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2502 Series Controllers

Instruction Manual

Form 1446

November 2006

2

No person may install, operate, or maintain this

product without first 

D

 being fully trained and

qualified in valve, actuator, and accessory

installation, operation, and maintenance, and 

D

carefully reading and understanding the contents of

this manual. If you have any questions about these

instructions, contact your Emerson Process

Management

t

 sales office before proceeding.

Description

The Type 2502 Level-Trol

R

 controller described in

this manual provides proportional-plus-reset and

proportional-plus-reset with differential relief valve

control. The controller output is a pneumatic signal

that operates a final control element. These

controllers are designed to control liquid level, the

level of interface between two liquids, or density

(specific gravity). Each unit consists of a 249 Series

liquid level sensor and a 2502 Series pneumatic

controller.

Refer to the Principle of Operation section for a more

comprehensive discussion of how the Type 2502

pneumatic controller operates.

Specifications

Table 1 gives general specifications for Type 2502

Series controllers.

Educational Services

For information on available courses for the Type

2502 Series Level-Trol Controller, as well as a

variety of other products, contact:

Emerson Process Management

Educational Services, Registration

P.O. Box 190; 301 S. 1st Ave.

Marshalltown, IA 50158

−

2823

Phone: 800

−

338

−

8155 or 

Phone: 641

−

754

−

3771

Fax: 641

−

754

−

3431

e-mail: [email protected]

Note

Neither Emerson, Emerson Process

Management, nor any of their affiliated

entities assumes responsibility for the

selection, use, and maintenance of any

product. Responsibility for the

selection, use, and maintenance of any

product remains with the purchaser

and end-user.

Installation

The 2502 Series controllers are used in combination

with 249 Series sensors, and unless ordered

separately, the controller will be attached to the

sensor.

WARNING

Wear protective eyewear, gloves and

clothing whenever possible when

performing any installation operations

to avoid personal injury.
Check with your process or safety

engineer for any additional measures

that must be taken to protect against

process media.
If installing into an existing

application, also refer to the WARNING

at the beginning of the Maintenance

section in this instruction manual.

WARNING

Personal injury or property damage

may result from fire or explosion if

natural gas is used as the supply

medium and preventative measures

are not taken. Preventative measures

may include: Re-evaluating the

hazardous area classification,

ensuring adequate ventilation, and the

removal of any ignition sources.

Содержание Fisher Level-Trol 2502 Series

Страница 1: ... Controller 15 Type 2502F Controller with Reset Relief Valve 17 Maintenance 18 Troubleshooting 18 Removing Controller from Sensor 18 Changing Mounting Method 20 Installing Controller on Sensor 20 Changing Proportional Reset or Differential Relief Valve 21 Testing Relay Dead Band 21 Changing Relay 21 TYPE 2502 CONTROLLER 249B SERIES SENSOR W8334 Figure 1 Type 2502 Controller Mounted on Type 249B Se...

Страница 2: ... Trol Controller as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 301 S 1st Ave Marshalltown IA 50158 2823 Phone 800 338 8155 or Phone 641 754 3771 Fax 641 754 3431 e mail education emersonprocess com Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection us...

Страница 3: ...4 to 2 0 bar 6 to 30 psig output signal Maximum Supply Pressure 4 3 4 bar 50 psig Supply Pressure Consumption 5 At 1 4 bar 20 Psig Minimum 0 11 normal m3 h 4 2 scfh at proportional band setting of 0 or 200 percent Maximum 0 72 normal m3 h 27 scfh at proportional band setting of 100 percent At 2 4 bar 35 psig Minimum 0 2 normal m3 h 7 scfh at proportional band setting of 0 or 200 percent Maximum 1 ...

Страница 4: ...NO INSULATOR NECESSARY AMBIENT TEMPERATURE _C STANDARD CONTROLLER OR TRANSMITTER AMBIENT TEMPERATURE _F HEAT INSULATOR REQUIRED TOO HOT NOTE FOR SERVICE BELOW 29_C 20_F CONTACT FACTORY PROCESS TEMPERATURE C _ PROCESS TEMPERATURE F _ B1413 1 IL 0 20 40 60 80 100 120 140 200 0 10 20 18 10 30 40 50 60 70 93 593 500 400 300 200 100 0 0 400 800 1100 20 29 NO INSULATOR NECESSARY AMBIENT TEMPERATURE _C H...

