Emerson Fisher 2503, Fisher 2500 Instruction Manual

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Fisher™ 2500 and 2503 Controllers and Transmitters

Contents

Introduction 2.................................

Scope of Manual 2.............................

Description 2.................................

Specifications 2...............................

Educational Services 2.........................

Installation

Sensor Assembly 6............................

Uncrating 6..................................

Controller/Transmitter Orientation 7.............

Mounting Caged Sensor 8......................

Mounting Cageless Sensor 10...................

Side‐Mounted Sensor 10....................

Top‐Mounted Sensor 12....................

Supply and Output Pressure Connection 12........

Supply Pressure 12.........................

Controller/Transmitter Output Connection 13..

Vent Assembly 13.............................

Prestartup Checks 14...........................

2500 Controller or 2500T Transmitter 17..........

2500S Controller 18...........................

2503 Controller 18............................

Adjustments 19...............................

Control Action 19..........................

Level Adjustment (Controllers Only) 19........

Zero Adjustment (Transmitters Only) 20.......

Proportional Band Adjustment

(Except Transmitters and 2503

Controllers) 20..........................

Specific Gravity Adjustment

(Transmitters Only) 20...................

Calibration

Precalibration Requirements 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

2500 Controller 27............................

2500T Transmitter 27..........................

2500S Controller 27...........................

2503 Controller 27............................

Figure 1. Fisher 2500 or 2503 Controller/Transmitter
on 249 Caged Sensor

5....................................

2500 OR 2503
CONTROLLER/
TRANSMITTER

249 SENSOR

W8334

Principle of Operation 27........................

2500 Controller or 2500T Transmitter 28..........

20...................................

Proportional Valve 28..........................

2500S Controller 28...........................

2503 Controller 29............................

Maintenance 30................................

Troubleshooting 31............................

Removing Controller/Transmitter from Sensor 32..

Changing Mounting Methods 33.................

Installing Controller/Transmitter on Sensor 34.....

Replacing the Bourdon Tube 35..................

Changing Action 35............................

Relay Deadband Testing (2500 Controller

27......................................

or 2500T Transmitter Only) 36................

Replacing the Proportional Valve 37..............

Changing Relay 37.............................

Parts Ordering 37...............................

Parts List 38...................................

www.Fisher.com

2500 and 2503 Controllers/Transmitters

June 2017

Instruction Manual

D200124X012

Introduction

Scope of Manual

This manual provides installation, operating, calibration, maintenance, and parts ordering information for 2500 and
2503 pneumatic controllers and transmitters used in combination with 249 displacer sensors.

Note

This manual does not include installation or maintenance procedures for the supply pressure regulator, sensor, or other devices.
For that information, refer to the appropriate instruction manual for the other device.

Do not install, operate, or maintain a 2500 or 2503 pneumatic controller/transmitter without being fully trained and
qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or

property damage, it is important to carefully read, understand, and follow all contents of this quick start guide,
including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson

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 density (specific
gravity). Each unit consists of a 249 displacer‐type fluid level sensor and a 2500 or 2503 pneumatic controller or
transmitter. Figure 1 shows a typical controller‐sensor combination.

Specifications

Refer to table 1 for specifications.

Educational Services

For information on available courses for 2500 or 2503 controller/transmitter as well as a variety of other products,
contact:

Emerson Automation Solutions
Educational Services - Registration
Phone: [phone] or 1-800-338-8158
E-mail: [e-mail]
emerson.com/fishervalvetraining

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Instruction Manual

D200124X012

Table 1. Specifications

2500 and 2503 Controllers/Transmitters

June 2017

Available Configurations

(1)

2500—Proportional‐only controller
2500C—Proportional‐only controller with indicator

(see figure 10)

2500R—Reverse acting proportional‐only controller
2500S—Differential gap (snap acting) controller. See

changing controller action procedure and figure 15

2500T—Transmitter
2503—Differential gap controller without

proportional valve; for applications requiring very
little adjustment

Input Signal

Fluid Level or Fluid‐to‐Fluid Interface Level: From 0 to
100% of displacer length—standard lengths for all
sensors are 356 mm or 812 mm
(14 inches or 32 inches). Other lengths available
depending on sensor construction.

