

400

300200100

-40

0

400

800

1100

-20NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (�C)

STANDARD CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (�F)

HEAT INSULATORREQUIRED

TOOHOT

NOTE: FOR APPLICATIONS BELOW -29�C (-20�F), BE SURE THE SENSOR MATERIALSOF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.

PR

OC

ES

S T

EM

PE

RA

TU

RE

( C

)

�

PR

OC

ES

S T

EM

PE

RA

TU

RE

( F

)

�

0 20 40 60 80 100 120 140 200

0 10 20-18 -10 30 40 50 60 70 105593

500

400

300

200

100

00

400

800

1100

-20

NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (�C)

HIGH−TEMPERATURE CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (�F)

HEAT INSULATORREQUIRED

TOOHOT

PR

OC

ES

S T

EM

PE

RA

TU

RE

( C

)

�

PR

OC

ES

S T

EM

PE

RA

TU

RE

( F

)

�

180160

80 90

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESSTEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTIONAND REDUCE INSULATOR EFFECTIVENESS.)

CV6190-EB1413-3/IL

-40

-29

-18

100

220

Sensor Assembly

Table 2 lists sensors recommended for use withcontroller/transmitters. For sensor installation andmaintenance, refer to the appropriate sensorinstruction manual.

WARNING

When replacing the sensor assembly,the displacer may retain process fluidor pressure. Personal injury orproperty damage may occur due tosudden release of the pressure.Contact with hazardous fluid, fire, orexplosion can be caused bypuncturing, heating, or repairing adisplacer retaining process pressureor fluid. This danger may not bereadily apparent when disassemblingthe sensor assembly or removing thedisplacer. Before disassembling thesensor or removing the displacer,observe the more specific warningprovided in the sensor instructionmanual.

UncratingUnless ordered separately, the controller/transmitteris attached to the sensor when shipped. Carefullyuncrate the assembly.

CAUTION

Sensors used for interface or densitycontrol may be so large and heavy thatthe torque tube cannot fully supporttheir weight in air. On the 249V, atravel stop is used to prevent damage.Do not remove this travel stopassembly without first removing thedisplacer from the displacer rod. Referto the instruction manual for cageless249 Series sensors.

Note

Caged sensors have rods and blocksinstalled at each end of the displacersto protect the displacers in shipping.Remove these parts before you installthe sensor to allow the displacer tofunction properly.

Caged sensors come with the displacer installed inthe cage. If a tubular gauge glass is ordered with thesensor, the gauge glass is crated separately andmust be installed at the site. A damping plate isinstalled in the lower screwed or flanged connection


Form 1013March 2005

6

Figure 3. Damping Plate Location

W0144-1/IL

W2141-1B/IL

DISPLACER

CAGE

SCREWEDCONNECTION

FLANGEDCONNECTIONDAMPING PLATE

(see figure 3) to provide more stable operation. Becertain that the cage equalizing connections and thedamping plate are not plugged by foreign material.

A cageless sensor comes with its displacerseparated from the sensor assembly. Displacerslonger than 813 mm (32 inches) come in a separatecrate. Shorter displacers come in the same crate asthe sensor, but are not attached to their displacerrods. Inspect the displacer to ensure it is not dented.A dent may reduce the pressure rating of thedisplacer. If a displacer is dented, replace it.

Controller/Transmitter Orientation

The controller/transmitter attaches to the sensor inone of the mounting positions shown in figure 4.Right-hand mounting is with the controller ortransmitter case to the right of the displacer whenyou look at the front of the case; left-hand mountingis with the case to the left of the displacer. Themounting position can be changed in the field.Changing this mounting position changes the controlaction from direct to reverse, or vice versa.

Figure 4. Cage Head Mounting Positions

AH9150-AA2613-2/IL

All caged sensors have a rotatable head. That is, thecontroller/transmitter may be positioned at any ofeight alternate positions around the cage asindicated by the numbers 1 through 8 in figure 4. Torotate the head, remove the head flange bolts andnuts and position the head as desired.

Mounting Caged Sensor

CAUTION

Install the cage so that it is plumb; thedisplacer must not touch the cagewall. If the displacer touches the cagewall, the unit will transmit anerroneous output signal.


7

Figure 5. Cage Connection Styles

A1271-2/IL

Note

If the controller/transmitter is notmounted on the sensor, refer to theInstalling Controller/Transmitter onSensor procedures in the Maintenancesection. This section also providesinstructions for adding a heat insulatorto a unit.

Cage connections normally are either 1-1/2 or2-inch, screwed or flanged. Figure 5 shows thecombinations. With flanged connections, usestandard gaskets or other flat-sheet gasketscompatible with the process fluid. Spiral-woundgaskets without compression-controlling centeringrings cannot be used for flange connections.

As shown in figure 6, mount the cage by runningequalizing lines between the cage connections andthe vessel. A shutoff or hand valve with a 1-1/2 inch

Figure 6. Caged Sensor Mounting

EQUALIZING LINE

DRAIN VALVE

EQUALIZING LINE

CENTER OFLIQUID OR INTERFACE LEVEL

DF5379-AA1883-2/IL

SHUTOFFVALVES

diameter or larger port should be installed in each ofthe equalizing lines. Also install a drain between thecage and shutoff or hand valve whenever the bottomcage line has a fluid-trapping low point.

On fluid or interface level applications, position thesensor so that the center line on the cage (see figure6) is as close as possible to the center of the fluidlevel or interface level range being measured. Alsoconsider installing a gauge glass on the vessel, oron the sensor cage (if the cage is tapped for agauge).

Mounting Cageless Sensor

CAUTION

If a stillwell is used, install it plumb sothat the displacer does not touch thewall of the stillwell. If the displacertouches the wall, the unit will transmitan erroneous output signal.

Since the displacer hangs inside the vessel, providea stillwell around the displacer if the fluid is in a stateof continuous agitation to avoid excessive turbulencearound the displacer.


Form 1013March 2005

8

Figure 7. Cageless Sensor Mounting

CF5380-AA3893/IL

TOPMOUNTED

SIDE VIEW (WITHOUT STILLWELL)SIDE VIEW (SHOWING STILLWELL)

SIDEMOUNTED

W0645-1/IL

Note

Displacers used in an interface levelapplication must be completelysubmerged during operation. Ifdisplacers aren’t completelysubmerged, they will not calibrate orperform properly. To obtain thedesired controller or transmittersensitivity may require using either athin-wall torque tube, an oversizeddisplacer, or both.

Note

If the controller/transmitter is notmounted on the sensor, refer to theInstalling Controller/Transmitter onSensor procedures in the Maintenancesection. This section also providesinstructions for adding a heat insulatorto a unit. If the sensor has a

temperature-compensated displacer orpiezometer ring, refer to the SpecialInstallations procedures in this sectionbefore proceeding.

Attach a cageless sensor to a flanged connection onthe vessel as shown in figure 7. For interface or fluidlevel applications, install a gauge glass on thevessel.

Side-Mounted SensorIf a stillwell is required (see figure 7), attach thedisplacer to the displacer rod from inside the vessel.

Connect the displacer as shown in figure 8, lockingthe assembly with the cotter spring provided. If astillwell is not required, attach the displacer rodbefore mounting the sensor on the vessel. Then, youcan swing the displacer out horizontally for insertioninto the vessel. However, once the sensor isinstalled and the displacer drops to a verticalposition, the displacer may not be capable of being


9

W0229-1A/IL

COTTER SPRING

DISPLACER ROD

LOCKING NUTS

DISPLACER SPUD

DISPLACERSTEMEXTENSION

DISPLACERSTEMEND PIECE

TYPE 249V

W0228-1A/IL DISPLACER ROD

DISPLACERSPUD

ALL OTHER TYPES

COTTER SPRING

Figure 8. Displacer and Displacer Rod Connections

withdrawn for servicing later. Be sure there isanother access to the displacer to permit swinging itto a horizontal position or to permit disconnecting itfrom the displacer rod.

If an extension is used between the displacer spudand the displacer stem end piece, make sure thenuts are tight at each end of the displacer stemextension. Install and tighten suitable bolting or capscrews in the flanged connection to complete theinstallation.

Top-Mounted Sensor

CAUTION

If inserting the displacer into thevessel before attaching to thedisplacer rod, provide a means ofsupporting the displacer to prevent itfrom dropping into the vessel andsuffering damage.

