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Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

15

Figure 10. Adjustment Locations

W0641-1B

1C9283-B

W0671-1

W0656-1

W0647-2B

W0648-1B

1E8731
1E8732
A1897-1

LEVEL SET ARM
MOUNTING SCREWS

LEVEL SET
ARM

LEVEL ADJUSTMENT

PROPORTIONAL
BAND ADJUSTMENT

FLAPPER ALIGNMENT SCREW

SHAFT CLAMP NUT

3-WAY VALVE

NOZZLE

PLUNGER

SPECIFIC GRAVITY ADJUSTMENT

ZERO ADJUSTMENT

POINTER
ASSEMBLY

FLAPPER

RELAY

SPAN ADJUSTMENT

BOURDON TUBE DETAIL OF 2500S

ON‐OFF CONTROLLER

RAISE LEVEL DIAL FOR

LEFT‐HAND MOUNTING

RIGHT‐HAND MOUNTED 2500
PROPORTIONAL CONTROLLER

RIGHT‐HAND MOUNTED 2503R

ON‐OFF CONTROLLER

DETAIL OF TRANSMITTER

ADJUSTMENTS

INDICATOR ASSEMBLY WITH

RIGHT‐HAND MOUNTING

TRAVEL INDICATOR PLATE

FOR LEFT‐HAND MOUNTING

VENT

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Summary of Contents for Fisher 2500

Page 1: ...ments 20 Wet Calibration 20 Dry Calibration 21 Controller Transmitter and Torque Tube Arm Disassembly 21 Determining the Amount of Suspended Weight 21 Calibration Procedure 22 2500 Controller and 2500T Transmitter 23 2500S and 2503 Controllers 25 Startup 27 2500 Controller 27 2500T Transmitter 27 2500S Controller 27 2503 Controller 27 Figure 1 Fisher 2500 or 2503 Controller Transmitter on 249 Cage...

Page 2: ...r 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 sales office or Local Business Partner before proceeding Description These instruments control or transmit the fluid level the level of interface between two fluids or the ...

Page 3: ...bricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Per ISO 8573 1 Maximum particle density size Class 7 Oil content Class 3 Pressure Dew Point Class 3 or at least 10_C less than the lowest ambient temperature expected Maximum Supply Pressure 2 3 3 bar 45 psig to the controller or transmitter If controller or transmitter is equip...

Page 4: ...factory set for reverse action see chang ing 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 Control and stability may be impaired if the maximum pressures are exceeded 3 The pressure temperature limits in this document and any applicable standard or code limitation should...

Page 5: ...ials 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 Torque Tube N05500 1 316 Stainless Steel N06600 N10276 1 N05500 is not recommended for spring applications above 232_C 450_F Contact your Emerson sales office or ...

Page 6: ... apparent when disassembling the sensor 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 ...

Page 7: ...place 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...

Page 8: ...roneous 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 ...

Page 9: ...S4 FLANGED F4 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 valve whenever the bottom cage line has a fluid trapping low point Figure 6 Caged Sensor Mounting EQUA...

Page 10: ...roller 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 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 Sens...

Page 11: ...ng CF5380 A A3893 TOP MOUNTED SIDE VIEW WITHOUT STILLWELL SIDE VIEW SHOWING STILLWELL SIDE MOUNTED W9517 1 Figure 8 Displacer and Displacer Rod Connections W0228 1A DISPLACER ROD DISPLACER SPUD ALL OTHER TYPES COTTER SPRING LOCKING NUTS DISPLACER SPUD DISPLACER STEM EXTENSION DISPLACER ROD COTTER SPRING W9357 249VS ...

Page 12: ...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 CAUTION Do not use sealing tape on pneumatic connections This instrument contains small passages that may become obstructed by detach...

Page 13: ...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 Pressur...

Page 14: ...ressure 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 LEVE...

Page 15: ...USTMENT FLAPPER ALIGNMENT SCREW SHAFT CLAMP NUT 3 WAY VALVE NOZZLE PLUNGER SPECIFIC GRAVITY ADJUSTMENT ZERO ADJUSTMENT POINTER ASSEMBLY FLAPPER RELAY SPAN ADJUSTMENT BOURDON TUBE DETAIL OF 2500S ON OFF CONTROLLER RAISE LEVEL DIAL FOR LEFT HAND MOUNTING RIGHT HAND MOUNTED 2500 PROPORTIONAL CONTROLLER RIGHT HAND MOUNTED 2503R ON OFF CONTROLLER DETAIL OF TRANSMITTER ADJUSTMENTS INDICATOR ASSEMBLY WIT...