Fluid Density: From 0 to 100% of displacement force
change obtained with given displacer volume.
Standard volume for displacers are listed in table 2.

Output Signal

2500 Controller and 2500T Transmitter: 0.2 to 1 bar
(3 to 15 psig) or 0.4 to 2 bar (6 to 30 psig)

2500S and 2503 Differential Gap Controllers: 0 bar (0
psig) when switched off and full supply [1.4 or 2.4 bar
(20 or 35 psig) nominal depending on controller
output pressure range] when switched on.

Area Ratio of Relay Diaphragms

3:1

Supply Pressure Data

See table 3

(2)

Supply Medium

Air or Natural Gas
Supply medium must be clean, dry, and noncorrosive

Per ISA Standard 7.0.01

A maximum 40 micrometer particle size in the air
system is acceptable. Further filtration down to 5
micrometer particle size is recommended. Lubricant
content is not to exceed 1 ppm weight (w/w) or
volume (v/v) basis. Condensation in the air supply
should be minimized

(continued)

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 equipped with an
integrally mounted 67CFR 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 Controllers and Transmitters (2500, 2500C,
2500R, 2500S, and 2500T): See table 3

2503 Controller: Vents only when relay is exhausting

Proportional Band Adjustment (Proportional‐Only
Controllers)

Full output pressure change adjustable over 10 to
100% of displacer length

(4)

Differential Gap Adjustment (Differential Gap
Controllers)

2500S Controller: Full output pressure change
adjustable from 20 to 100% of displacer length.

(4)

2503 Controller: Full output pressure change
adjustable over approximately 25 to 40% of displacer

(4)

length

Span Adjustment (2500T Transmitter)

Full output pressure change adjustable from 20 to
100% of displacer length

(4)

Set Point (controllers only) or Zero (transmitters
only) Adjustment

For proportional‐only controllers or transmitters,
level adjustment positions the set point or zero for
the fluid level, interface level, or displacer force
change (density) within the displacer length.
For differential gap controllers, level adjustment
simultaneously positions both ends of the gap within
the displacer length.

3

2500 and 2503 Controllers/Transmitters

June 2017

Table 1. Specifications (Continued)

Instruction Manual

D200124X012

Performance

Independent Linearity (transmitters only): 1% of
output pressure change for 100% span.
Hysteresis: 0.6% of output pressure change at 100%
proportional band, differential gap, or span

Typical Ambient Temperature Operating Influence

Output pressure changes 1.5% per 10_C (50_F)
change in temperature at 100% proportional band
when using a standard wall torque tube with 249
sensors

Repeatability: 0.2% of displacer length or
displacement force change

Deadband (except differential gap controllers

(5)

):

0.05% of proportional band or span
Typical Frequency Response: 4 Hz and 90 degree
phase shift at 100% proportional band with output

Hazardous Area Classification

2500 and 2503 controllers/transmitters comply with
the requirements of ATEX Group II Category 2 Gas

and Dust
piped to typical instrument bellows using 6.1 meters
(20 feet) of 1/4‐inch tubing

Ambient Operating Temperature Limits

For ambient temperature ranges and guidelines for
use of the optional heat insulator assembly, see figure

(3)

Supply and Output Connections

1/4 NPT internal

2. Relay temperature limits are:

Standard Construction: ‐40 to 71_C (‐40 to 160_F)
High‐Temperature Construction: ‐18 to 104_C

(0 to 220_F)

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.

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 (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 not be exceeded.

4. These statements apply only to units sized to produce a full output change for a 100% level change at the maximum proportional band dial setting.

5. Adjusting the span of the differential gap controller is equivalent to adjusting the deadband.

Maximum Working Pressure (sensors only)

Refer to the appropriate sensor instruction manual

Table 2. Standard Displacer Volumes

Sensor

249, 249B, 249BF, 249BP, 249K, 249P, 249W
249C, 249CP, 249W
249L
249VS

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.

Standard Volume

Liters

1.6

1.0

1.9

(3)

1.3

Table 3. Supply Pressure Data

STANDARD SUPPLY AND

OUTPUT SIGNAL RANGE

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

0.4 to 2 bar (6 to 30 psig) 0 to 60 psig 2.4 35 7 scfh

1. Consult your Emerson Automation Solutions 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 m

4

OUTPUT

PRESSURE GAUGE

INDICATIONS

3

/hr at 0_C and 1.01325 bar, multiply scfh by 0.0258.