Figure 7 shows an example of a top-mountedcageless sensor. You may attach the displacer tothe displacer rod before installing the sensor on thevessel. If the displacer diameter is small enough,you may install a long or sectionalized displacerthrough the sensor head access hole after thesensor is installed on the vessel. Connect thedisplacer as shown in figure 8, locking the assembly

with the cotter springs provided. If a stem extensionis used between the displacer spud and the stemend piece, make sure the nuts are tight at each endof the stem. Install and tighten suitable cap screws inthe flanged connection to complete the installation.

A special travel stop may be provided ontop-mounted sensors to aid in servicing of thesensor. This option prevents dropping the displacerand stem when the displacer rod is disconnected.

Supply and Output PressureConnections

WARNING

To avoid personal injury or propertydamage resulting from the suddenrelease of pressure, do not install anysystem component where serviceconditions could exceed the limitsgiven in this manual. Usepressure-relieving devices as requiredby government or accepted industrycodes and good engineering practices.

Figure 9 shows dimensions, locations, andconnections for controller/transmitter installation. Allpressure connections to the controller/transmitter are1/4-inch NPT female.


Form 1013March 2005

10

Figure 9. Controller/Transmitter Dimensions and Connections

AP4158-DE0859

176.36.94

OPTIONAL HEATINSULATOR EXTENSION

5/6-18 UNC-2B4 MOUNTING HOLESON� 95.3/3.75 DBC

1/4-18 NPTOUTPUT CONN

1/4-18 NPTOUTLET CONNPLUGGED

TYPE 67CFR1/4-18 NPTSUPPLY CONN

VENT

223.88.81

117.64.63

123.74.87

239.09.41

255.510.06

231.69.12

58.72.31

TOP VIEW

FRONT VIEW

mmINCH

BACK VIEW

Supply Pressure

WARNING

Personal injury or property damagemay occur from an uncontrolledprocess if the supply medium is notclean, dry, oil-free air, or non-corrosivegas. While use and regularmaintenance of a filter that removesparticles larger than 40 microns indiameter will suffice in mostapplications, check with a Fisher Fieldoffice and Industry Instrument airquality standards for use withcorrosive air or if you are unsure aboutthe proper amount or method of airfiltration or filter maintenance.

Supply pressure must be clean, dry air ornoncorrosive gas that meets the requirements of ISA

Standard S7.3. Use a suitable supply pressureregulator to reduce the supply pressure to thenormal operating supply pressure shown in table 3.As shown in figure 9, a Type 67FR filter/regulatormounts on the back of the controller/transmitter caseand mates with the supply pressure connection onthe controller/transmitter case. Pipe the supplypressure to the IN connection of the regulator.Typically, the Type 67FR filter/regulator acceptssupply pressures between 2.5 and 17 bar (35 and250 psig). For specific regulator limits, refer to theappropriate regulator instruction manual.

If operating the controller or transmitter from a highpressure source [up to 138 bar (2000 psig)], use ahigh pressure regulator system, such as the Type1367 High Pressure Instrument Supply System. ForType 1367 system installation, adjustment. andmaintenance information, see the separateinstruction manual.

Controller/Transmitter OutputConnectionAs shown in figure 9, the output pressure connectionis on the back of the controller/transmitter case. Afterconnecting the output pressure line, turn on thesupply pressure, adjust the filter/regulator to theappropriate supply pressure required for thecontroller/transmitter and check all connections forleaks.

Prestartup ChecksAdjustments are shown in figure 10 unless otherwiseindicated. Open-loop conditions must exist whenperforming the prestartup checks. To obtainopen-loop conditions:

� make sure there is no process flow through thefinal control element, or

� disconnect the controller/transmitter outputsignal line and connect it to a pressure gauge.

During prestartup, the displacer must be positionedfrom its maximum to its minimum range of operation.Provide a means to change the process variable (theprocess level or interface). If the process variablecannot be varied sufficiently, use the precalibrationprocedures in the Calibration section to simulate theprocess variable changes required for these checks.

Make sure the RAISE LEVEL dial on the controller ismounted with the correct side facing out. The dial is


11

Figure 10. Adjustment Locations

W0641-1B/IL1C9283-B/DOC

W0671-1/IL W0656-1/IL

W0647-2B/IL W0648-1B/IL1E87311E8732A1897-1/IL

LEVEL SET ARMMOUNTING SCREWS

LEVEL SETARM

LEVEL ADJUSTMENT

PROPORTIONAL BAND ADJUSTMENT

FLAPPER ALIGNMENT SCREW

SHAFT CLAMP NUT

3-WAY VALVE

NOZZLE

PLUNGER

SPECIFIC GRAVITY ADJUSTMENT

ZEROADJUSTMENT

POINTERASSEMBLY

FLAPPERRELAY

SPAN ADJUSTMENT

BOURDON TUBE DETAIL OFTYPE 2500S ON−OFF

CONTROLLERRAISE LEVEL DIAL FORLEFT −HAND MOUNTING

RIGHT −HAND MOUNTED TYPE 2500PROPORTIONAL CONTROLLER

RIGHT −HAND MOUNTED TYPE 2503RON−OFF CONTROLLER

DETAIL OF TRANSMITTERADJUSTMENTS

INDICATOR ASSEMBLY WITHRIGHT −HAND MOUNTING

TRAVEL INDICATOR PLATEFOR LEFT−HAND MOUNTING

VENT


Form 1013March 2005

12

marked on both sides with an arrow. The arrowpoints to the left on one side and to the right on theother. When the sensor is mounted to the left of thecontroller/transmitter, the arrow on the raise leveldial should point to the left, as shown in figure 10. Ifthe sensor is to the right, the arrow should point tothe right. If necessary, remove the two mountingscrews, turn the dial over so the arrow pointscorrectly, and reinstall the mounting screws. Thelevel directions shown on the dial will be correct forboth direct-acting and reverse-acting controllers. Fora transmitter, use the same side of the ZEROADJUSTMENT dial for both right- and left-handsensor mountings.

On a controller or transmitter with an optionalmechanical indicator assembly, the travel indicatorplate is also marked with an arrow on both sides. Ifthe sensor is to the left of the controller/transmitter,the arrow on the plate should point to the left. If thesensor is to the right, the arrow should point to theright. If necessary, reinstall the plate so that thearrow points in the correct direction.

Set the PROPORTIONAL BAND control on a Type2500 or 2500S controller, or the SPECIFICGRAVITY control on a Type 2500T transmitter, asfollows:

� Sensor with Both Standard Torque Tubeand Standard Volume Displacer—If the torquetube is standard and the displacer volume is close tothat listed in table 2, use figure 11 to find thePROPORTIONAL BAND or SPECIFIC GRAVITYsetting. Locate the specific gravity of the processfluid on fluid level applications, or the differencebetween minimum and maximum specific gravity oninterface level or density applications, on the verticalaxis of the chart. From this location, tracehorizontally to the curve with the desired percentageof displacer used, then trace vertically up or down todetermine the proper dial setting on the horizontalaxis.

� Sensor with Nonstandard Torque Tubeand/or Displacer with Other than StandardVolume—If the construction does not have astandard wall torque tube or has a displacer volumethat deviates significantly from the volume listed intable 2, or both, the PROPORTIONAL BAND orSPECIFIC GRAVITY dial setting does notnecessarily indicate the actual proportional band orspecific gravity. To determine the correct dial setting,solve the following equation:

Figure 11. Proportional Band and Specific Gravity Setting Chart (chart assumes standard wall torque tube and

displacer volume in table 2)

NOTE:EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.1C9259-GA3891-1/IL

CorrectedDial SettingRequired

� ( L100

)(SP GR)�Va

Vr�(X)

where:

L = percentage of displacer length desired for fulloutput pressure change (e.g., if 80% ofdisplacer is used, L = 80)

SP GR = specific gravity of the process fluid (forinterface level control, use the differencebetween the specific gravity of the twofluids; for specific gravity control, use thedifference between the upper and lowerrange limits of specific gravity).

Va = actual displacer volume, cubic inches listedon the sensor nameplate.

Vr = standard displacer volume, cubic inches,from table 2.

X = torque tube factor (1.0 for standard torquetubes, 2.0 for thin-wall torque tubes, or 0.5for heavy-wall torque tubes).


13

Table 4. Recommended Settings For Pre-Startup ChecksRECOMMENDED RAISE LEVEL SETTING

FOR TYPE 2500 CONTROLLERRECOMMENDED ZERO ADJUSTMENT SETTING FOR

TYPE 2500T TRANSMITTERMOUNTING ACTION For Predetermined

PROPORTIONAL BANDDial Setting of 10(1)

For PredeterminedPROPORTIONAL BAND

Dial Setting of 0(1)

For PredeterminedSPECIFIC GRAVITY Dial

Setting of 1.0(1)

For PredeterminedSPECIFIC GRAVITY Dial

Setting of 0(1)

Right handDirect 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to right 0.5 to 1.0 to right

Right-handReverse 6.5 to 7.0 0.5 to 1.0 1.5 to 2.0 to left 4.0 to 4.5 to right

Left handDirect 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to left 0.5 to 1.0 to left

Left-handReverse 6.5 to 7.0 0.5 to 1.0 1.5 to 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.

