Emerson Level-Trol 2500 Instruction Manual Download Page 25

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Type 2500

Instruction Manual

Form 1013

December 2005

Table 7. Troubleshooting Chart for 2500 Series Controller/Transmitters

FAULT

POSSIBLE CAUSE

CHECK

CORRECTION

1. Process wanders or cycles

around set point.

1.1 Proportional band or specific

gravity adjustment incorrect or

improperly tuned control loop.

Ensure the prestartup procedures

are completed correctly. Tune

control loop.

If stable control cannot be attained

and all other elements are

functionally correct, examine other

possible causes related to the

controller/transmitter.

1.2 Supply pressure varying or

incorrect supply pressure setting.

Use input pressure gauge to

monitor stability. Make sure

regulator IN supply pressure is

within limits.

Apply correct supply pressure. Use

one regulator per instrument.

1.3 Sensor not plumb and is in

contact with sidewall or leak in

displacer.

Check cage vessel and stillwell

installation, or for leaking

displacer.

Make sure the displacer and

displacer rod hangs freely. Make

sure linkage is tight. Replace

displacer if leaking.

1.4 Relay malfunction.

Check for relay malfunction by

using the testing relay deadband

procedure.

Depress plunger to clean out the

fixed restriction. Replace relay

using the procedure in the

Maintenance section.

2. Controller/transmitter controlling

off set point or switching point.

2.1 Supply pressure not set

correctly.

Make sure regulator supply

pressure is set correctly. Make

sure regulator IN supply pressure

is within limits.

Reset the supply regulator

pressure. If the condition occurs

again, rebuild or replace regulator.

Provide a regulator input pressure

within regulator limits.

2.2 Leak in the

controller/transmitter loop.

Use soap and water to check for

internal and external leaks.

Replace or repair leaking parts as

necessary.

2.3 Leaking displacer.

Ensure the displacer is not filling

with process fluid.

Refer to sensor maintenance

procedures in the appropriate

sensor instruction manual.

2.4 Flapper adjustment.

Ensure the flapper is not loose on

the torque tube shaft and is

centered on the nozzle.

Replace or tighten flapper

assembly as necessary and/or

center flapper on nozzle.

2.5 Process variable changed.

Ensure the process variable has

not changed from original

calibration settings, or displacer

not designed for specific gravity of

process.

Change process variable back to

original specification or recalibrate.

If necessary, provide replacement

displacer of correct size and

recalibrate.

3. Controller/transmitter cannot

attain full output range.

3.1 Supply pressure not set

correctly.

Make sure supply pressure is set

correctly. Make sure regulator IN

supply pressure is within limits.

Reset the regulator pressure. If

problem reoccurs, replace or

rebuild the regulator. Ensure

regulator IN supply pressure is

within limits at all operating levels.

3.2 Flapper 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

displacer’s designed specific

gravity.

Change process variable back to

original specification or recalibrate.

If necessary, provide replacement

displacer of correct size and

recalibrate.

3.4 Relay malfunction

Check for relay malfunction by

using the testing relay deadband

procedure.

Depress plunger to clean out the

fixed restriction. Replace relay

using the procedure in the

Maintenance section.

3.5 Leak in the

controller/transmitter loop.

Use soap and water to check for

internal and external leaks.

Replace or repair leaking parts as

necessary.

4. Controller/transmitter remains

at full or zero output pressure.

4.1 Supply or output pressure

gauge malfunction.

Ensure the pressure gauges are

registering correctly.

Replace pressure gauges. Use

corrective action given in section 3

of this table.

4.2 Flapper adjustment.

Ensure the flapper is not loose on

the torque tube shaft and is

centered on the nozzle.

Replace or tighten flapper

assembly as necessary and/or

center flapper on nozzle.

Summary of Contents for Level-Trol 2500

Page 1: ...c Gravity Adjustment Transmitters Only 15 Calibration 15 Precalibration Requirements 15 Wet Calibration 16 Dry Calibration 16 Controller Transmitter and Torque Tube Arm Disassembly 16 Determining the Amount of Suspended Weight 16 Calibration Procedure 17 Type 2500 Controller and 2500T Transmitter 18 Type 2500S and 2503 Controllers 19 Figure 1 2500 or 2503 Series Level TrolR Controller Transmitter ...

Page 2: ...ading and understanding the contents of this manual If you have any questions about these instructions contact your Emerson Process Managementt sales office Description These instruments control or transmit the fluid level the level of interface between two fluids or the density specific gravity Each unit consists of a 249 Series displacer type fluid level sensor and a 2500 or 2503 Series pneumati...

Page 3: ...smitter If controller or transmitter is equipped with an integrally mounted Type 67FR filter regulator typical supply pressure to the regulator is from 2 5 bar 35 psig to 17 bar 250 psig maximum For supply pressures to the filter regulator refer to the appropriate regulator instruction manual Steady State Air Consumption 2500 Series Controllers and Transmitters 2500 2500C 2500R 2500S and 2500T See...