(1)

NORMAL OPERATING

SUPPLY PRESSURE

Bar Psig Minimum

(2)

AIR CONSUMPTION AT

NORMAL OPERATING

SUPPLY PRESSURE

(3)

(5)

(5)

Maximum

27 scfh

42 scfh

Standard Volume

Cubic Inches

(1)

100

(2)

60

120

(3)

80

(4)

(5)

(5)

SUPPLY PRESSURE

3 bar (45 psig)

3 bar (45 psig)

MAXIMUM

Instruction Manual

PROCESS TEMPERATURE ( C)

D200124X012

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

2500 and 2503 Controllers/Transmitters

June 2017

AMBIENT TEMPERATURE (_C)

01020

−10

−18

1100

_

800

HEAT INSULATOR

30 40 50 60 70

REQUIRED

400

0

−20

−40

PROCESS TEMPERATURE ( F)

NO INSULATOR NECESSARY

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

0 20 40 60 80 100 120 140 160

AMBIENT TEMPERATURE (_F)

STANDARD CONTROLLER OR TRANSMITTER

NOTE:
FOR APPLICATIONS BELOW -29_C (-20_F), BE SURE THE SENSOR MATERIALS OF CONSTRUCTION
ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.

CV6190-E
B1413‐3

TOO
HOT

71

593
500

_

_

400
300

200
100

−18

−29

−40

PROCESS TEMPERATURE ( C)

PROCESS TEMPERATURE ( F)

AMBIENT TEMPERATURE (_C)

0

10 20

30 40 50 60 70

1100

800

400

−18

−10

HEAT INSULATOR
REQUIRED

NO INSULATOR NECESSARY

0

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

−20
0 20 40 60 80 100 120 140 200

AMBIENT TEMPERATURE (_F)

HIGH‐TEMPERATURE CONTROLLER OR TRANSMITTER

80 90

180160

thank

Table 4. Displacer and Torque Tube Materials

Part Standard Material Other Materials

Displacer 304 Stainless Steel 316 Stainless Steel, N10276, N04400, Plastic, and Special Alloys

Displacer Stem, Driver Bearing,
Displacer Rod and Driver

Torque Tube N05500

1. N05500 is not recommended for spring applications above 232_C (450_F). Contact your Emerson sales office or application engineer if temperatures exceeding this limit are required.

316 Stainless Steel N10276, N04400, other Austenitic Stainless Steels, and Special Alloys

(1)

316 Stainless Steel, N06600, N10276

100

TOO
HOT

105

220

593
500
400
300
200
100
0

_

Installation

2500 and 2503 controller/transmitters work in combination with 249 displacer‐type sensors. The factory attaches the
controller/transmitter to the sensor, unless it is ordered separately.

If using natural gas as the pneumatic supply medium, natural gas will be used in the pressure connections of the unit
to any connected equipment. The unit will vent natural gas into the surrounding atmosphere.

WARNING

Always wear protective clothing, gloves, and eyewear 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.

CAUTION

Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed
by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.

5

2500 and 2503 Controllers/Transmitters

June 2017

Instruction Manual

D200124X012

WARNING

Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and
preventive measures are not taken. Preventive measures may include, but are not limited to, one or more of the following:
Remote venting of the unit, re‐evaluating the hazardous area classification, ensuring adequate ventilation, and the
removal of any ignition sources. For information on remote venting of this controller refer to page 13.

Sensor Assembly

Table 2 lists sensors recommended for use with controller/transmitters. Table 4 contains displacer and torque tube
materials. For sensor installation and maintenance, refer to the appropriate sensor instruction manual.

WARNING

When replacing the sensor assembly, the displacer may retain process fluid or pressure. Personal injury or property
damage may occur due to sudden release of the pressure. Contact with hazardous fluid, fire, or explosion can be caused by
puncturing, heating, or repairing a displacer retaining process pressure or fluid. This danger may not be readily apparent
when disassembling the sensor assembly or removing the displacer. Before disassembling the sensor or removing the
displacer, observe the more specific warning provided in the sensor instruction manual.