Type 2500 Controller or 2500TTransmitter

Note

In the following steps the outputpressure can go as high as thecontroller supply pressure.

1. Turn on the supply pressure and check that thesupply pressure gauge reads 1.4 bar (20 psig) for a0.2 to 1 bar (3 to 15 psig) or 2.4 bar (35 psig) for a0.4 to 2 bar (6 to 30 psig) output pressure range. Ifthe pressure is incorrect, loosen the locknut of theType 67FR filter/regulator (figure 9); turn theadjusting screw clockwise to increase the pressureor, counterclockwise to decrease the pressure.Tighten the locknut after setting the regulatorpressure.

2. Set the process variable to its minimum value.

3. Make sure that the PROPORTIONAL BAND orSPECIFIC GRAVITY control is at the settingdetermined earlier in this section. Then, set theRAISE LEVEL or ZERO ADJUSTMENT control at anappropriate value according to table 4. This tablegives recommended settings based on maximumand minimum possible PROPORTIONAL BAND andSPECIFIC GRAVITY settings. If an intermediatePROPORTIONAL BAND or SPECIFIC GRAVITYsetting is necessary, extrapolation may be used todetermine an appropriate RAISE LEVEL or ZEROADJUSTMENT setting.

Note

The raise level dial does not reflectactual fluid level in the tank or fluidlevel position on the displacer.

4. The OUTPUT gauge on a 0.2 to 1 bar (3 to 15psig) range should read 0.2 bar (3 psig) for direct or1 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) forreverse action.

5. On a controller or transmitter with a mechanicalindicator assembly, the pointer should be over theLOW point on the indicator plate. If a slightadjustment is necessary, loosen the side hex clampnut (key 40, figure 16), shift the pointer, andretighten the nut.

6. Increase the process variable to the level desiredfor full output change. The OUTPUT gauge on a 0.2to 1 bar (3 to 15 psig) range should read 1 bar (15psig) for direct or 0.2 bar (3 psig) for reverse action.On a 0.4 to 2 bar (6 to 30 psig) range the OUTPUTgauge should read 2 bar (30 psig) for direct or 0.4bar (6 psig) for reverse action. On a controller ortransmitter with an indicator assembly, the pointershould be over the HIGH point on the indicator plate;slight plate adjustment may be necessary, asdescribed at the end of step 5.

7. If all prestartup checks are satisfactory, go to thestartup procedure. If performance is unsatisfactory,proceed to the Calibration section.

Type 2500S Controller

Note


1. Turn on the supply pressure and check that theSUPPLY pressure gauge reads 1.4 bar (20 psig) fora 0 to 1.4 bar (0 to 20 psig) output pressure range or2.4 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 Type 67FR filter/regulator(figure 9); turn the adjusting screw clockwise toincrease the pressure or counterclockwise todecrease pressure. Tighten the locknut after settingthe pressure.

2. Set the process variable to its minimum value.


Form 1013March 2005

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3. On a controller with a mechanical indicatorassembly, the pointer should be over the LOW pointon the indicator plate. If a slight adjustment isnecessary, loosen the hex clamp nut (key 40, figure16), shift the pointer and retighten the nut.

Note

Adjustment of the RAISE LEVELcontrol can set the switching pointsanywhere within the length of thedisplacer. Be careful not to set theswitching points so that one is off thedisplacer.

4. Make sure that the PROPORTIONAL BANDcontrol is at the setting determined in the previousprocedures. Set the RAISE LEVEL control to 0, thenset it to 1.0 for a direct-acting or 4.0 for areverse-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 OUTPUTgauge changes to either supply pressure for direct or0 bar (0 psig) for reverse acting. The processvariable should be at the desired high trip value. Ona controller with an indicator assembly, the pointershould be over the HIGH point on the indicator plate;slight adjustment may be necessary, as described atthe end of step 3.

7. Decrease the process variable until the OUTPUTgauge changes to 0 bar (0 psig) for direct or supplypressure for reverse action (depending on controllerrange). The process variable should be at thedesired low trip value.

8. If all prestartup checks are satisfactory, proceedto the Startup section. If performance isunsatisfactory, proceed to the Calibration section.

Type 2503 Controller

Note


Note

Since the Type 2503 controller has noproportional valve, the differential gapbetween switching points is adjustedby varying the supply pressure. This

gap can be varied from approximatelya 89 mm (3.5 inch) level change at 1bar (15 psig) to a 152 mm (6.0 inch)level change at 1.7 bar (25 psig) with astandard volume displacer and a fluidwith a specific gravity of 1.0. The gapalso varies inversely according todensity; a fluid with 0.8 specific gravityproduces a 112 mm (4.4 inch) levelchange at 1 bar (15 psig) to a 191 mm(7.5 inch) change at 1.7 bar (25 psig).Set the gap at a pressure low enoughto be compatible with the limitations ofthe diaphragm control valve or otherfinal control element.

1. Turn on the supply pressure. If necessary, adjustthe Type 67FR regulator to produce the desireddifferential gap by loosening the locknut (figure 9)and turning the adjusting screw clockwise toincrease or counterclockwise to decrease pressure.Tighten the locknut.

2. Locate the process variable at its minimum value.

Note

Adjustment of the RAISE LEVELcontrol can set the switching pointsanywhere within the length of thedisplacer. Be careful not to set theswitching points so that one is off thedisplacer.

3. Set the RAISE LEVEL control to 0 and then resetit as follows:

a. For direct-acting controllers, set it between 1.0and 1.5.

b. For reverse-acting controllers, set it between3.5 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 OUTPUTgauge changes to full supply pressure for direct or 0bar (0 psig) for reverse action. The process variableshould be at the desired high trip value.

6. Decrease the process variable until the OUTPUTgauge changes to 0 bar (0 psig) for direct or fullsupply pressure for reverse action. The processvariable should be at the desired low trip value.

7. If all prestartup checks are satisfactory, proceedto the Startup section. If performance isunsatisfactory, proceed to the Calibration section.


15

AdjustmentsThis section explains controller/transmitter actionand adjustments. Figure 10 shows adjustmentlocations.

Control Action

The following is a definition of control action.

� Direct Action—Increasing fluid level, interfacelevel, or density, increases the output signal.

� Reverse Action—Increasing fluid level,interface level, or density, decreases the outputsignal. Controller/transmitters factory-set forreverse-acting have the suffix letter R added to theirtype number.

The control action is determined by the cage headmounting position and by the Bourdon tube-flapperarrangement in the controller/transmitter. Refer tofigure 4 for mounting positions and to figure 15 forBourdon tube-flapper arrangements. To change theaction, refer to the changing action procedure in theMaintenance section.

Level Adjustment (Controllers Only)

To make a level adjustment, open the controllercover, loosen the knurled adjustment screw, androtate the adjustment lever around the RAISELEVEL dial. To raise the fluid or interface level, orincrease density, rotate this knob in the direction ofthe arrows. To lower the level or decrease density,rotate the knob in the opposite direction. Thisprocedure is the same for either direct or reverseaction. Tighten the knurled screw.

Note

The RAISE LEVEL dial does not reflectactual fluid level in the tank or fluidlevel position on the displacer.

Zero Adjustment (Transmitters Only)

To make a zero adjustment, open the transmittercover, loosen the adjustment screw and rotate theadjustment lever around the ZERO ADJUSTMENTdial. This adjustment sets the output pressure tocorrespond to a specific level on the displacer.Tighten the knurled screw.

Proportional Band Adjustment (ExceptTransmitters and 2503 SeriesControllers)The proportional band adjustment varies the amountof process variable change required to obtain a fulloutput pressure change. To perform this adjustment,open the controller cover and turn thePROPORTIONAL BAND adjustment (see figure 10).Refer to the prestartup check procedures todetermine the proper setting.

Specific Gravity Adjustment(Transmitters Only)This adjustment also varies the amount of processvariable change required to obtain a full outputpressure change. To perform this adjustment, openthe transmitter cover and turn the SPECIFICGRAVITY adjustment (see figure 10). Refer to theprestartup check procedures to determine the propersetting.

