Emerson Fisher Level-Trol 2502R, Fisher Level-Trol 2502CR, Fisher Level-Trol 2502, Fisher Level-Trol 2502C, Fisher Level-Trol 2502F Instruction Manual

...
Instruction Manual
Form 1446 November 2006
2502 Series Controllers
2502 Series Level-TrolR Controller
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Educational Services 2. . . . . . . . . . . . . . . . . . . . . .
Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
249 Series Sensors 4. . . . . . . . . . . . . . . . . . . . . . .
Uncrating 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Orientation 5. . . . . . . . . . . . . . . . . . . . .
Controller-Sensor Action 5. . . . . . . . . . . . . . . . . . .
Mounting Caged Sensors 6. . . . . . . . . . . . . . . . . .
Mounting Cageless Sensors 7. . . . . . . . . . . . . . .
Side-Mounted Sensor 8. . . . . . . . . . . . . . . . . . . .
Top-Mounted Sensor 8. . . . . . . . . . . . . . . . . . . .
Regulator Supply Pressure 9. . . . . . . . . . . . . . . .
Prestartup Checks 9. . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Set Adjustment 11. . . . . . . . . . . . . . . . . . .
Proportional Band Adjustment 11. . . . . . . . . . . .
Reset Adjustment 11. . . . . . . . . . . . . . . . . . . . . .
Differential Relief Adjustment 12. . . . . . . . . . . .
Calibration 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precalibration Requirements 12. . . . . . . . . . . . . .
Wet Calibration 12. . . . . . . . . . . . . . . . . . . . . . . . .
Dry Calibration 12. . . . . . . . . . . . . . . . . . . . . . . . .
Controller and Torque Tube Arm
Disassembly 12. . . . . . . . . . . . . . . . . . . . . . . .
Determining Suspended Weight
for Calibration 13. . . . . . . . . . . . . . . . . . . . . . .
Calibration Procedure 14. . . . . . . . . . . . . . . . . . . .
Startup 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of Operation 15. . . . . . . . . . . . . . . . . . . . .
Type 2502 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. . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Scope of Manual

This instruction manual provides installation, operating, calibration, and maintenance procedures for 2502 Series pneumatic controllers (figure 1) used in combination with 249 Series level sensors.
This manual does not include regulator or sensor installation or maintenance procedures. For this information, refer to the instruction manual for the appropriate regulator and 249 Series level sensor.
W8334
Figure 1. Type 2502 Controller Mounted on
Type 249B Sensor
Replacing Bellows 22. . . . . . . . . . . . . . . . . . . . . . .
Reversing Action 22. . . . . . . . . . . . . . . . . . . . . . . .
Parts Ordering 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPE 2502 CONTROLLER
249B SERIES SENSOR
www.Fisher.com
D200126X012
2502 Series Controllers
Instruction Manual
Form 1446
November 2006
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 Managementt sales office before proceeding.