Страница 5: ...or assembly A displacer longer than 813 mm 32 inches is crated separately A shorter displacer is crated with the sensor but is 1 4 18 NPT SUPPLY CONNECTION ADJUSTING SCREW DRAIN VALVE LOCKNUT 1 4 18 NPT OUTPUT CONNECTION VENT PRESSURE REGULATOR Figure 3 Pressure Connections not attached to the displacer rod Inspect the displacer and replace if it is dented A dent may reduce the pressure rating of ...

Страница 6: ...ge connections will normally be either 1 1 2 or 2 inch screwed or flanged Figure 5 shows the combinations With flanged connections use standard gaskets or other flat sheet gaskets compatible with the process liquid Spiral wound gaskets without compression controlling centering rings cannot be used for flanged connections Mount the cage by running equalizing lines between the cage connections and t...

Страница 7: ...t an erroneous output signal Since the displacer hangs inside the vessel provide a stillwell around the displacer if the liquid is in a state of continuous agitation to avoid excessive turbulence around the displacer Note Displacers used in an interface level application must be completely submerged during operation If displacers aren t completely submerged they will not calibrate or perform prope...

Страница 8: ...el connection The displacer may then be swung out horizontally for insertion into the vessel However once the sensor is installed and the displacer drops to a vertical position the displacer may not be capable of being withdrawn for servicing later Be sure there is another access to the displacer to permit swinging it to a horizontal position or to permit disconnecting it from the displacer rod W0...

Страница 9: ... pressure and check all connections for leaks Prestartup Checks WARNING The following procedure requires taking the controller out of service To avoid personal injury and property damage caused by an uncontrolled process provide some temporary means of control for the process before taking the controller out of service Adjustment locations are shown in figure 9 unless otherwise indicted When perfo...

Страница 10: ...r Adjustments 1 Turn on the supply pressure and check that the controller supply gauge reads 1 4 bar 20 psig for a 0 2 to 1 0 bar 3 to 15 psig output pressure range or 2 4 bar 35 psig for a 0 4 to 2 0 bar 6 to 30 psig output pressure range If the pressure is incorrect loosen the locknut of the filter regulator figure 3 turn the adjusting screw clockwise to increase or counterclockwise to decrease ...

Страница 11: ...he unit would appear to be out of calibration and recalibration may be desirable See the Calibration Procedure on page 14 On a controller with level indicator the pointer should reflect the magnitude of the process variable for instance with liquid or interface level covering 50 percent of the displacer the pointer should be in the middle of the high low scale Slight plate adjustment might be nece...

Страница 12: ...sel For caged sensors pour the liquid into the cage For cageless sensors suspend the displacer to an appropriate depth in a liquid having a specific gravity equal to that of the process liquid If necessary use water for wet calibration in the shop However this procedure requires compensation for the difference between the specific gravity of the water and that of the process liquids For example as...

Страница 13: ...ondition of liquid level or specific gravity solve the following equation Ws Wd 0 0361 V SP GR where Ws Total suspended weight in pounds should never be less than 0 5 pounds For a unit with a horizontal displacer make sure the center of gravity of the substitute weight is where it would be on the actual displacer Note For liquid level control only simulate the lower range limit of the input span b...

Страница 14: ...Rotate the reset knob to 0 01 minutes per repeat 3 Rotate the proportional band knob to zero 4 Set the liquid at the minimum limit dry displacer 5 Turn the RAISE LEVEL knob to zero 6 Adjust the nozzle until output pressure is between 0 and 0 2 bar for a 0 2 to 1 0 bar signal range 0 and 3 psig for a 3 to 15 psig signal range or 0 and 0 4 bar for a 0 4 to 2 0 bar signal range 0 and 6 psig for a 6 t...

Страница 15: ...roller which uses a nozzle bellows and pneumatic relay to convert the rotary motion to a standard pneumatic output signal The output signal is sent to a final control element In conjunction with this control element 2502 249 Series controller sensors are capable of bringing the controlled variable back to a specific control point all the time The following descriptions show how the relay works in ...

Страница 16: ...OT BEAM AND FLAPPER CAM RESET VALVE PROPORTIONAL VALVE FIXED RESTRICTION EXHAUST END OF RELAY VALVE LARGE DIAPHRAGM OF ASSEMBLY SMALL DIAPHRAGM OF ASSEMBLY INLET END OF RELAY VALVE SUPPLY PRESSURE REGULATOR DIRECT ACTING DIAPHRAGM CONTROL VALVE VESSEL INFLOW PROPORTIONAL PRESSURE SUPPLY PRESSURE OUTPUT PRESSURE NOZZLE PRESSURE RESET PRESSURE EXHAUST NOZZLE Figure 10 Direct Acting Right Hand Mounte...