Calibration

Precalibration RequirementsThe controller/transmitter can be calibrated in thefield, mounted on the vessel containing the processfluid. It may also be done in the shop, but othermeans of obtaining a displacement force changemust be provided. There are wet and dry methods ofadapting the calibrating procedure.

Wet CalibrationRemove the entire controller/transmitter and sensorassembly from the vessel. For caged sensors, pourthe fluid into the cage. For cageless sensors,suspend the displacer to an appropriate depth in afluid having a specific gravity equal to that of theprocess fluid.

If necessary, you may use water for wet calibrationin the shop. You must compensate for the differencebetween the specific gravities of water and theprocess fluid, however. As an example, assume theprocess fluid has a specific gravity of 0.7. Thespecific gravity of water is 1.0. To simulate a processlevel of 50 percent of the input span, would require awater level of 35 percent (0.7/1.0 x 50 percent = 35percent).


Form 1013March 2005

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Dry Calibration

Remove the controller/transmitter and torque tubearm, as a single unit, from the cage or vessel. Then,wherever the standard calibration procedures in thismanual require a specific process variable input tothe sensor, simulate the process variable bysuspending the proper weight (such as a can ofsand) from the end of the displacer rod. Completethe following procedures (Controller/Transmitter andTorque Tube Arm Disassembly) and (Determiningthe Amount of Suspended Weight) beforeproceeding to the Calibrating Procedure.

Controller/Transmitter and Torque TubeArm Disassembly

WARNING

To avoid personal injury from contactwith the process fluid, lower the vessellevel below the sensor torque tubearm, or shut off the cage equalizingvalves and drain the cage beforeproceeding. For closed vessels,release any pressure that may be inthe vessel before removing the sensorassembly.

When removing the displacer from the displacer rodor removing the controller/transmitter and torquetube arm from the cage or vessel, refer to theappropriate 249 Series instruction manual forassistance. The method of removing the displacer ortorque tube arm and attached controller/ transmittervaries with the type of sensor.

For a caged sensor with top equalizing connection, itmay be appropriate to remove the entire cage fromthe vessel before disassembling.

CAUTION

If the displacer is to be disconnectedfrom the displacer rod before thesensor assembly is removed from thecage or vessel, provide a means ofsupporting the displacer to prevent itfrom dropping and suffering damage.The spuds or stem end pieces on alldisplacers have holes suitable forinserting rods or other supports.

Additionally, a threaded rod may beinstalled into the 1/4-inch 28 UNFthreaded hole in the displacer spud orstem end piece of top-mountedcageless and all caged sensors. Forsome top-mounted sensors with longdisplacers, the sensor may beremoved through the access hole inthe sensor head.

For Type 249BP sensors with travelstop, the stem end piece pins willsecure the displacer on the travel stopas long as the travel stop plate isinstalled and the sensor head is inposition.

Determining the Amount of SuspendedWeight

CAUTION

Avoid overloading a torque tube sizedfor interface or density applications.Consult your Fisher sales office for themaximum allowable substitute weight,Ws, that may be used with yourparticular construction.

To determine the total weight that must besuspended from the displacer rod to simulate acertain condition of fluid level or specific gravity,solve the following equation:

Ws � Wd–[(0.0361)(V)(SP GR)]

where:

Ws = Total suspended weight in pounds (shouldnever be less than 0.5 pounds). For a unitwith a horizontal displacer, make sure thecenter of gravity of the substitute weight iswhere it would be on the actual displacer.

Note

For liquid level control only, simulatethe lower range limit of the input spanby suspending the displacer from thedisplacer rod. For other values of inputspan, remove the displacer andsuspend the appropriate weight asdetermined in the equation above.

Wd = Weight of the displacer, in pounds(determine by weighing displacer).


17

Table 5. Minimum and Maximum Limits for Setting Process VariablesAPPLICATION 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 twoprocess liquids

Displacer must be completely submerged inheavier of two process liquids

Density Displacer must be completely submerged in liquid havingspecific gravity of lowest range point

Displacer must be completely submerged in liquid havingspecific gravity of highest range point

0.0361 = Weight of one cubic inch of water(specific gravity = 1.0), in pounds.

V = Volume, in cubic inches, of the portion of thedisplacer submerged. Or,

V = (π/4) (displacer diameter)2 (length ofdisplacer submerged)

SP GR = Specific gravity of the process fluid atoperating temperature.

For interface level measurement, the equationbecomes:

Ws�Wd–[(0.0361)(Vt)(SP GRl)

� (0.0361)(Vh)(SP GRh � SP GRl)]

where:

Vt = Total volume, in cubic inches, of thedisplacer.

SP GRl = Specific gravity of the lighter of thefluids at operating temperature.

Vh = Volume, in cubic inches, of the portion of thedisplacer submerged in the heavier of thefluids.

Or,

V = (π/4) (displacer diameter)2 (length of thedisplacer submerged)

SP GRh = Specific gravity of the heavier of thefluids at operating temperature.

Calibration Procedure

WARNING

The following calibration proceduresrequire taking thecontroller/transmitter out of service.To avoid personal injury and propertydamage caused by an uncontrolledprocess, provide some temporarymeans of control for the processbefore taking the controller/transmitterout of service.

Figure 10 shows adjustment locations, except asotherwise indicated. In order to calibrate, open-loopconditions must exist. One way to obtain an openloop is to ensure that there is no flow through thefinal control element. Another way to obtain an openloop is to disconnect the controller/transmitter outputsignal line and plug the output connection with a testpressure gauge.

Several steps in these calibrating procedures requiresetting the process variable at its minimum andmaximum limits, according to table 5.

Note

If the process cannot be varied readilyor the Wet Calibration method cannotbe used in the following steps, be sureto use the proper sequence of correctweights as found in the DeterminingAmount of Suspended Weightprocedure. Whenever the followingsteps require particular prestartupchecks, refer to the appropriateprocedures for: Type 2500 Controlleror 2500T Transmitter, Type 2500SController, or Type 2503 Controller.

Type 2500 Controller and 2500TTransmitter1. Turn on the supply pressure and check that it isset according to the appropriate prestartup checksprocedure.


Form 1013March 2005

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2. Make sure that the PROPORTIONAL BAND orSPECIFIC GRAVITY adjustment is at the settingdetermined according to the appropriate prestartupcheck procedure.

3. Adjust the RAISE LEVEL (Type 2500) or ZEROADJUSTMENT (Type 2500T) to the appropriatevalue per table 4. This table gives recommendedsettings based on maximum and minimum possiblePROPORTIONAL BAND (Type 2500) or SPECIFICGRAVITY (Type 2500T) settings. If an intermediatePROPORTIONAL BAND or SPECIFIC GRAVITYsetting is necessary, extrapolation may be used todetermine a new RAISE LEVEL or SPECIFICGRAVITY setting.

4. Set the process variable to the minimum value ofthe input range as shown in table 5. Forconstructions with an indicator assembly, make surethat the pointer is over the LOW mark.

Note

In the following step, the alignmentscrew (key 33, figure 16) must alwaysremain screwed in far enough toprovide spring tension on theunderside of the alignment screwhead.

5. Adjust the flapper (key 32, figure 16) to obtain theappropriate pressure listed below. For coarse flapperadjustment, loosen the hex nut (key 40, figure 16)and rotate the flapper assembly about the torquetube shaft. For fine flapper adjustment, turn theflapper alignment screw (key 33, figure 16).

� For Direct Acting Type 2500, 2500T, 0.2 bar(3 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or0.4 bar (6 psig) for a 0.4 to 2.0 bar (6 to 30 psig)output.

� For Reverse Acting Type 2500, 2500T, 1.0bar (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) outputor 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 toensure the nozzle is as square as possible with theflapper. The nozzle can be realigned by looseningthe Bourdon tube mounting screws (key 45, figure16) and rotating the Bourdon tube slightly. If thenozzle is realigned, tighten the mounting screws andrepeat step 5.

7. Set the process variable to the maximum value ofthe input range as shown in table 5.

8. The output pressure should be:

� For Direct Acting Type 2500, 2500T, 1.0 bar(15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig)output.

� For Reverse Acting Type 2500, 2500T, 0.2bar (3 psig) for a 0.2 to 1.0 bar (3 to 15 psig) outputor 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 instep 8, proceed to step 10. If the output pressuredoes not agree, go to step 11.

10. If the unit does not contain an indicatorassembly, go to the Startup section. If the unitcontains an indicator assembly, change the pointerspan by loosening the indicator plate screws (key41, figure 16, detail of indicator assembly), slide theplate until the HIGH mark is under the pointer.Tighten the plate screws and go to the Startupsection.

