Fisher 2500 Series, 2500R Series, 2503 Series, 2500S Series, 2500T Series Instruction Manual

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Page 1

Instruction Manual Form 1013 February 1997

Type 2500

2500 an

d 2

3 S

erie

s L

Transmitters

Contents

Introduction

Scope of Manual 2. Description 2 Specifications 2

Installation

Sensor Assembly 2. Uncrating 2 Controller/Transmitter Orientation 6. Mounting Caged Sensor 6. Mounting Cageless Sensor 7.

Side-Mounted Sensor 7. Top-Mounted Sensor 8.

Special Installations 8.

Temperature-Compensated Displacer 8. Piezometer Ring 9.

Supply and Output Pressure Connection 9.

Supply Pressure 10. Controller/Transmitter Output Connection 11.

Prestartup Checks

Type 2500 Controller or Type 2500T

Transmitter 13. Type 2500S Controller 13. Type 2503 Controller 14. Adjustments 15

Control Action 15. Level Adjustment

(Controllers Only) 15.

Zero Adjustment

(Transmitters Only) 15.

Proportional Band Adjustment

(Except Transmitters and 2503 Series Controllers) 15.

Specific Gravity Adjustment

(Transmitters Only) 15.

Calibration

Precalibration Requirements 15.

Wet Calibration 15. Dry Calibration 16.

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evel-Trol C

W3121-3/IL/A

11.

Figure 1. 2500 or 2503 Series Level-Trol

Transmitter on Caged 249 Series Sensor

Controller/Transmitter and Torque Tube Arm

Disassembly 16.

Determining the Amount of

Suspended Weight 16.

Calibration Procedure 17.

Type 2500 Controller and

2500T Transmitter 17.

Type 2500S and 2503 Controllers 19.

Startup

Type 2500 Controller 20. Type 2500T Transmitter 20. Type 2500S Controller 20. Type 2503 Controller 20.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ontroller

249 SERIES SENSOR

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s a

2500 OR 2503 SERIES CONTROLLER/ TRANSMITTER



Controller/

. . . . . . . . . .

Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.

D200124X012

Page 2

Type 2500

Contents

Principle of Operation

Type 2500 Controller or Type 2500T

Transmitter 21. Proportional Valve 21. Type 2500S Controller 21. Type 2503 Controller 21.

Maintenance

Troubleshooting 23 Removing Controller/Transmitter from

Sensor 23. Changing Mounting Methods 25. Installing Controller/Transmitter on Sensor 26. Replacing the Bourdon Tube 26. Changing Action 26. Relay Deadband Testing (Type 2500 Controller

or 2500T Transmitter Only) 27. Replacing the Proportional Valve 27. Changing Relay 28.

Relay Assembly Maintenance 28.

Parts Ordering Parts List

(Continued)

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Description

These instruments control or transmit the fluid level, the level of interface between two fluids, or the density

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

displacer-type fluid level sensor and a 2500 or 2503 Series pneumatic controller or transmitter. Figure 1 shows a typical controller-sensor combination.

Specifications

Refer to table 1 for specifications.

Installation

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

Sensor Assembly

29. Table 2 lists sensors recommended for use with controller/transmitters. For sensor installation and mainte-

29. nance, refer to the appropriate sensor instruction

manual.

Introduction

Scope of Manual

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

Only qualified personnel should install, operate, and maintain these controller/transmitters. If you have any questions concerning these instructions, contact your Fisher Controls sales office or sales representative before proceeding.

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.

Page 3

Table 1. Specifications

Type 2500

Available Configurations

(1)

Type 2500—Proportional-Only controller Type 2500C—Proportional-Only controller with indi-

cator (see figure 12) Type 2500R—Reverse acting proportional-only controller Type 2500S—Differential gap (snap acting) controller. See changing controller action procedure and figure 17.

Type 2500T—Transmitter Type 2503—Differential gap controller without pro-

portional valve; for applications requiring very little adjustment.

Input Signal

(2)

Fluid Level or Fluid-to-Fluid Interface Level:

From 0 to 100% of displacer length—standard lengths for all sensors are 14 inches or 32 inches (356 mm or 812 mm). 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

(2)

Type 2500 Controller and 2500T Transmitter: 3

to 15 psig (0.2 to 1 bar) or 6 to 30 psig (0.4 to 2 bar)

Type 2500S and 2503 Differential Gap Controllers: 0 psig (0 bar) when switched off and full sup-

ply [20 or 35 psig (1.4 or 2.4 bar) nominal depending on controller output pressure range] when switched on.