Description

The Type 2502 Level-TrolR 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

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.
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 501582823 Phone: 8003388155 or Phone: 6417543771 Fax: 6417543431 e-mail: education@emersonprocess.com
2
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.
Instruction Manual
Form 1446 November 2006
2502 Series Controllers
Table 1. Specifications
Available Configurations
Type 2502: A direct-acting controller which
provides proportional-plus-reset control Type 2502C: A Type 2502 with a level indicator assembly Type 2502F: A Type 2502 with a differential relief valve
These type numbered products are also available with reverse action. For example, Type 2502R, Type 2502CR, and 2502FR
Input Signal
(1)
Liquid Level or Liquid-to-Liquid Interface Level: From 0 to 100 percent of displacer
length—standard lengths for all sensors are 356 mm (14 inches) or 813 mm (32 inches). Other lengths available depending on sensor construction Liquid Density: From 0 to 100 percent of displacement force change obtained with given displacer volume—standard volumes are 980 cm (60 inches3) for Types 249C and 249CP sensors, or 1640 cm
3
(100 inches3) for most other 249 Series sensors; other volumes available depending on construction
Output Signal
(1)
0.2 to 1.0 bar (3 to 15 psig) or 0.4 to 2.0 bar (6 to 30 psig) Action: Field reversible between direct (increasing liquid or interface level or specific gravity increases output pressure) and reverse (increasing liquid or interface level or specific gravity decreases output pressure)
Area Ratio of Relay Diaphragms
3:1
Supply Medium
Air or Natural Gas
(2)
Supply Pressure Requirement
(3)
1.4 bar output signal or 2.4 bar
(20 psig) for 0.2 to 1.0 bar (3 to 15 psig)
(3)
(35 psig) for 0.4 to 2.0
bar (6 to 30 psig) output signal
3
(continued)
Maximum Supply Pressure
(4)
3.4 bar (50 psig)
Supply Pressure Consumption
At 1.4 bar (20 Psig)
Minimum: 0.11 normal m proportional band setting of 0 or 200 percent Maximum: 0.72 normal m
(5)
3
/h (4.2 scfh) at
3
/h (27 scfh) at
proportional band setting of 100 percent
At 2.4 bar (35 psig)
Minimum: 0.2 normal m band setting of 0 or 200 percent Maximum: 1.1 normal m
3
/h (7 scfh) at proportional
3
/h (42 scfh) at
proportional band setting of 100 percent
Performance
Hysteresis: 0.6 percent of output pressure
change at 100 percent of proportional band
Repeatability
or displacement force change
Dead Band
(1)
: 0.2 percent of displacer length
(1)
: 0.05 percent of proportional band
or span
Typical Frequency Response
(1)
: 4 Hz and
90-degree phase shift at 100 percent of proportional band with output piped to typical instrument bellows using 6.1 meters (20 feet) of
6.4 mm (1/4 inch) tubing Ambient Temperature Error: $1.5 percent of
output pressure change per 50_F (28_C) of temperature change at 100 percent of proportional band when using sensor with standard-wall N05500 torque tube with 249 Series sensors
(1)
Reset
: Adjustable from 0.01 to 74 minutes per
repeat (100 to 0.01 repeats per minute)
Differential Relief (Type 2502F and 2502FR Controllers Only): Adjustable from 0.1 to 0.48
bar differential (2 to 7 psi) to relieve excessive difference between proportional and reset pressures. Differential relief can be switched between rising output pressure and falling output pressure.
Standard Tubing Connections
1/4-inch NPT female
Maximum Working Pressures (Sensors Only)
Consistent with applicable ASME pressure/temperature ratings
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2502 Series Controllers
Instruction Manual
Form 1446
November 2006
Table 1. Specifications (continued)
Hazardous Area Classification
Declaration of SEP
2502 Series controllers comply with the requirements of ATEX Group II Category 2 Gas and Dust
Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 of the Pressure Equipment Directive (PED) 97 / 23 / EC. It was designed and
Operative Ambient Temperatures
(4)
Standard Construction: 40 to 71_C (*40 to
manufactured in accordance with Sound Engineering Practice (SEP) and cannot bear the CE marking related to PED compliance.
160_F*) High Temperature Construction: *18 to 104_C (0 to 220_F).
See figure 2.
1. Term defined in ISA Standard S51.1.
2. Natural gas should contain no more that 20 ppm of H2S.
3. Control and stability may be impaired if this pressure is exceeded.
4. The pressure/temperature limits in this document, and any applicable standard or code limitation should not be exceeded.
5. Normal cubic meters per hour (m
AMBIENT TEMPERATURE (_C)
18 10
1100
_
800
400
0
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY
PROCESS TEMPERATURE ( F)
CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
20 29 0 20 40 60 80 100 120 140 160
01020
HEAT INSULATOR REQUIRED
NO INSULATOR NECESSARY
AMBIENT TEMPERATURE (_F)
STANDARD CONTROLLER OR TRANSMITTER
3
/hr) at 0_C and 1.01325 bar. Scfh=standard cubic feet per hour at 60_F and 14.7 psia .
30 40 50 60 70
TOO HOT
71
593
500
_
400
300
200
100
0
18 10
1100
_
800
400
0
PROCESS TEMPERATURE ( F)
PROCESS TEMPERATURE ( C)
20 29 0 20 40 60 80 100 120 140 200
NOTE: FOR SERVICE BELOW −29_C (−20_F) CONTACT FACTORY.
B1413-1/IL
However, the product may bear the CE marking to indicate compliance with other applicable EC Directives.
01020
HEAT INSULATOR REQUIRED
NO INSULATOR NECESSARY
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
HIGH-TEMPERATURE CONTROLLER OR TRANSMITTER
AMBIENT TEMPERATURE (_C)
30 40 50 60 70
AMBIENT TEMPERATURE (_F)
80 90
TOO HOT
180160
93
593
500
400
300
200
100
0
Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