Note

Any sliding of the level set arm (key28, figure 16) in the following stepchanges the zero as well as the outputpressure span.

11. To adjust the output pressure span, loosen thetwo level set mounting screws (see figure 16) andslide the flexure strip base (key 27) right or left alongthe elongated slotted hole as follows:

� To increase the output pressure span, slidethe flexure strip base away from the torque tubeshaft.

� To decrease the output pressure span, slidethe flexure strip base toward the torque tube shaft.

Retighten the screws. If the flexure strip base hasbeen moved as far as possible and the outputpressure span is still too large or too small, proceedto step 13.

12. Repeat the procedure from step 4 until therequired calibration points are obtained.

Note

Any change of the PROPORTIONALBAND or SPECIFIC GRAVITYadjustment in the following stepchanges the zero as well as the outputpressure span.

13. If the flexure strip base has been moved as faras possible and the output pressure span is still too


19

large or too small, slightly adjust thePROPORTIONAL BAND or SPECIFIC GRAVITYadjustment as follows:

� If the output pressure span is too large, slightlyincrease the PROPORTIONAL BAND or SPECIFICGRAVITY setting.

� If the output pressure span is too small, slightlydecrease the PROPORTIONAL BAND or SPECIFICGRAVITY setting.


Note

If you cannot calibrate the controller ortransmitter, look for other problems asdescribed in the Troubleshootingprocedures, such as leakingconnections, or a binding displacerrod. If none of these troubles areapparent, ensure that the displacer issized correctly for the application.

Type 2500S and 2503 Controllers1. Turn on the supply pressure and check that it isset according to the appropriate prestartup checksprocedure.

2. Make sure that the PROPORTIONAL BANDadjustment (Type 2500S only) is at the settingdetermined according to the appropriate prestartupcheck procedure.

3. Perform one or the other of the following:

� For direct acting controllers, set the RAISELEVEL adjustment between 1.0 and 1.5.

� For reverse acting controllers, set the RAISELEVEL adjustment between 3.5 and 4.0.

4. Set the process variable at the minimum value ofthe input range as shown in table 5. Forconstructions with an indicator assembly, make surethat the pointer is over the LOW mark.

Note

In the following step, the alignmentscrew (key 33, figure 16) must alwaysremain screwed in far enough toprovide spring tension on theunderside of the alignment screwhead.

5. Be sure the flapper is centered over the nozzle. Ifnot, loosen the hex nut (key 40, figure 16) andreposition the flapper, tighten the hex nut.

6. Adjust the flapper (key 32, figure 16) asdescribed below. For coarse flapper adjustment,loosen the hex nut (key 40, figure 16) and rotate theflapper assembly about the torque tube shaft. Forfine flapper adjustment, turn the flapper alignmentscrew (key 33, figure 16).

� For Direct Acting Controllers, move theflapper toward the nozzle until the output pressureswitches to full supply pressure, then carefully adjustthe flapper away from the nozzle until the outputpressure switches to 0 bar (0 psig).

� For Reverse Acting Controllers, move theflapper away from the nozzle until the outputpressure switches to 0 bar (0 psig), then carefullyadjust the flapper toward the nozzle until the outputpressure switches to full supply pressure.

7. Slowly increase the process variable until theoutput pressure switches:

� For Direct Acting Controllers, slowly increasethe process variable until the output pressureswitches to full supply pressure. The processvariable should be at the maximum value of inputrange as shown in table 5. If the process variableagrees with table 5, proceed with step 8. If theprocess variable does not agree with table 5,proceed to step 9.

� For Reverse Acting Controllers, slowlyincrease the process variable until the outputpressure switches to 0 bar (0 psig). The processvariable should be at the maximum value of inputrange as shown in table 5. If the process variableagrees with table 5, proceed with step 8. If theprocess variable does not agree with table 5,proceed to step 9.

8. If the unit does not contain an indicator assembly,go to the startup section. If the unit contains anindicator assembly, change the pointer span byloosening the indicator plate screws (key 41, figure16, indicator assembly detail), slide the plate untilthe HIGH mark is under the pointer. Tighten theplate screws and go to the startup section.

Note

Any sliding of the level set arm (key28, figure 16) in the following stepchanges the zero as well as thedifferential gap.


Form 1013March 2005

20

9. To adjust the differential gap, loosen the two levelset mounting screws (see figure 16) and slide theflexure strip base (key 27) right or left along theelongated slotted hole as follows:

� To decrease the differential gap, slide theflexure strip base away from the torque tube shaft.

� To increase the differential gap, slide theflexure strip base toward the torque tube shaft.

Retighten the screws. For the Type 2500S only, ifthe flexure strip base has been moved as far aspossible and the differential gap is still too low,proceed to step 11.


Note

Any change in the PROPORTIONALBAND adjustment in the following stepchanges the zero as well as thedifferential gap.

11. If the flexure strip base has been moved as faras possible and the differential gap is still too largeor too small, adjust the PROPORTIONAL BAND asfollows:

� If the differential gap is too large, slightlydecrease the PROPORTIONAL BAND setting.

� If the differential gap is too small, slightlyincrease the PROPORTIONAL BAND setting.


Note

If you cannot calibrate the controller,look for other problems as describedin the Troubleshooting procedures,such as a nozzle that is notperpendicular to the flapper, leakyconnections, or a binding displacerrod. If none of these troubles areapparent, ensure the displacer is sizedcorrectly for the application.

StartupAdjustment locations are shown in figure 10. Thepre-startup or calibration procedures must becompleted prior to startup.

Type 2500 Controller1. Slowly open the upstream and downstreammanual control valves in the pipeline. If the pipelinehas a bypass valve, close the valve.

2. If desired, adjust the proportional band to thenarrowest (lowest) setting that maintains stablecontrol. Proportional band adjustments will affect theprocess level and may require a level adjustment. Ifadjusting proportional band, make the adjustmentsin small increments.

3. To confirm the optimum proportional bandsetting, momentarily create a load upset. If cyclingoccurs, broaden (increase) the proportional banduntil process oscillations diminish rapidly. In general,the narrowest proportional band that does notproduce cycling provides the best control.

Type 2500T Transmitter1. Make sure that the SPECIFIC GRAVITY andZERO ADJUSTMENT controls are set according tothe Type 2500 Controller or 2500T Transmitterportion of the pre-startup checks procedures.

2. Slowly open the upstream and downstreammanual control valves in the pipeline. If the pipelinehas a manual bypass valve, close the valve.

Type 2500S Controller1. Set the switching points according to the Type2500S Controller portion of the prestartup checksprocedures.


3. If necessary, the proportional band may beadjusted to increase or decrease the differential gap.Adjust the RAISE LEVEL adjustment to repositionthe differential gap. After readjustment, confirm thecontroller is still switching correctly at both switchingpoints.

Type 2503 Controller1. Set the switching points according to the Type2503 Controller portion of the prestartup checksprocedures.


21


3. If necessary, reposition the switching points byadjusting the RAISE LEVEL control. For example, ifthe differential gap is set for 102 mm (4-inches) oflevel change, this 102 mm (4-inches) can be setanywhere within the length of the displacer. Afterreadjustment, confirm the controller is still switchingcorrectly at both switching points.

Principle of OperationThe controller/transmitter receives the change influid level, fluid-to-fluid interface level, or densityfrom the change in the buoyant force the fluid exertson the sensor displacer. The displacer, through amechanical linkage, imparts a rotary motion to thetorque tube shaft. This rotary motion positions theflapper according to the level position of thedisplacer; the nozzle/Bourdon tube arrangementsends a pneumatic signal to the relay valve.

All 2500 and 2503 Series controller/transmitters usethe same basic pressure-balanced relay assembly.The following descriptions explain how the relayaction produces the output signal with the variouscontroller/transmitter constructions.

Type 2500 Controller or 2500TTransmitterFull supply pressure comes to the relay from theregulator, as shown in figure 12. The relay has afixed restriction through which supply pressurebleeds before entering the large diaphragm area andthe inner Bourdon tube channel. In a steady-statecondition, the process level holds the torque tubeand attached flapper steady in relation to the nozzle.This allows pressure to escape between the nozzleand flapper at the same rate it bleeds into the largediaphragm area. The large diaphragm holds the inletend of the relay valve slightly open to compensatefor the venting of output pressure through theproportional valve as it maintains a steady-stateposition of the final control element. The outputpressure, through the three-way proportional valve,affects the Bourdon tube outer channel, holding theBourdon tube in a steady-state position.