Page 4: ...isual 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 sett...

Page 5: ...nitic Stainless Steels and Special Alloys Torque Tube N05500 1 316 Stainless Steels N06600 N10276 1 N05500 is not recommended for spring applications above 232_C 450_F Contact your Emerson Process Management sales office or application engineer if temperatures exceeding this limit are required Installation The 2500 and 2503 Series controller transmitters work in combination with 249 Series displac...

Page 6: ...must be installed at the site A damping plate is installed in the lower screwed or flanged connection see figure 3 to provide more stable operation Be certain that the cage equalizing connections and the damping plate are not plugged by foreign material A cageless sensor comes with its displacer separated from the sensor assembly Displacers Figure 3 Damping Plate Location W0144 1 IL W2141 1B IL DI...

Page 7: ...ations With flanged connections use standard gaskets or other flat sheet gaskets compatible with the process fluid Spiral wound gaskets without compression controlling centering rings cannot be used for flange connections 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 shou...

Page 8: ...vel applications install a gauge glass on the vessel Side Mounted Sensor If a stillwell is required see figure 7 attach the displacer to the displacer rod from inside the vessel Connect the displacer as shown in figure 8 locking the assembly with the cotter spring provided If a stillwell is not required attach the displacer rod before mounting the sensor on the vessel Then you can swing the displa...

Page 9: ...E VIEW WITHOUT STILLWELL SIDE VIEW SHOWING STILLWELL SIDE MOUNTED W0645 1 IL W0229 1A IL COTTER SPRING DISPLACER ROD LOCKING NUTS DISPLACER SPUD DISPLACER STEM EXTENSION DISPLACER STEM END PIECE TYPE 249V W0228 1A IL DISPLACER ROD DISPLACER SPUD ALL OTHER TYPES COTTER SPRING Figure 8 Displacer and Displacer Rod Connections ...

Page 10: ... gas While use and regular maintenance of a filter that removes particles larger than 40 microns in diameter will suffice in most applications check with a Fisher Field office and Industry Instrument air quality standards for use with corrosive air or if you are unsure about the proper amount or method of air filtration or filter maintenance Figure 9 Controller Transmitter Dimensions and Connectio...

Page 11: ...APPER 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 TYPE 2500S ON OFF CONTROLLER RAISE LEVEL DIAL FOR LEFT HAND MOUNTING RIGHT HAND MOUNTED TYPE 2500 PROPORTIONAL CONTROLLER RIGHT HAND MOUNTED TYPE 2503R ON OFF CONTROLLER DETAIL OF TRANSMITTER ADJUSTMENTS INDICATOR ASSEMBL...

Page 12: ...rked on both sides with an arrow The arrow points to the left on one side and to the right on the other When the sensor is mounted to the left of the controller transmitter the arrow on the raise level dial should point to the left as shown in figure 10 If the sensor is to the right the arrow should point to the right If necessary remove the two mounting screws turn the dial over so the arrow poin...

Page 13: ...rease the pressure Tighten the locknut after setting the regulator pressure 2 Set the process variable to its minimum value 3 Make sure that the PROPORTIONAL BAND or SPECIFIC GRAVITY control is at the setting determined earlier in this section Then set the RAISE LEVEL or ZERO ADJUSTMENT control at an appropriate value according to table 6 This table gives recommended settings based on maximum and ...

Page 14: ...nt on the indicator plate slight adjustment may be necessary as described at the end of step 3 7 Decrease the process variable until the OUTPUT gauge changes to 0 bar 0 psig for direct or supply pressure for reverse action depending on controller range The process variable should be at the desired low trip value 8 If all prestartup checks are satisfactory proceed to the Startup section If performa...

Page 15: ...loosen the knurled adjustment screw and rotate the adjustment lever around the RAISE LEVEL dial To raise the fluid or interface level or increase density rotate this knob in the direction of the arrows To lower the level or decrease density rotate the knob in the opposite direction This procedure is the same for either direct or reverse action Tighten the knurled screw Note The RAISE LEVEL dial do...

Page 16: ...assembly WARNING To avoid personal injury from contact with the process fluid lower the vessel level below the sensor torque tube arm or shut off the cage equalizing valves and drain the cage before proceeding For closed vessels release any pressure that may be in the vessel before removing the sensor assembly When removing the displacer from the displacer rod or removing the controller transmitte...

Page 17: ...eight as determined in the equation above Wd Weight of the displacer in pounds determine by weighing displacer 0 0361 Weight of one cubic inch of water specific gravity 1 0 in pounds V 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 m...

Page 18: ... check procedure 3 Adjust the RAISE LEVEL Type 2500 or ZERO ADJUSTMENT Type 2500T to the appropriate value per table 6 This table gives recommended settings based on maximum and minimum possible PROPORTIONAL BAND Type 2500 or SPECIFIC GRAVITY Type 2500T settings If an intermediate PROPORTIONAL BAND or SPECIFIC GRAVITY setting is necessary extrapolation may be used to determine a new RAISE LEVEL or...