Uncrating

Unless ordered separately, the controller/transmitter is attached to the sensor when shipped. Carefully uncrate the
assembly.

CAUTION

Sensors used for interface or density control may be so large and heavy that the torque tube cannot fully support their
weight in air. On the 249VS, a travel stop is used to prevent damage. Do not remove this travel stop assembly without first
removing the displacer from the displacer rod. Refer to the appropriate instruction manual for 249 cageless sensors.

Note

Caged sensors have rods and blocks installed at each end of the displacers to protect the displacers in shipping. Remove these
parts before you install the sensor to allow the displacer to function properly.

Caged sensors come with the displacer installed in the cage. If a tubular gauge glass is ordered with the sensor, the
gauge glass is crated separately and must be installed at the site. A damping plate is installed in the lower screwed or
flanged connection (see figure 3) to provide more stable operation. Be certain that the cage equalizing connections
and the damping plate are not plugged by foreign material.

6

Instruction Manual

D200124X012

Figure 3. Damping Plate Location

W2141-1B

2500 and 2503 Controllers/Transmitters

June 2017

DISPLACER

CAGE

SCREWED
CONNECTION

DAMPING PLATE

W0144-1

FLANGED
CONNECTION

A cageless sensor comes with its displacer separated from the sensor assembly. Displacers longer than 813 mm (32
inches) come in a separate crate. Shorter displacers come in the same crate as the sensor, but are not attached to their
displacer rods. Inspect the displacer to ensure it is not dented. A dent may reduce the pressure rating of the displacer.
If a displacer is dented, replace it.

Controller/Transmitter Orientation

The controller/transmitter attaches to the sensor in one of the mounting positions shown in figure 4. Right‐hand
mounting is with the controller or transmitter case to the right of the displacer when you look at the front of the case;
left‐hand mounting is with the case to the left of the displacer. The mounting position can be changed in the field.
Changing this mounting position changes the control action from direct to reverse, or vice versa.

All caged sensors have a rotatable head. That is, the controller/transmitter may be positioned at any of eight alternate
positions around the cage as indicated by the numbers 1 through 8 in figure 4. To rotate the head, remove the head
flange bolts and nuts and position the head as desired.

7

2500 and 2503 Controllers/Transmitters

June 2017

Figure 4. Cage Head Mounting Positions

Instruction Manual

D200124X012

RIGHT‐HAND MOUNTING

1 67CFR FILTER/REGULATOR.

AH9150-A
A2613-2

LEFT‐HAND MOUNTING

Mounting Caged Sensor

Note

Install the cage so that it is plumb; the displacer must not touch the cage wall. If the displacer touches the cage wall, the unit will
transmit an erroneous output signal.

Note

If the controller/transmitter is not mounted on the sensor, refer to the Installing Controller/Transmitter on Sensor procedures in
the Maintenance section. This section also provides instructions for adding a heat insulator to a unit.

Cage connections normally are either NPS 1‐1/2 or 2, screwed or flanged. Figure 5 shows the combinations. With
flanged connections, use standard gaskets or other flat‐sheet gaskets compatible with the process fluid. Spiral‐wound
gaskets without compression‐controlling centering rings cannot be used for flange connections.

8

Instruction Manual

D200124X012

Figure 5. Cage Connection Styles

2500 and 2503 Controllers/Transmitters

June 2017

STYLE 1: TOP
AND BOTTOM

SCREWED: S1
FLANGED: F1

A1271-2

STYLE 2: TOP
AND LOWER SIDE

SCREWED: S2
FLANGED: F2

STYLE 3: UPPER
AND LOWER SIDE

SCREWED: S3
FLANGED: F3

STYLE 4: UPPER
SIDE AND BOTTOM

SCREWED: 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

CENTER OF LIQUID
OR INTERFACE LEVEL

DF5379‐A
A1883‐2

EQUALIZING LINE

SHUTOFF
VALVES

DRAIN VALVE

EQUALIZING LINE

9

2500 and 2503 Controllers/Transmitters

June 2017

Instruction Manual

D200124X012

On fluid or interface level applications, position the sensor so that the center line on the cage (see figure 6) is as close
as possible to the center of the fluid level or interface level range being measured. Also consider installing a gauge
glass on the vessel, or on the sensor cage (if the cage is tapped for a gauge).