A process level change raises or lowers thedisplacer, moving the flapper with respect to the

nozzle. If the process level change increases nozzlepressure, the large diaphragm moves down; thiscloses the exhaust end and opens the inlet end ofthe relay valve (see figure 12). This action of therelay valve increases the output pressure to the finalcontrol element. Since the area ratio of the largediaphragm to the small diaphragm is three-to-one,the small diaphragm action amplifies the outputpressure change. The three-way proportional valvelets the increase in output pressure apply to theBourdon tube outer channel. The expansion of theBourdon tube moves the nozzle away from theflapper slowing the response of the pneumaticcircuit.

If the process level change decreases the nozzlepressure, the large diaphragm moves up. This actioncloses the inlet end and opens the exhaust end ofthe relay valve which allows output pressure toexhaust. This relay valve action reduces the outputpressure to the final control element and is thereverse of the previous explanation.

The proportional valve varies the reaction of theBourdon tube to changes in the output pressure. Foradditional information on the proportional valveaction, refer to the following proportional valvesubsection.

Proportional ValveThe three-way proportional valve is adjustable toallow some or all of the output pressure change tofeed back to the Bourdon tube outer channel,providing proportional band control (see figure 12).The Bourdon tube moves to counteract the pressurechanges in the nozzle, equaling the relay diaphragmpressure differential. The relay valve maintains anew output pressure according to the change in theprocess variable.

A wide-open proportional valve (fullycounterclockwise) permits feedback of the outputpressure signal change and produces 100 percentproportional response. A closed (fully clockwise)proportional valve produces smaller proportionalresponses, because part of the output pressurechange vents through the proportional valveexhaust.

Type 2500S ControllerThis construction has the same flapper, relay, andproportional valve as the Type 2500 controller.However, the nozzle is connected (figure 12) in sucha way that output pressure feedback (from the


Form 1013March 2005

22

Figure 12. Direct-Acting, Right-Hand-Mounted 2500-249 Series Controller/Transmitter

CD2114-EBO998-1/IL

movement of the Bourdon tube) moves the nozzle inthe opposite direction of the flapper. This actioncompletely opens the relay valve for full outputpressure or completely closes the relay valve for fullexhaust of the output pressure, allowing noin-between throttling.

Type 2503 ControllerThis construction has the same flapper and sensorarrangement as the Type 2500 controller, but itsBourdon tube has a three way valve operated by aplunger (see figure 13). Note that the switch pointadjustment changes the position of the moveable


23

Figure 13. Direct-Acting Left-Hand-Mounted Type 2503 Controller

BD4466-ACD2114-EA1890-1/IL

arm and attached Bourdon tube assembly; this inturn changes the switch point in relationship to theprocess level. The differential gap of the 2503 eithercompletely opens the relay valve for full outputpressure or completely closes the relay valve for fullexhaust of the output pressure, allowing noin-between throttling.

For a direct-acting controller, as long as the processvariable remains above the switch point, the flapperdoes not depress the plunger of the Bourdon tubevalve. In this condition, the Bourdon tube valveremains closed, providing full loading pressure to theBourdon tube. This loading pressure moves theBourdon tube away from the flapper. Also, in thiscondition, full loading pressure is on the upperdiaphragm of the relay. The loading pressure movesthe diaphragm down, closing the exhaust end andopening the inlet end of the relay valve, allowing fulloutput pressure.

When the process level sufficiently decreases, theflapper pushes in the plunger of the Bourdon tubevalve enough to release the loading pressure and

seal the inner Bourdon tube channel (see figure 13).This decrease in the loading pressure moves theBourdon tube toward the flapper, producing the snapaction. Also, this decrease in loading pressureallows relay spring pressure to move the largediaphragm up, closing the inlet end and opening theexhaust end of the relay valve, allowing full exhaustof the output pressure. This control action continuesuntil a sensor level change moves the flapper awayfrom the plunger, permitting the Bourdon tube valveto close, restoring loading pressure to the pneumaticcircuit. Reverse-acting controllers produce theopposite effect.

MaintenanceThe 2500 and 2503 Series controllers/transmitterswork in combination with 249 Series displacers.Refer to figure 16 for key number locations, unlessotherwise indicated.


Form 1013March 2005

24

WARNING

Always wear protective clothing andeyewear when performing anymaintenance operations to avoidpersonal injury.

When replacing the sensor assembly,the displacer may retain process fluidor pressure. Personal injury orproperty damage may occur due tosudden release of the pressure.Contact with hazardous fluid, fire, orexplosion can be caused bypuncturing, heating, or repairing adisplacer that is retaining processpressure or fluid. This danger may notbe readily apparent whendisassembling the sensor assembly orremoving the displacer. Beforedisassembling the sensor or removingthe displacer, observe the morespecific warning provided in thesensor instruction manual.

Check with your process or safetyengineer for any additional measuresthat must be taken to protect againstprocess media.

TroubleshootingWhen troubleshooting, open loop conditions mustexist unless otherwise stated. When monitoring theprocess variable, use the most accurate levelindicating device available. The output signalmeasuring device should have correspondingaccuracy.

Table 6 lists some common operating faults, theirprobable causes, and corrective action.

Removing Controller/Transmitter fromSensor

WARNING

To avoid injury in the following steps,turn off the supply pressure andcarefully release any pressure trappedin the controller/transmitter beforebreaking any pressure connection.Provide a bypass for the control

device if continuous operation isrequired during maintenance.

1. Disconnect the supply and output pressure tubingfrom the controller or transmitter. For acontroller/transmitter with an indicator, remove thepointer assembly by referring to the Replacing theBourdon Tube section.

2. Loosen the top hex clamp nut (key 40, figure 16)and remove the flapper base (key 30, figure 16) fromthe torque tube rotary shaft.

CAUTION

If the hex clamp nut has not beenloosened or the pointer removedaccording to step 2, attempting toremove the controller/transmitter fromthe sensor may bend the flapper orrotary shaft. Be careful that the back ofthe controller/transmitter case or theheat insulator does not drop down andbend the rotary shaft or shaftextension.

3. Remove any insulating tape from the jointbetween the controller/transmitter case and thetorque tube arm. Remove the four cap screws (key39, figure 14) that hold the controller/transmitter orheat insulator to the torque tube arm. Pull the casestraight out from the torque tube arm, easing it overthe shaft coupling (key 36, figure 14) if one isinstalled.

4. If the controller/transmitter has a heat insulator,remove the four button head cap screws andwashers (keys 40 and 53, figure 14) and remove theinsulator assembly.

Changing Mounting Methods

WARNING

To avoid personal injury from contactwith the process fluid, lower the vesselfluid level below the torque-tube armbefore proceeding. For closed vessels,release any pressure that may beabove the fluid. Also, be careful toavoid overloading a thin-wall torquetube with an overweight displacer.

Refer to figure 16 for key number locations.

1. Remove the controller/transmitter as describedpreviously.


25

Table 6. Troubleshooting Chart for 2500 Series Controller/TransmittersFAULT POSSIBLE CAUSE CHECK CORRECTION

1. Process wanders or cyclesaround set point.

1.1 Proportional band or specificgravity adjustment incorrect orimproperly tuned control loop.

Ensure the prestartup proceduresare completed correctly. Tunecontrol loop.

If stable control cannot be attainedand all other elements arefunctionally correct, examine otherpossible causes related to thecontroller/transmitter.

1.2 Supply pressure varying orincorrect supply pressure setting.

Use input pressure gauge tomonitor stability. Make sureregulator IN supply pressure iswithin limits.

Apply correct supply pressure.Use one regulator per instrument.

1.3 Sensor not plumb and is incontact with sidewall or leak indisplacer.

Check cage vessel and stillwellinstallation, or for leakingdisplacer.

Make sure the displacer anddisplacer rod hangs freely. Makesure linkage is tight. Replacedisplacer if leaking.

1.4 Relay malfunction. Check for relay malfunction byusing the testing relay deadbandprocedure.

Depress plunger to clean out thefixed restriction. Replace relayusing the procedure in theMaintenance section.

2. Controller/transmittercontrolling off set point orswitching point.

2.1 Supply pressure not setcorrectly.

Make sure regulator supplypressure is set correctly. Makesure regulator IN supply pressureis within limits.

Reset the supply regulatorpressure. If the condition occursagain, rebuild or replace regulator.Provide a regulator input pressurewithin regulator limits.

2.2 Leak in thecontroller/transmitter loop.

Use soap and water to check forinternal and external leaks.

Replace or repair leaking parts asnecessary.