Area Ratio of Relay Diaphragms

3:1

Supply Pressure Data

See table 3

Maximum Supply Pressure

(3)

45 psig (3 bar) to the controller or transmitter. If controller or transmitter is equipped with an integrally mounted Type 67FR filter/regulator, typical supply pressure to the regulator is from 35 psig (2.5 bar) to 250 psig (17 bar), 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 Table 3. Type 2503 Controller: Vents only when relay is

exhausting.

Proportional Band

(2)

Adjustment (Proportional-

Only Controllers)

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

Differential Gap

(2)

Adjustment (Differential Gap

(5)

Controllers)

Type 2500S Controller: Full output pressure

change adjustable from 20 to 100% of displacer length.

(5)

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

Span

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

Set Point

(5)

(2)

Adjustment (Type 2500T Transmitter)

(5)

(2)

(controllers only) or Zero

ters 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.

Performance

Independent Linearity

(2)

(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.

Repeatability

placement force change.

Deadband

(4)

lers

): 0.05% of proportional band or span.

(2)

: 0.2% of displacer length or dis-

(2)

(except differential gap control-

Typical Frequency Response

gree phase shift at 100% proportional band with output piped to typical instrument bellows using 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 2. Relay temperature limits are: Standard Construction: -40 to 160F (-40 to 71C) High-Temperature Construction: 0 to 220F (-18 to 104C)

(continued)

(2)

(transmit-

(2)

: 4 Hz and 90 de-

Page 4

Type 2500

PRESSURE GAUGE

SUPPLY PRESSURE

Table 1. Specifications (Continued)

Typical Ambient Temperature Operating Influence

Output pressure changes 1.5% per 50F (10C)change in temperature at 100% proportional band when using a standard wall torque tube with 249 Series sensors.

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 changing 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. This term is defined in ISA Standard S51.1-1979.

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 setting.

Table

2. Standard Displacer Volumes

SENSOR TYPE

249, 249B, 249BP, 249K, 249N 249C, 249CP 249L 249V

1. With standard 12-inch (305 mm) flange-face-to-displacer centerline dimension only.

STANDARD VOLUME,

Cubic Inches

Supply and Output Connections

1/4-inch NPT female

Maximum Working Pressure (sensors only)

Refer to the appropriate sensor instruction manual.

100

120

STANDARD VOLUME,

(1)

Liters

1.6

1.0

1.9

(1)

1.3

Table 3. Supply Pressure Data

STANDARD SUPPLY

OUTPUT SIGNAL RANGE

3 to 15 psig (0.2 to 1 bar) 0 to 30 psig 20 1.4 4.2 scfh 6 to 30 psig (0.4 to 2 bar) 0 to 60 psig 35 2.4 7 scfh

1. Consult your Fisher Controls representative 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 m3/hr at 0C and 1.01325 bar, multiply scfh by 0.0258.

AND OUTPUT

PRESSURE GAUGE

INDICATIONS

NORMAL OPERATING

SUPPLY PRESSURE

(1)

Psig Bar Minimum

(2)

AIR CONSUMPTION AT

NORMAL OPERATING

SUPPLY PRESSURE

(3)

(5) (5)

Maximum

27 scfh 42 scfh

MAXIMUM

(4)

(5) (5)

SUPPLY PRESSURE

45 psig (3 bar) 45 psig (3 bar)

Page 5

Type 2500

AMBIENT TEMPERATURE (C)

01020

–10

–18

1100



800

400

–20 –40

PROCESS TEMPERATURE ( F)

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.)

0 20 40 60 80 100 120 140 160

AMBIENT TEMPERATURE (F)

30 40 50 60 70

TOO HOT

   

NOTE: FOR APPLICATIONS BELOW –20F (–29C), BE SURE THE SENSOR MATERIALS OF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.

CV6190–E B1413-2/IL

Figure 2. Guidelines for Use of Optional Heat Insulator 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 249V, 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 instruction manual for cageless 249 Series sensors.

593 500 400 300 200 100

–18 –29 –40



PROCESS TEMPERATURE ( C)

–18

–10

1100



800

400

PROCESS TEMPERATURE ( F)

–20

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.)