Страница 17: ...ssure into a reset bellows that opposes proportional bellows action This automatically dampens the effect of any proportional overcorrection by a set amount per time interval as long as there is a deviation from the control point Figure 10 illustrates these principles at work in a direct acting right hand mounted construction controlling liquid inflow to a vessel by means of a direct acting diaphr...

Страница 18: ...sult from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources Check with your process or safety engineer for any additional measures that must be taken to protect against process media Troubleshooting When troubleshooting open loop conditions must exist unless otherwise stated When monitoring the process variable use the mos...

Страница 19: ... 4 Flapper adjustment 2 4 Insure the flapper is not loose on the torque tube shaft and is centered on the nozzle 2 4 Replace or tighten flapper assembly as necessary and or center flapper on nozzle 2 5 Process variable changed 2 5 Insure the process variable has not changed from original calibration settings or displacer not design specific gravity of process 2 5 Change process variable back to or...

Страница 20: ...que tube arm in the opposite position according to the appropriate instruction manual 3 Check the desired control action to determine if it is also necessary to reverse the controller action The nozzle block and bellows tubing should be arranged in the proper position as shown in figure 13 4 Remove the RAISE LEVEL dial turn it over and install it in the desired position The arrow on it under the w...

Страница 21: ...band 2 To change the reset restriction valve assembly key 91 remove the two mounting screws key 182 located on the back side of case Install the replacement valve assembly and reconnect the tubing connections 3 Remove the differential relief valve assembly key 186 figure 14 by removing the two mounting screws figure 9 that anchor the valve to the manifold key 184 figure 14 Install the valve with t...

Страница 22: ...to the bellows frame Unscrew each bellows from the spacer key 98 being careful not to lose the O ring key 57 not shown from the spacer end of the bellows 3 Inspect each bellows and O ring and replace if necessary using an unpainted bellows for a 0 2 to 1 0 bar 3 to 15 psig range and a red bellows for a 0 4 to 2 0 bar 6 to 30 psig range Be sure to install the O ring at the spacer end of the bellows...

Страница 23: ...ponsibility for the selection use and maintenance of any product remains with the purchaser and end user Parts Kits Description Part Number Controller Parts Kit Contains keys 12 15 21 24 38 55 57 58 60 62 63 64 77 79 84 86 87 93 101 and 187 Standard Temperature R2502X00L52 High Temperature R2502X00H52 Relay Replacement Kit Contains keys 22 43 and the relay assembly Standard Temperature RRELAYX0L22...

Страница 24: ...2502 Series Controllers Instruction Manual Form 1446 November 2006 24 30A8942 H DOC 43A2366 H DOC 30A8943 H DOC Figure 14 2502 Series Controller Constructions ...

Страница 25: ...l 1U639135132 59 Beam steel pl 1K873825072 60 Flapper K93600 alloy 1J416241132 61 Flapper Base stainless steel 1J416335032 62 Connecting Link N04400 1L379641012 63 Sealing Screw stainless steel 14A5721X012 64 Screw stainless steel 24A5720X012 65 Bellows Ass y brass 2 req d 0 2 to 1 0 bar 3 to 15 psig 14A5726X012 0 4 to 2 0 bar 6 to 30 psig 14A5726X032 66 Level Set Arm steel pl 1J416425072 67 Opera...

Страница 26: ...2F and 2502FC 1D6875X0132 184 Manifold aluminum Type 2502F and 2502FC 23A2072X012 185 Manifold Nipple aluminum Type 2502F and 2502FC 13A2074X012 Key Description Part Number 186 Differential Relief Valve Ass y Types 2502F and 2502FC Standard 21A6447X0A2 High temperature 21A6447X012 187 Sleeve plastic 16A0976X012 188 0 Ring Types 2502F and 2502FC 1C8538X0132 215 Nameplate metal Pipe Plug Types 2502 ...

Страница 27: ...2502 Series Controllers Instruction Manual Form 1446 November 2006 27 ...

Страница 28: ... designs or specifications of such products at any time without notice Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use and maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user EFisher Controls International LLC 1977 2006 All Rights Reserved ...

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