Page 16: ...rmine 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 NOTE EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED 1C9259 G A3891 1 TRANSMITTER SPECIFIC GRAVITY SETTING CONTROLLER PROPORTIONAL BAND SETTING SPECIFIC GRAVITY OR SPECIFIC GRAVITY DIFFERENTIAL D Sensor with ...

Page 17: ...g 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 pos...

Page 18: ...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...

Page 19: ...esired 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 contro...

Page 20: ...startup 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 ...

Page 21: ...ng the sensor assembly When removing the displacer from the displacer rod or removing the controller transmitter and torque tube 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 ...

Page 22: ...ne cubic inch of water specific gravity 1 0 in pounds V Volume in cubic inches of the portion of the displacer submerged Or V π 4 displacer diameter 2 length of displacer submerged SP GR Specific gravity of the process fluid at operating temperature For interface level measurement the equation becomes Ws Wd ƪ 0 0361 Vt ǒSP GRl Ǔ 0 0361 ǒVh ǓǒSP GRh SP GRl Ǔ where Vt Total volume in cubic inches of...

Page 23: ...IONAL BAND 2500 or SPECIFIC GRAVITY 2500T 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 MOUNTING ACTION RECOMMENDED RAISE LEVEL SETTING FOR 2500 CONTROLLER RECOMMENDED ZERO ADJUSTMENT SETTING FOR 2500T TRANSMITTER For Pred...

Page 24: ...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 D 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...

Page 25: ...the following D For direct acting controllers set the RAISE LEVEL adjustment between 1 0 and 1 5 D For reverse acting controllers set the RAISE LEVEL adjustment between 3 5 and 4 0 4 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 alignmen...

Page 26: ...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 D To decrease the differential gap slide the flexure strip base away from the torque tube shaft D To increase the differential gap slide the flexure strip base toward the torque tube shaft Retighte...

Page 27: ...ntroller 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 ...

Page 28: ... 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 pressure to exhaust This relay valve...

Page 29: ...SURE PROPORTIONAL PRESSURE EXHAUST 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 le...

Page 30: ...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 circuit Reverse acting controllers produce the opposite effect Figure 13 Direct Acting Left Hand Mounted Fisher 2503 Contro...

Page 31: ... 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 Troublesh...

Page 32: ...pper 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 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 recal...

Page 33: ...old 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 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 insu...

Page 34: ... 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 t...

Page 35: ...y 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 Mount the Bourdon tube on the level set arm key 28 Secure it with the mounting screws using the proper orientation as shown in figure 15 Con...

Page 36: ...nd 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 changes and record the value of the process variabl...

Page 37: ...indicator assembly loosen the two lower relay screws key 96 and slide out the indicator base plate key 53 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...

Page 38: ...troller Cover Gasket Kit Contains qty 5 cover gaskets key 21 R2500CVR012 Common Controller Transmitter Parts figure 16 Note Contact your Emerson sales office or Local Business Partner for Part Ordering information Key Description 1 Case back 2 Case cover aluminum 3 Door handle pl steel Key Description 4 Door handle shaft not shown brass 5 Machine screw steel 6 Spring washer stainless steel 7 Door ...

Page 39: ...re 16 Fisher 2500 Controller Transmitter Constructions 30A8865 D 30A8869 D 30A8866 C TYPICAL CONTROLLER 2503R CONTROLLER CONSTRUCTION DETAIL OF INDICATOR ASSEMBLY ON C VERSIONS SEE VIEW A LEVEL SET MOUNTING SCREWS NOTE PARTS NOT SHOWN 4 24 38 39 47 AND 48 SEE 2503 CONNECTION DETAIL VIEW A ...

Page 40: ...s steel brass pl 52 Washer C versions only steel 2 req d 53 Base plate C versions only aluminum 54 Front plate C versions only aluminum 73 Pipe plug 2503 only brass not shown 90 Specific gravity adjustment assembly Standard and high temperature Corrosive service 215 Nameplate Heat Insulator figure 14 Note All Heat Insulator parts are included in the Heat Insulator Parts Kit 35 Heat Insulator Assem...

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