0 20 40 60 80 100 120 140 200

AMBIENT TEMPERATURE (C)

10 20

30 40 50 60 70

AMBIENT TEMPERATURE (F)

   

W2141–1B/IL

80 90

180160

DISPLACER

CAGE

100

TOO HOT

105

220

593 500 400 300 200 100 0



PROCESS TEMPERATURE ( C)

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.

W0144–1/IL

DAMPING PLATE

Figure

SCREWED CONNECTION

FLANGED CONNECTION

3. Damping Plate Location

Page 6

Type 2500

tion 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.

Mounting Caged Sensor

CAUTION

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

AH9150–A A2613–1/IL

Figure

4. Cage Head Mounting Positions

A cageless sensor comes with its displacer separated from the sensor assembly. Displacers longer than 32 inches (813 mm) 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 insure 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 posi-

If a temperature-compensated displacer or piezometer ring is used, refer to the Special Installation procedures in this section before proceeding.

Cage connections normally are 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 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 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.

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).

Page 7

Type 2500

Mounting Cageless Sensor

CAUTION

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.

CAUTION

Displacers used in an interface level application must be completely submerged during operation. To obtain the desired controller or transmitter sensitivity may require using either a thinwall torque tube, an oversized displacer, or both.

A1271–2/IL

CENTER OF LIQUID OR INTERFACE LEVEL

DF5379-A A1883-2/IL

Figure

5. Cage Connection Styles

SHUTOFF VALVES

EQUALIZING LINE

Figure 6. Caged Sensor Mounting

EQUALIZING LINE

DRAIN VALVE

Note

If the controller/transmitter is not mounted on the sensor, refer to the Installing Controller/Transmitter on Sensor procedures in the Maintenance section. That section also provides instructions for adding a heat insulator to a unit. If the sensor has a temperaturecompensated displacer or piezometer ring, refer to the Special Installations procedures in this section before proceeding.

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.

Page 8

Type 2500

SIDE MOUNTED

TOP MOUNTED

W0645–1/IL

Figure

7. Cageless Sensor Mounting

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.

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 desire 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 extension is used between the displacer spud and the stem end piece, make sure

CF5380-A A3893/IL

      

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

Special Installations

Temperature-Compensated Displacer

CAUTION

The bellows style temperature compensating displacers are relatively fragile and must be protected from all physical damage.

Some sensor assemblies use a temperature-compensated displacer shown in figure 9. This displacer is appropriate only for density applications that measure fluid composition regardless of temperature. The displacer must be filled completely with the fluid to be measured, or with a fluid of equal volumetric expan-

Page 9

DISPLACER STEM END PIECE

DISPLACER STEM EXTENSION

COTTER SPRING

LOCKING NUTS

DISPLACER SPUD

DISPLACER ROD

DISPLACER SPUD

Type 2500

COTTER SPRING

W0229-1A/IL

 

Figure

8. Displacer and Displacer Rod Connections

Piezometer Ring

A piezometer ring, shown in figure 10, is used when measuring the specific gravity of a flowing fluid in a line. The piezometer ring reduces the velocity effects caused by fluid passing through the displacer cage. However, the fluid velocity through the cage should not exceed two feet per minute (10 mm/second).

To install this type of sensor, connect a line to the cage inlet and outlet piping at each end of the cage. Use hand valves to balance the fluid flow through the cage and keep the displacer cage filled. Provide a rotameter or sight flow gauge for measuring velocity through the cage. If the flow rates are properly balanced, the transmitter output shows little change when flow through the cage is shut off. If the flow rate through the cage is too high, the turbulence may cause an erratic output pressure signal. Readjust the hand valves to stabilize the output pressure signal.

W0228-1A/IL

  

DISPLACER ROD

A0746–1/IL

Figure 9. Temperature-Compensated Displacer

sion coefficient. In service, the displacer expands and contracts the same amount as the measured fluid to nullify signal changes that would be caused by temperature changes.

This type of displacer comes in a separate carton, but is in the same crate as the rest of the assembly. See the appropriate sensor manual for displacer filling instructions.

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.

Page 10

Type 2500

10A1211–A 22A9197–B CD1700–E A2708–1/IL

Figure

11. Controller/Transmitter Dimensions and Connections

A6620/IL

Figure

10. Piezometer-Ring Cage for Flow Line Mounting

Figure 11 shows dimensions, locations, and connections for controller/transmitter installation. All pressure connections to the controller/transmitter are 1/4-inch NPT female.