249 Series Sensors

D The Type 249, 249B, 249C, 249K, and 249L sensors side-mount on the vessel with the displacer mounted inside a cage (caged) outside the vessel.
D The Type 249BP and 249CP sensors top-mount on the vessel with the displacer hanging down into the vessel (cageless).
D The Type 249V sensor side-mounts on the vessel with the displacer hanging out into the vessel (cageless).
D The Type 249W sensor top-mounts on the vessel or on a customer supplied cage.
4
External sensors provide more stable operation than do internal sensors for vessels with internal obstructions or considerable internal turbulence.
WARNING
When replacing the sensor assembly, the displacer may retain process liquid or pressure. Personal injury or property damage due to sudden release of pressure, contact with hazardous liquid, fire, or explosion can be caused by puncturing, heating, or repairing a displacer that is retaining
Instruction Manual
Form 1446 November 2006
2502 Series Controllers
process pressure or liquid. This danger may not be readily apparent when disassembling the sensor 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 will be attached to the sensor when shipped. Carefully uncrate the assembly.
CAUTION
If the sensor has a thin-walled torque tube, always support the displacer if the travel stop must be removed. A thin-walled torque tube has a T stamped on the sensor end flange (not visible unless the controller is removed from the sensor).
Note
Caged sensors have a rod and block installed on each end of the displacer to protect the displacer in shipping. Remove these parts before installing the sensor to allow the displacer to function properly.
Caged sensors will be shipped with the displacer installed in the cage. If the sensor is ordered with a tubular gauge glass, the gauge glass will be crated separately and must be installed at the site. Be certain that the cage equalizing connections are not plugged with foreign material.
A caged sensor has a damping plate installed in the lower screwed or flanged connection to provide more stable operation. If the process liquid could clog the plate opening with sediment, then remove the damping plate. For screwed connections, use a 1/2-inch hexagon wrench to unscrew the damping plate. For flanged connections, use a screwdriver to pry the damping plate out of the flange.
PRESSURE REGULATOR
1/4”-18 NPT OUTPUT CONNECTION
LOCKNUT
VENT
Figure 3. Pressure Connections
ADJUSTING SCREW
1/4”-18 NPT SUPPLY CONNECTION
DRAIN VALVE
not attached to the displacer rod. Inspect the displacer and replace if it is dented. A dent may reduce the pressure rating of the displacer.

Controller Orientation

A controller is to be mounted with the vent opening pointing downward as shown in figure 3. This orientation is necessary to ensure draining of accumulated moisture. The controller is attached to the sensor in one or the other of the mounting positions shown in figure 4: Right hand (with the case to the right of the displacer when looking at the front of the case) or left hand (with the case to the left of the displacer). The mounting position can be changed in the field if required; refer to the appropriate sensor manual for instructions. Changing this mounting position will change controller action from direct to reverse, or vice versa.
All caged sensors have a rotatable head. That is, the controller 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.

Controller-Sensor Action

The following controller description is for right-hand mounting. Left-hand mounting produces an output signal with the opposite action. Figure 4 shows cage head mounting positions.
For right-hand mounting:
D Direct Action—Increasing liquid or interface
level, or density, increases the output signal.
A cageless sensor is shipped with the displacer separated from the sensor assembly. A displacer longer than 813 mm (32 inches) is crated separately. A shorter displacer is crated with the sensor, but is
D Reverse Action—Decreasing liquid or interface level, or density, increases the output signal. A factory-supplied reverse-acting unit has the suffix letter R added to the type number.
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2502 Series Controllers
Instruction Manual
Form 1446
November 2006
RIGHT-HAND MOUNTING
STYLE 1: TOP AND BOTTOM
SCREWED: S1 FLANGED: F1
STYLE 2: UPPER AND LOWER SIDE
STYLE 2: TOP AND LOWER SIDE
SCREWED: S2 FLANGED: F2
STYLE 2: UPPER SIDE AND BOTTOM
AH9150A A26132/IL
Figure 4. Cage Head Mounting Positions
LEFT-HAND MOUNTING

Mounting Caged Sensor

Note
The cage must be installed plumb so that the displacer does not touch the cage wall. Should the displacer touch the cage wall, the unit will transmit an erroneous output signal.
Note
If the controller is not mounted on the sensor, refer to the Installing Controller on Sensor section. This section also provides instructions for adding a heat insulator to a unit.
A12712/IL
SCREWED: S3 FLANGED: F3
Figure 5. Cage Connection Styles
SCREWED: S4 FLANGED: F5
Cage 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 the vessel (figure 6). 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 liquid-trapping low point.
On liquid or interface level applications, position the sensor so that the line marked FLOAT CENTER on the cage is located as close as possible to the center of the liquid level or interface level range being measured. Also consider installing a gauge glass either on the vessel, or on the sensor cage (if the cage is tapped for a gauge).
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Instruction Manual
Form 1446 November 2006
CENTER OF LIQUID OR INTERFACE LEVEL
SHUTOFF VALVES
VENT
EQUALIZING LINE
2502 Series Controllers
DRAIN
DF5379-A A6771/IL
Figure 6. Caged Sensor Mounting