2.3 Leaking displacer. Ensure the displacer is not fillingwith process fluid.

Refer to sensor maintenanceprocedures in the appropriatesensor instruction manual.

2.4 Flapper adjustment. Ensure the flapper is not loose onthe torque tube shaft and iscentered on the nozzle.

Replace or tighten flapperassembly as necessary and/orcenter flapper on nozzle.

2.5 Process variable changed. Ensure the process variable hasnot changed from originalcalibration settings, or displacernot designed for specific gravity ofprocess.

Change process variable back tooriginal specification orrecalibrate. If necessary, providereplacement displacer of correctsize and recalibrate.

3. Controller/transmitter cannotattain full output range.

3.1 Supply pressure not setcorrectly.

Make sure supply pressure is setcorrectly. Make sure regulator INsupply pressure is within limits.

Reset the regulator pressure. Ifproblem reoccurs, replace orrebuild the regulator. Ensureregulator IN supply pressure iswithin limits at all operating levels.



3.3 Process variable changed. Ensure the process variable hasnot changed from originalcalibration settings, or fromdisplacer’s designed specificgravity.

Change process variable back tooriginal specification orrecalibrate. If necessary, providereplacement displacer of correctsize and recalibrate.

3.4 Relay malfunction Check for relay malfunction byusing the testing relay deadbandprocedure.

Depress plunger to clean out thefixed restriction. Replace relayusing the procedure in theMaintenance section.

3.5 Leak in thecontroller/transmitter loop.

Use soap and water to check forinternal and external leaks.

Replace or repair leaking parts asnecessary.

4. Controller/transmitter remainsat full or zero output pressure.

4.1 Supply or output pressuregauge malfunction.

Ensure the pressure gauges areregistering correctly.

Replace pressure gauges. Usecorrective action given in section 3of this table.




Form 1013March 2005

26

Figure 14. Heat Insulator for 249 Series Sensor

20A7423-C/DOC

2. A controller/transmitter is attached to the sensorin one of the mounting positions shown in figure 4.Right-hand mounting is with the controller/transmittercase (key 1) to the right of the displacer (FLOAT), asyou look at the front of the case, left-hand mountingis with with the case to the left of the displacer. For a249 Series sensor, remove the torque tube arm fromthe sensor or vessel and reinstall the torque tubearm in the opposite position according to theappropriate instruction manual. Note that the termFLOAT is marked on the RAISE LEVEL dial and theindicator plate, if one is used.

3. Check the desired control action. If the controlaction is not correct, refer to the changing actionprocedures to change it. Mount the Bourdon tube inone of the positions shown in figure 15.

4. The arrow on the RAISE LEVEL dial under theword FLOAT should point toward the displacer. Ifnot, remove the dial from the controller, turn it over,and install it in the correct position.

5. For a controller/transmitter with an indicatorassembly, the arrow near the word FLOAT on the

indicator plate should point toward the displacer. If itdoes not, remove the two screws (key 41, see detailof indicator assembly in figure 16), turn the frontplate (key 54) to the side with the FLOAT arrowpointing toward the displacer, and secure the platewith the screws.

6. Install the controller/transmitter according to thenext section.

Installing Controller/Transmitter onSensor

Note

If the installation is in a location that isnot readily accessible and shopcalibration is required, remove thetorque tube arm from the cage orvessel before installing the controlleror transmitter to the sensor. Install thecontroller/transmitter on the torquetube arm in the shop; then calibrateand return the controller/transmitterwith the torque tube arm assemblyattached for installation.Perform step 1 only if adding a heatinsulator to a unit that does not haveone. Key numbers in this step areshown in figure 14.

1. To install the heat insulator, secure the shaftextension (key 37) to the torque tube assemblyrotary shaft with the shaft coupling (key 36). Tightenboth set screws (key 38), with the coupling centeredas shown in figure 14. Then mount the insulatorassembly (key 35) on the controller/transmitter casewith four button head cap screws and washers (keys40 and 53). Tighten the screws.

CAUTION

In the following step, avoid bendingthe rotary shaft of the torque tubeassembly. Bending or side loading ofthis shaft could cause erroneousreadings. Additionally, make sure theball bearing assembly (key 12, figure16) is removed from the case (key 1,figure 16) to provide clearance wheninstalling 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 casestraight in. Secure the case on the torque arm orinsulator with the four cap screws (key 39).


27

Note

If a heat insulator is used, do notinsulate its exterior.

4. Slide the bearing assembly (key 12, figure 16)onto the shaft or shaft extension of the insulator, andinstall the bearing assembly (key 12, figure 16) intothe case (key 1, figure 16).

5. Install the flapper base (key 30, figure 16) on thetorque tube rotary shaft, making sure the flapper iscentered over the nozzle or Bourdon tube valve.Secure the base with the hex nut (key 40, figure 16).For a controller/transmitter with an indicatorassembly, install the pointer assembly according tothe Replacing the Bourdon Tube section.

6. Connect the supply and output pressure tubingand perform the calibration procedure.

Replacing the Bourdon TubeRefer to figure 16 for key number locations.

1. Disconnect the tubing (key 10 for Type 2503 andkey 11 for Type 2500) from the Bourdon tube base.For a controller/transmitter with indicator assembly,loosen the side hex clamp nut (key 40) and removethe pointer assembly (key 51) from the torque tuberotary shaft.

2. Remove the mounting screws (key 45) andBourdon tube assembly (key 16).

3. Inspect the Bourdon tube. Replace it ifnecessary, using a tube with a black color code for a0.2 to 1 bar or 0 to 1.4 bar (3 to 15 psig or 0 to 20psig) range. Use a tube with a red color code for a0.4 to 2 bar or 0 to 2.4 bar (6 to 30 psig or 0 to 35psig) range. The range is stamped at the Bourdontube base.

4. Mount the Bourdon tube on the level set arm (key28). Secure it with the mounting screws, using theproper orientation as shown in figure 15. Connectthe tubing to the tube base, with tubing from the Rconnection on the relay (key 34) going to the markedbase connection. The other tubing goes to theunmarked base connection. With an indicatorassembly, install the pointer assembly on the rotaryshaft and tighten the hex nut.

5. Perform the calibration procedure.

Changing ActionNote

The following procedure is necessaryto restore previous action if themounting method has been changed.Figure 16 shows key numbers.

1. Reposition the Bourdon tube (and indicatorassembly, if used) according to steps 1 through 4 ofthe Replacing the Bourdon Tube section.

2. Loosen the hex nut (key 40) and remove theflapper base (key 30) from the torque tube rotaryshaft. Turn the flapper base over and install it on therotary shaft, using the proper orientation as shown infigure 15 and making sure the flapper is centeredover the nozzle or Bourdon tube valve.

3. Perform the calibration procedure.

Relay Deadband Testing (Type 2500Controller or 2500T Transmitter Only)1. Replace the appropriate (proportional or specificgravity) adjustment assembly with the 1/8-inch NPTpipe plug according to the Replacing theProportional Valve section.

2. Turn on the supply pressure and set it to 1.4 to2.4 bar (20 or 35 psig), depending on thecontroller/transmitter operating range.

3. By changing the process variable and adjustingthe RAISE LEVEL or ZERO ADJUSTMENT control,set the output pressure to 1.0 or 2.0 bar (15 or 30psig). While monitoring the output pressure, slowlychange the process variable until the outputpressure just changes, and record the value of theprocess variable at the detection point.

4. Change the process variable in the oppositedirection until the output pressure just changes andagain record the value of the process variable. If thedifference between the two recorded values (thedeadband) is more than 0.2% of the maximumdisplacer length, the relay must be replaced orrepaired according to the Changing Relay section.

5. Turn off the supply pressure, remove the pipeplug, and install the appropriate adjustmentassembly.


Form 1013March 2005

28

Figure 15. Bourdon Tube-Flapper Arrangements for Various Actions and Mountings

AC9554AR8148BO996-1/IL

Replacing the Proportional Valve

Note

The following procedure, to convert toor from the pipe plug or the desiredadjustment assembly, can be used forany type number covered in thismanual.

1. Remove the tubing (key 10) from the proportionalband valve assembly.

2. Unscrew the base of the PROPORTIONALBAND or SPECIFIC GRAVITY adjustment assembly(key 36 or 90, figure 16), or the 1/8-inch NPT pipeplug (key 73, not shown), from the relay base (key23, figure 16).

3. Install the pipe plug or the desired adjustmentassembly into the relay base.

4. Replace the tubing (key 10) to the proportionalband valve assembly.

Changing RelayThe relay may be removed for cleaning orreplacement.