Supply Pressure

WARNING

Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oilfree, or a noncorrosive gas. Industry instrument air quality standards describe acceptable dirt, oil, and moisture content. Due to the variability in nature of the problems these influences can have on pneumatic equipment, Fisher Controls has no technical basis to rec-

ommend the level of filtration equipment required to prevent performance degradation of pneumatic equipment. A filter or filter regulator capable of removing particles 40-microns in diameter should suffice for most applications. Use of suitable filtration equipment and the establishment of a maintenance cycle to monitor its operation is recommended.

Supply pressure must be clean, dry air or noncorrosive gas that meets the requirements of ISA Standard S7.3-1975 (R1981). Use a suitable supply pressure regulator to reduce the supply pressure to the normal operating supply pressure shown in table 3. As shown in figure 11, a Type 67FR filter/regulator mounts on the back of the controller/transmitter case and mates with the supply pressure connection on the controller/ transmitter case. Pipe the supply pressure to the IN connection of the regulator. Typically, the Type 67FR filter/regulator accepts supply pressures between 35 and 250 psig (2.5 and 17 bar). For specific regulator limits, refer to the appropriate regulator instruction manual.

If operating the controller or transmitter from a high pressure source [up to 2000 psig (138 bar)], use a high pressure regulator system, such as the Type 1367 High Pressure Instrument Supply System. For Type 1367 system installation, adjustment. and maintenance information, see the separate instruction manual.

Page 11

Type 2500

Controller/Transmitter Output Connection

As shown in figure 11, the output pressure connection is on the back of the controller/transmitter case. After connecting the output pressure line, turn on the supply pressure, adjust the filter/regulator to the appropriate supply pressure required for the controller/transmitter and check all connections for leaks.

Prestartup Checks

Adjustments are shown in figure 12 unless otherwise indicated. Open-loop conditions must exist when performing the prestartup checks. To obtain open-loop conditions:

 make sure there is no process flow through the

final control element, or

 disconnect the controller/transmitter output signal

line and connect it to a pressure 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 LEVEL dial on the controller is mounted with the correct side facing out. The dial is marked 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 12. 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 points correctly, and reinstall the mounting screws. The level directions shown on the dial will be correct for both direct-acting and reverseacting controllers. For a transmitter, use the same side of the ZERO ADJUSTMENT dial for both right- and left-hand sensor mountings.

On a controller or transmitter with an optional mechanical indicator assembly, the travel indicator plate is also marked with an arrow on both sides. If the sensor is to the left of the controller/transmitter, the arrow on the plate should point to the left. If the sensor is to the right, the arrow should point to the right. If necessary, reinstall the plate so that the arrow points in the correct direction.

Set the PROPORTIONAL BAND control on a Type 2500 or 2500S controller, or the SPECIFIC GRAVITY control on a Type 2500T transmitter, as follows:

 Sensor with Both Standard Torque Tube and

Standard Volume Displacer—If the torque tube is

standard and the displacer volume is close to that listed in table 2, use figure 13 to find the PROPORTIONAL BAND or SPECIFIC GRAVITY setting. Locate the specific gravity of the process fluid on fluid level applications, or the difference between minimum and maximum specific gravity on interface level or density applications, on the vertical axis of the chart. From this location, trace horizontally to the curve with the desired percentage of displacer used, then trace vertically up or down to determine the proper dial setting on the horizontal axis.

 Sensor with Nonstandard Torque Tube and/

or Displacer with Other than Standard Volume—If

the construction does not have a standard wall torque tube or has a displacer volume that deviates significantly from the volume listed in table 2, or both, the PROPORTIONAL BAND or SPECIFIC GRAVITY dial setting does not necessarily indicate the actual proportional band or specific gravity. To determine the correct dial setting, solve the following equation:

Corrected

Dial Setting

Required

where:

= percentage of displacer length desired for full

output pressure change (e.g., if 80% of displacer is used, L = 80)

SP GR = specific gravity of

face level control, use the difference between the specific gravity of the two fluids; for specific gravity control, use the difference between the upper and lower range limits of specific gravity).

Va = actual displacer volume, cubic inches listed

on the sensor nameplate.

Vr = standard displacer volume, cubic inches, from

table 2.

X = torque tube factor (1.0 for standard torque

tubes, 2.0 for thin-wall torque tubes, or 0.5 for heavy-wall torque tubes).