Page 19: ...far as possible and the output pressure span is still too large or too small slightly adjust the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment as follows D If the output pressure span is too large slightly increase the PROPORTIONAL BAND or SPECIFIC GRAVITY setting D If the output pressure span is too small slightly decrease the PROPORTIONAL BAND or SPECIFIC GRAVITY setting 14 Repeat the procedu...

Page 20: ...ighten the plate screws and go to the startup section Note Any sliding of the level set arm key 28 figure 16 in the following step changes the zero as well as the differential gap 9 To adjust the differential gap loosen the two level set mounting screws see figure 16 and slide the flexure strip base key 27 right or left along the elongated slotted hole as follows D To decrease the differential gap...

Page 21: ...e in fluid level fluid to fluid interface level or density from the change in the buoyant force the fluid exerts on the sensor displacer The displacer through a mechanical linkage imparts a rotary motion to the torque tube shaft This rotary motion positions the flapper according to the level position of the displacer the nozzle Bourdon tube arrangement sends a pneumatic signal to the relay valve A...

Page 22: ... end of the relay valve which allows output pressure to exhaust This relay valve action reduces the output pressure to the final control element and is the reverse of the previous explanation The proportional valve varies the reaction of the Bourdon tube to changes in the output pressure For additional information on the proportional valve action refer to the following proportional valve subsectio...

Page 23: ... part of the output pressure change vents through the proportional valve exhaust Type 2500S Controller This construction has the same flapper relay and proportional valve as the Type 2500 controller However the nozzle is connected figure 12 in such a way that output pressure feedback from the movement of the Bourdon tube moves the nozzle in the opposite direction of the flapper This action complet...

Page 24: ... effect Maintenance The 2500 and 2503 Series controllers transmitters work in combination with 249 Series displacers Refer to figure 16 for key number locations unless otherwise indicated WARNING Always wear protective clothing gloves and eyewear when performing any maintenance operations to avoid personal injury When replacing the sensor assembly the displacer may retain process fluid or pressure...

Page 25: ...justment Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle Replace or tighten flapper assembly as necessary and or center flapper on nozzle 2 5 Process variable changed Ensure the process variable has not changed from original calibration settings or displacer not designed for specific gravity of process Change process variable back to original specification or...

Page 26: ... from the joint between the controller transmitter case and the torque tube arm Remove the four cap screws key 39 figure 14 that hold the controller transmitter or heat insulator to the torque tube arm Pull the case straight out from the torque tube arm easing it over the shaft coupling key 36 figure 14 if one is installed 4 If the controller transmitter has a heat insulator remove the four button...

Page 27: ...e tube assembly rotary shaft with the shaft coupling key 36 Tighten both set screws key 38 with the coupling centered as shown in figure 14 Then mount the insulator assembly key 35 on the controller transmitter case with four button head cap screws and washers keys 40 and 53 Tighten the screws CAUTION In the following step avoid bending the rotary shaft of the torque tube assembly Bending or side ...

Page 28: ...ed base connection The other tubing goes to the unmarked base connection With an indicator assembly install the pointer assembly on the rotary shaft and tighten the hex nut 5 Perform the calibration procedure Changing Action Note The following procedure is necessary to restore previous action if the mounting method has been changed Figure 16 shows key numbers 1 Reposition the Bourdon tube and indi...

Page 29: ...hown from the relay base key 23 figure 16 3 Install the pipe plug or the desired adjustment assembly into the relay base 4 Replace the tubing key 10 to the proportional band valve assembly Changing Relay The relay may be removed for cleaning or replacement Removal 1 For a controller or transmitter with indicator assembly loosen the two lower relay screws key 96 and slide out the indicator base pla...

Page 30: ...ring pl steel 2 req d 1A465828992 14 Gauge glass 2 req d 0T019206042 15 Gauge glass gasket chloroprene 2 req d 0T019104082 16 Bourdon tube assembly Brass Type 2500 and 2500T 3 to 15 psig 32B1231X012 6 to 30 psig 32B1231X022 Type 2500S 0 to 20 psig 32B1233X012 0 to 35 psig 32B1233X022 Type 2503 0 to 20 psig 32B1234X012 0 to 35 psig 32B1234X022 Stainless steel Type 2500 and 2500T 3 to 15 psig 32B123...

Page 31: ... 2500 Series Controller Transmitter Constructions 30A8865 D DOC 30A8869 D DOC 30A8866 C DOC TYPICAL CONTROLLER TYPE 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 ...

Page 32: ...1A621914012 90 Specific gravity adjustment assembly Standard and high temperature 10A8870X0A2 Corrosive service 10A8870X022 215 Nameplate Heat Insulator figure 14 35 Heat Insulator Assembly stainless steel 22A0033X012 36 Shaft Coupling stainless steel 1A577935032 37 Shaft extension N05500 1B681540022 38 Set screw stainless steel 2 req d 1E6234X0022 39 Cap screw pl steel 4 req d 1A381624052 40 Cap ...

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