Removal

1. For a controller or transmitter with indicatorassembly, loosen the two lower relay screws (key96) and slide out the indicator base plate (key 53).

2. Disconnect the tubing (key 10 or 11) from therelay.

3. Remove both mounting screws, relay, and relaygasket (keys 43, 34, and 22).

Replacement

1. Install a new gasket (key 22), the replacementrelay (key 34), and secure with two mounting screws


29

(key 43). On a controller or transmitter with anindicator assembly, slide the base plate under thetwo lower screws of the relay case, align the plate sothe pointer will read properly, and tighten the screws.

2. Connect the tubing (key 10 or 11) to the relay.

3. Test the relay deadband, according to the RelayDeadband Testing procedure in this section.

4. If the deadband is within tolerance, go to theCalibration section.

Parts Ordering

Whenever corresponding with your Fisher salesoffice about this equipment, use thecontroller/transmitter type number and the serialnumber. The serial number is found on thenameplate (key 215, figure 16). When orderingreplacement parts, also state the complete11-character part number of each part required asfound in the following parts list.

Note

Use only genuine Fisher replacementparts. Components that are notsupplied by Fisher should not, underany circumstances, be used in anyFisher instrument. Use of componentsnot supplied by Fisher will void yourwarranty, might adversely affect theperformance of the instrument, andmight jeopardize worker andworkplace safety.

Note

Neither Emerson, Emerson ProcessManagement, nor Fisher assumeresponsibility for the selection, use, ormaintenance of any product.Responsibility for the selection, use,and maintenance of any Fisherproduct remains with the purchaserand end-user.

Parts ListDescription Part Number

Controller Parts KitsType 2500 Controller Repair KitsContains keys 12, 15, 21, 24, 38, andthe flapper assemblyStandard temperature R2500X00L32High temperature R2500X00H32

Type 2503 Controller Repair KitStandard temperature onlyThe kit containskeys 12, 21, 22, 24, 38, and theflapper assembly. R2503X00022

Relay Replacement KitContains keys 22, 43, and the relay assemblyStandard temperature RRELAYX0L22High temperature RRELAYX0H22

Heat Insulator Retrofit KitContains the heat insulator parts shownin figure 14 and listed under HeatInsulator in this parts list R2500XH0012

Common Controller/Transmitter Parts(figure 16)Key Description Part Number1 Case back 57A0953X0122 Case cover, aluminum 50B9454X0123 Door handle, pl steel 1C8972250824 Door handle shaft (not shown), brass 1C8984140125 Machine screw, steel 1C8958X00226 Spring washer, stainless steel 1C8970360327 Door hook, pl steel 1C8971250828 Stop nut, pl steel 1C8959X00129 Drive-lock pin, (2 req’d) 1C8991X002210 Tubing assembly, stainless steel

For all 2500 Series except Type 2503 1N7983X0012For Type 2503 only 1H3093X0012

11 Relay tubing, stainless steel 1N7984X001212 Ball bearing assembly, Brass, pl 1C8983000A2

13 Retaining ring, pl steel (2 req’d) 1A46582899214 Gauge glass (2 req’d) 0T01920604215 Gauge glass gasket, neoprene (2 req’d) 0T01910408216* Bourdon tube assembly,

BrassType 2500 and 2500T3 to 15 psig 32B1231X0126 to 30 psig 32B1231X022

Type 2500S0 to 20 psig 32B1233X0120 to 35 psig 32B1233X022

Type 25030 to 20 psig 32B1234X0120 to 35 psig 32B1234X022

Stainless steelType 2500 and 2500T3 to 15 psig 32B1232X0326 to 30 psig 32B1232X042

*Recommended spare parts


Form 1013March 2005

30

Figure 16. 2500 Series Controller / Transmitter Constructions

30A8865-D/DOC

30A8869-D/DOC

30A8866-C/DOC

TYPICAL CONTROLLER

TYPE 2503R CONTROLLERCONSTRUCTION

DETAIL OF INDICATORASSEMBLY ON C VERSIONS

SEE VIEW ALEVEL SET MOUNTING SCREWS

NOTE:

PARTS NOT SHOWN 4, 24, 38, 39, 47, AND 48.


31

Key Description Part Number19* Triple scale gauge (2 req’d)

Brass0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8577X0120 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8577X022

Stainless steel0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8583X0120 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8583X022

19* Dual scale gauge (2 req’d)Brass0 to 30 psig / 0 to 2 kg/cm2 11B8577X0420 to 60 psig / 0 to 4 kg/cm2 11B8577X052

Stainless steel0 to 30 psig / 0 to 2 kg/cm2 11B8583X032

21* Cover gasket, nitrile 1C91980634222* Relay gasket

Standard temperature, neoprene 1C897403012High temperature, silicon 1N873804142

23 Relay base 47A0950X01224* Relay base gasket (not shown)


25 Flexure strip, stainless steel, 1C897836012

26 Flexure strip nut, pl steel (2 req’d) 1C89752508227 Flexure strip base, pl steel 1C89772508228 Level set arm, pl steel 1C89762508229 Drivelok pin, pl steel 1C8989X001230 Flapper base, brass, pl 1C92611402231 Shaft clamp screw, SST

(2 req’d for C version only, 1 req’d for all others)1B451435172

32 Flapper, stainless steel 1C92623899233 Alignment screw, brass, pl 1B45171402234 Relay assembly

For all 2500 Series except Type 2503Standard temperature 22B0463X012High temperature 22B0462X012Corrosive service 22B0463X032

Type 2503 onlyStandard temperature 32B0464X012High temperature 32B0465X012

35 Level adjustment assembly (controllers only) 10A8939X0A235 Zero adjustment assembly (transmitters only) 10A8939X0C236 Proportional band adjustment assembly

(except transmitters and Type 2503 controllers, see key 90)Standard and high temperature 10A9122X032Corrosive service 10A9122X122

Key Description Part Number37 Type 67FR regulator38A* Filter gasket (not shown)


38B Spacer, aluminum (not shown) T21043T001238C* O-ring (not shown)

Standard temperature, nitrile 1E591406992High temperature, fluoroelastomer 1E5914X0062

39 Cap screw (not shown), pl steel (2 req’d) 1C19702405240 Hex nut, pl steel

(2 req’d for C versions, 1 req’d for all others) 1L28633899241 Screw, pl steel

(2 req’d for C versions only) 16A6938X022

42 Machine screw, pl steel (8 req’d) 1V7435X002243 Machine screw, pl steel (2 req’d) 1A3776X001244 Machine screw, pl steel (6 req’d) 1A5733X001245 Machine Screw, pl steel (2 req’d) 1H1581X001246 Machine Screw, pl steel (4 req’d) 1C8990X0012

47 Spring (not shown), stainless steel 1J42343702248 Cap screw, pl steel (4 req’d) 1A3816K001249 Machine screw, pl steel (13 req’d) 1B7839X001250 Screen, alloy 400 0L07834306251 Pointer assembly (C versions only),

Stainless steel/brass, pl 1E8735000A2

52 Washer (C versions only), steel (2 req’d) 1E8730X001253 Base plate (C versions only), aluminum 1E87311199254 Front plate (C versions only), aluminum 1E87321199273 Pipe plug (Type 2503 only), brass (not shown) 1A62191401290 Specific gravity adjustment assembly

Standard and high temperature 10A8870X0A2Corrosive service 10A8870X022

215 Nameplate - - - - - - - -

Heat Insulator (figure 14)35 Heat Insulator Assembly, stainless steel 22A0033X01236 Shaft Coupling, stainless steel 1A57793503237 Shaft extension, alloy K500 1B68154002238 Set screw, stainless steel (2 req’d) 1E6234X0022

39 Cap screw, pl steel (4 req’d) 1A38162405240 Cap screw, pl steel (4 req’d) 1V23952898253 Washer, carbon steel, pl (4 req’d) 1B865928982

*Recommended spare parts


Form 1013March 2005

32

Fisher Marshalltown, Iowa 50158 USACernay 68700 France Sao Paulo 05424 BrazilSingapore 128461

Emerson Process Management

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

Neither Emerson, Emerson Process Management not Fisher assume responsibility for the selection, use or maintenance of any product. Responsibilityfor proper selection, use and maintenance of any Fisher product remains solely with the purchaser and end-user.

�Fisher Controls International LLC 1977, 2005; All Rights Reserved Printed in USA

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

Documents

2500 and 2503 Series Level-Trol Controllers and Transmitters · 2013-07-15 · 2500 and 2503 Series Level-Trol Controllers and Transmitters 1013 March 2005 This errata sheet provides