 (

)(SP GR)

100

the process fluid (for inter





(X)

Page 12

Type 2500

LEVEL SET ARM MOUNTING SCREWS

LEVEL SET ARM

W0671–1/IL

RIGHT-HAND MOUNTED TYPE 2503R

W0641–1B/IL

BOURDON TUBE DETAIL OF

TYPE 2500S ON-OFF

CONTROLLER

3–WAY VALVE

FLAPPER ALIGNMENT SCREW

SHAFT CLAMP NUT

VENT

ON-OFF CONTROLLER

W0656–1/IL

NOZZLE

PLUNGER

1C9283–B/DOC

RAISE LEVEL DIAL FOR

LEFT-HAND MOUNTING

LEVEL ADJUSTMENT

PROPORTIONAL BAND ADJUSTMENT

FLAPPERRELAY

SPAN ADJUSTMENT

RIGHT-HAND MOUNTED TYPE 2500

PROPORTIONAL CONTROLLER

SPECIFIC GRAVITY ADJUSTMENT

W0647–2B/IL

ZERO ADJUSTMENT

DETAIL OF TRANSMITTER

ADJUSTMENTS

W0648–1B/IL

INDICATOR ASSEMBLY WITH

RIGHT-HAND MOUNTING

Figure

12. Adjustment Locations

POINTER ASSEMBLY

1E8731 1E8732 A1897–1/IL

TRAVEL INDICATOR PLATE

FOR LEFT-HAND MOUNTING

Page 13

NOTE: EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.

1C9259–G A3891–1/IL

Figure 13. Proportional Band and Specific Gravity

Setting Chart (chart assumes standard wall torque tube and

displacer volume in table 2)

Type 2500 Controller or 2500T Transmitter

Note

Type 2500

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 position on the displacer.

4. The OUTPUT gauge on a 3 to 15 psig (0.2 to 1 bar) range should read 3 psig (0.2 bar) for direct or 15 psig (1 bar) for reverse action. On a 6 to 30 psig (0.4 to 2 bar) range the OUTPUT gauge should read 6 psig (0.4 bar) for direct or 30 psig (2 bar) for reverse action.

5. On a controller or transmitter with a mechanical indicator assembly, the pointer should be over the LOW point on the indicator plate. If a slight adjustment is necessary, loosen the side hex clamp nut (key 40, figure 19), shift the pointer, and retighten the nut.

6. Increase the process variable to the level desired for full output change. The OUTPUT gauge on a 3 to 15 psig (0.2 to 1 bar) range should read 15 psig (1 bar) for direct or 3 psig (0.2 bar) for reverse action. On a 6 to 30 psig (0.4 to 2 bar) range the OUTPUT gauge should read 30 psig (2 bar) for direct or 6 psig (0.4 bar) for reverse action. On a controller or transmitter with an indicator assembly, the pointer should be over the HIGH point on the indicator plate; slight plate adjustment may be necessary, as described at the end of step 5.

7. If all prestartup checks are satisfactory, go to the startup procedure. If performance is unsatisfactory, proceed to the Calibration section.

In the following steps the output pressure can go as high as the controller supply pressure.

1. Turn on the supply pressure and check that the supply pressure gauge reads 20 psig (1.4 bar) for a 3 to 15 psig (0.2 to 1 bar) or 35 psig (2.4 bar) for a 6 to 30 psig (0.4 to 2 bar) output pressure range. If the pressure is incorrect, loosen the locknut of the Type 67FR filter/regulator (figure 11); turn the adjusting screw clockwise to increase the pressure or, counterclockwise to decrease 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 4. 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

Type 2500S Controller

Note

In the following steps the output pressure can go as high as the controller supply pressure.

1. Turn on the supply pressure and check that the SUPPLY pressure gauge reads 20 psig (1.4 bar) for a 0 to 20 psig (0 to 1.4 bar) output pressure range or 35 psig (2.4 bar) for a 0 to 35 psig (0 to 2.4 bar) output pressure range. If the pressure is incorrect, loosen the locknut of the Type 67FR filter/regulator (figure 11); turn the adjusting screw clockwise to increase the pressure or counterclockwise to decrease pressure. Tighten the locknut after setting the pressure.

2. Set the process variable to its minimum value.

3. On a controller with a mechanical indicator assembly, the pointer should be over the LOW point on the indicator plate. If a slight adjustment is necessary, loosen the hex clamp nut (key 40, figure 19), shift the pointer and retighten the nut.