Mounting Cageless Sensor

Note
If a stillwell is used, it must be installed plumb so that the displacer does not touch the wall of the stillwell. Should the displacer touch the wall while the unit is in service, the unit will transmit 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.
W0645-1
SIDE (SHOWING STILLWELL)
TOP MOUNTED
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 sensitivity may require using either a thin-wall torque tube, an oversized displacer, or both.
CF5380-A A3893/IL
TOP
Figure 7. Cageless Sensor Mounting
7
2502 Series Controllers
Note
Instruction Manual
Form 1446
November 2006
If the controller is not mounted on the sensor, refer to the Installing Controller on Sensor 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 liquid level applications, install a gauge glass on the vessel.
CAUTION
If the displacer is to be inserted into the vessel before being attached to the displacer rod, provide a suitable means of supporting the displacer to prevent it from dropping into the vessel and suffering damage.
To help support a Type 249BP or 249CP displacer, install the displacer stem and stem end piece, or a threaded rod, into the 1/4 inch-28 UNF threaded hole in the displacer spud or stem end piece (figure
8). On the Type 249BP with optional travel stop, the stem end piece pins will secure the displacer as long as the travel stop plate is installed and the sensor head is in position.

Side-Mounted Sensor

DISPLACER STEM END PIECE
DISPLACER ROD
DISPLACER STEM EXTENSION
W0229-1A/IL
DISPLACER SPUD
W0228-1A/IL
Figure 8. Displacer/Displacer Rod Connections
TYPE 249V
ALL OTHER TYPES
COTTER SPRING
LOCKING NUTS
DISPLACER SPUD
COTTER SPRING
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.
If a stillwell is required (figure 7), the displacer must be attached 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, the displacer can be attached to the displacer rod before mounting the sensor to the vessel 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.
8

Top-Mounted Sensor

Figure 7 shows the installation of a top-mounted cageless sensor. The displacer may be attached to the displacer rod before installing the sensor on the vessel. Where the displacer diameter is small enough, it may be desirable to 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 is used between the displacer as shown in figure 8, lock the assembly with the cotter springs provided. If a stem is used between the displacer spud and the stem end piece, make sure
Instruction Manual
Form 1446 November 2006
2502 Series Controllers
the nuts are tight at each end of the stem. Install and tighten suitable cap screws in the flanged connection to complete the installation.

Regulator Supply Pressure

WARNING
Do not overpressurize any system component. Personal injury or property damage may occur due to sudden pressure release or explosion. To avoid damage, provide suitable pressure-relieving or pressure limiting devices if supply pressure can exceed the maximum supply pressure listed in table 1.
Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oil-free, or non-corrosive 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 an Emerson Process Management field office and industry instrument air quality standards for used with corrosive gas or if you are unsure about the proper amount or method of air filtration or filter maintenance.
Standard 2502 Series controllers come complete with supply and output pressure gauges and an integrally mounted Type 67CFR regulator to reduce supply pressure from a maximum of 17.3 bar (250 psig) to the 1.4 or 2.4 bar (20 or 35 psig) required. This regulator has built-in relief and a standard 40-micron to remove particles from the supply source.
The output pressure connection is on the back of the controller case (figure 3). Pipe the supply pressure to the in connection of the regulator mounted to the case back. Provide a clean, dry, and noncorrosive air or gas supply to the controller as follows:
After pressure connections have been made, turn on the supply 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 performing the checks open loop conditions must exist. To obtain open-loop conditions:
D make sure there is no process flow through the final control element, or
D disconnect the controller output signal line and plug the output connection.
During startup, it is necessary to change process levels to position the displacer from its maximum to its minimum range of operations. Provide a means to change the process level or interface. If the process variable cannot be varied sufficiently, follow the instructions in the Calibration section to simulate the process variable changes required for these checks.
Make sure that the RAISE LEVEL dial on the controller is mounted with the correct side facing out. The dial is printed on both sides with the arrow on one side pointing to the left and the arrow on the other side pointing to the right. Figure 9 shows the dial arrow positioned for a sensor that is mounted to the left of the controller; the arrow points to the left. If the sensor is to the right of the controller, remove the two mounting screws, turn the dial over so the arrow points to the right, then reinstall the mounting screws.
On a controller with optional level indicator assembly the travel indicator plate is printed on both sides. If the sensor is to the left of the controller (right-hand mounting), use the side of the plate that has the arrow pointing to the left. If displacer is to right of controller (left-hand mounting), use the side of the plate that has the arrow pointing to the right.
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