Mounting Cageless Sensor

Note

If a stillwell is used, install it plumb so that the displacer does not touch the wall of the stillwell. If the displacer touches the wall,
the unit will transmit an erroneous output signal.

Since the displacer hangs inside the vessel, provide a stillwell around the displacer if the fluid is in a state of continuous
agitation to avoid excessive turbulence around the displacer.

Note

Displacers used in an interface level application must be completely submerged during operation. If displacers aren't completely
submerged, they will not calibrate or perform properly. To obtain the desired controller or transmitter sensitivity may require
using either a thin‐wall torque tube, an oversized displacer, or both.

Note

If the controller/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 Sensor

If a stillwell is required (see figure 7), attach the displacer to the displacer rod from inside the vessel.

Connect the displacer as shown in figure 8, locking the assembly with the cotter spring provided. If a stillwell is not
required, attach the displacer rod before mounting the sensor on the vessel. Then, you can swing the displacer out
horizontally for insertion into the vessel. However, once the sensor is installed and the displacer drops to a vertical
position, the displacer may not be capable of being withdrawn for servicing later. Be sure there is another access to the
displacer to permit swinging it to a horizontal position or to permit disconnecting it from the displacer rod.

If an extension is used between the displacer spud and the displacer stem end piece, make sure the nuts are tight at
each end of the displacer stem extension. Install and tighten suitable bolting or cap screws in the flanged connection
to complete the installation.

10

Instruction Manual

D200124X012

Figure 7. Cageless Sensor Mounting

2500 and 2503 Controllers/Transmitters

June 2017

TOP MOUNTED

SIDE MOUNTED

W9517‐1

SIDE VIEW (SHOWING STILLWELL)

Figure 8. Displacer and Displacer Rod Connections

COTTER SPRING

DISPLACER ROD

DISPLACER

STEM EXTENSION

LOCKING NUTS

DISPLACER
SPUD

CF5380‐A
A3893

SIDE VIEW (WITHOUT STILLWELL)

COTTER SPRING

W9357

249VS

DISPLACER SPUD

W0228‐1A

DISPLACER ROD

ALL OTHER TYPES

11

2500 and 2503 Controllers/Transmitters

June 2017

Instruction Manual

D200124X012

Top‐Mounted Sensor

CAUTION

If inserting the displacer into the vessel before attaching to the displacer rod, provide a means of supporting the displacer
to prevent it from dropping into the vessel and suffering damage.

Figure 7 shows an example of a top‐mounted cageless sensor. You may attach the displacer to the displacer rod before
installing the sensor on the vessel. If the displacer diameter is small enough, you may install a long or sectionalized
displacer through the sensor head access hole after the sensor is installed on the vessel. Connect the displacer as
shown in figure 8, locking the assembly with the cotter springs provided. If a stem extension is used between the
displacer spud and the stem end piece, make sure the nuts are tight at each end of the stem. Install and tighten
suitable cap screws in the flanged connection to complete the installation.

A special travel stop may be provided on top‐mounted sensors to aid in servicing of the sensor. This option prevents
dropping the displacer and stem when the displacer rod is disconnected.

Supply and Output Pressure Connections

WARNING

To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any system
component where service conditions could exceed the limits given in this manual. Use pressure‐relieving devices as
required by government or accepted industry codes and good engineering practices.

CAUTION

Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed
by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.

Figure 9 shows dimensions, locations, and connections for controller/transmitter installation. All pressure connections
to the controller/transmitter are 1/4 NPT internal.

Supply Pressure

WARNING

Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oil‐free
air, or noncorrosive gas. While use and regular maintenance of a filter that removes particles larger than 40 micrometers in
diameter will suffice in most applications, check with an Emerson Automation Solutions field office and industry
instrument air quality standards for use with corrosive air or if you are unsure about the proper amount or method of air
filtration or filter maintenance.

Supply pressure medium must be clean, dry, and noncorrosive and meet the requirements of ISA Standard 7.0.01 or
ISO 8573-1. A maximum 40 micrometer particle size in the air system is acceptable. Further filtration down to 5

12