Page 14

Type 2500

Table

4. Recommended Settings For Pre-Startup Checks

RECOMMENDED RAISE LEVEL SETTING

FOR TYPE 2500 CONTROLLER

MOUNTING ACTION

Right-hand

Left-hand

1. For proportional band dial settings between 10 and 0 or for specific gravity dial settings between 1.0 and 0, interpolate the value.

Direct 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to right 0.5 to 1.0 to right

Reverse 6.5 to 7.0 0.5 to 1.0 1.5 to 2.0 to left 4.0 to 4.5 to right

Direct 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to left 0.5 to 1.0 to left

Reverse 6.5 to 7.0 0.5 to 1.0 1.5 to 2.0 to right 4.0 to 4.5 to left

For Predetermined

PROPORTIONAL BAND

Dial Setting of 10

For Predetermined

PROPORTIONAL BAND

Dial Setting of 0

RECOMMENDED ZERO ADJUSTMENT SETTING FOR

For Predetermined

SPECIFIC GRAVITY Dial

TYPE 2500T TRANSMITTER

Setting of 1.0

For Predetermined

SPECIFIC GRAVITY Dial

Setting of 0

Note

Adjustment of the RAISE LEVEL control can set the switching points anywhere within the length of the displacer. Be careful not to set the switching points so that one is off the displacer.

4. Make sure that the PROPORTIONAL BAND control is at the setting determined in the previous procedures. Set the RAISE LEVEL control to 0, then set it to 1.0 for a direct-acting or 4.0 for a reverse-acting controller.

5. The OUTPUT gauge should read 0 psig (0 bar) 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 psig (0 bar) 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 over the HIGH point 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 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 performance is unsatisfactory, proceed to the Calibration section.

Type 2503 Controller

Note

In the following steps the output pressure can go as high as the controller supply pressure.

Note

Since the Type 2503 controller has no proportional valve, the differential gap between switching points is adjusted by varying the supply pressure. This gap can be varied from approximately a

3.5-inch (88.9 mm) level change at 15 psig (1 bar) to a 6.0-inch level change at 25 psig (1.7 bar) with a standard volume displacer and a fluid with a specific gravity of 1.0. The gap also varies inversely according to density; a fluid with 0.8 specific gravity produces a

4.4-inch (112 mm) level change at 15 psig to a 7.5-inch change at 25 psig (1.7 bar). Set the gap at a pressure low enough to be compatible with the limitations of the diaphragm control valve or other final control element.

1. Turn on the supply pressure. If necessary, adjust the Type 67FR regulator to produce the desired differential gap by loosening the locknut (figure 11) and turning the adjusting screw clockwise to increase or counterclockwise to decrease pressure. Tighten the locknut.

2. Locate the process variable at its minimum value.

Note

Adjustment of the RAISE LEVEL control can set the switching points anywhere within the length of the displacer. Be careful not to set the switching points so that one is off the displacer.

3. Set the RAISE LEVEL control to 0 and then reset it as follows:

a. For direct-acting controllers, set it between 1.0 and 1.5.

b. For reverse-acting controllers, set it between 3.5 and 4.0.

4. The OUTPUT gauge should read 0 psig (0 bar) for direct or full supply pressure for reverse action.

Page 15

Type 2500

5. Increase the process variable until the OUTPUT gauge changes to full supply pressure for direct or 0 psig (0 bar) for reverse action. The process variable should be at the desired high trip value.

6. Decrease the process variable until the OUTPUT gauge changes to 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 controller/transmitter action and adjustments. Figure 12 shows adjustment locations.

Control Action

The following is a definition of control action.

 Direct Action—Increasing fluid level, interface

level, or density, increases the output signal.

 Reverse Action—Increasing fluid level, interface level, or density, decreases the output signal. Controller/transmitters factory-set for reverse-acting have the suffix letter R added to their type number.

Zero Adjustment (Transmitters Only)

To make a zero adjustment, open the transmitter cover, loosen the adjustment screw and rotate the adjustment lever around the ZERO ADJUSTMENT dial. This adjustment sets the output pressure to correspond to a specific level on the displacer. Tighten the knurled screw.

Proportional Band Adjustment (Except Transmitters and 2503 Series Controllers)

The proportional band adjustment varies the amount of process variable change required to obtain a full output pressure change. To perform this adjustment, open the controller cover and turn the PROPORTIONAL BAND adjustment (see figure 12). Refer to the prestartup 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 12). Refer to the prestartup check procedures to determine the proper setting.

The control action is determined by the cage head mounting position and by the Bourdon tube-flapper arrangement in the controller/transmitter. Refer to figure 4 for mounting positions and to figure 17 for Bourdon tube-flapper arrangements. To change the action, refer to the changing action procedure in the Maintenance section.

Level Adjustment (Controllers Only)

To make a level adjustment, open the controller cover, 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 does not reflect actual fluid level in the tank or fluid level position on the displacer.

Calibration

Precalibration Requirements

The controller/transmitter can be calibrated in the field, mounted on the vessel containing the process fluid. It may also be done in the shop, but other means of obtaining a displacement force change must be provided. There are wet and dry methods of adapting the calibrating procedure.

Wet Calibration

Remove the entire controller/transmitter and sensor assembly from the vessel. For caged sensors, pour the fluid into the cage. For cageless sensors, suspend the displacer to an appropriate depth in a fluid having a specific gravity equal to that of the process fluid.

If necessary, you may use water for wet calibration in the shop. You must compensate for the difference between the specific gravities of water and the process fluid, however. As an example, assume the process fluid has a specific gravity of 0.7. The specific gravity of water is 1.0. To simulate a process level of 50 percent of the input span, would require a water level of 35 percent (0.7/1.0 x 50 percent = 35 percent).

Page 16

Type 2500

Dry Calibration

Remove the controller/transmitter and torque tube arm, as a single unit, from the cage or vessel. Then, wherever the standard calibration procedures in this manual require a specific process variable input to the sensor, simulate the process variable by suspending the proper weight (such as a can of sand) from the end of the displacer rod. Complete the following procedures (Controller/Transmitter and Torque Tube Arm Disassembly) and (Determining the Amount of Suspended Weight) before proceeding to the Calibrating Procedure.

Controller/Transmitter and Torque Tube Arm Disassembly

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/transmitter and torque tube arm from the cage or vessel, refer to the appropriate 249 Series 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 be appropriate to remove the entire cage from the vessel before disassembling.

CAUTION

the sensor may be removed through the access hole in the sensor head.

For Type 249BP sensors with travel stop, the stem end piece pins will secure the displacer on the travel stop as long as the travel stop plate is installed and the sensor head is in position.

Determining the Amount of Suspended Weight

CAUTION

Avoid overloading a torque tube sized for interface or density applications. Consult your Fisher Controls sales office or sales representative for the maximum allowable substitute weight, Ws, that may be used with your particular construction.

To determine the total weight that must be suspended from the displacer rod to simulate a certain condition of fluid level or specific gravity, solve the following equation:

Ws Wd–[(0.0361)(V)(SP GR)]

where:

Ws = Total suspended weight in pounds (should never

less

than 0.5 pounds). For a unit with a hori zontal displacer, make sure the center of grav ity of the substitute weight on the actual displacer.

is where it would be

If the displacer is to be disconnected from the displacer rod before the sensor assembly is removed from the cage or vessel, provide a means of supporting the displacer to prevent it from dropping and suffering damage. The spuds or stem end pieces on all displacers have holes suitable for inserting rods or other supports.

Additionally, a threaded rod may be installed into the 1/4-inch 28 UNF threaded hole in the displacer spud or stem end piece of top-mounted cageless and all caged sensors. For some topmounted sensors with long displacers,

Note

For liquid level control only, simulate the lower range limit of the input span by suspending the displacer from the displacer rod. For other values of input span, remove the displacer and suspend the appropriate weight as determined in the equation above.

Wd = Weight

of the displacer, in pounds (determine by

weighing displacer).

Page 17

Type 2500

Table 5. Minimum and Maximum Limits for Setting Process Variables

APPLICATION MINIMUM LIMIT MAXIMUM LIMIT

Liquid Level Displacer must be completely out of liquid Displacer must be completely submerged in liquid Interface Displacer must be completely submerged in lighter of two

process liquids

Density Displacer must be completely submerged in liquid having

specific gravity of lowest range point

Displacer must be completely submerged in heavier of two process liquids

Displacer must be completely submerged in liquid having specific gravity of highest range point

0.0361 = Weight of one cubic inch of water (specific gravity = 1.0), in pounds.

= Volume, in cubic inches, of the portion

of the dis

placer submerged. Or,

V = (π/4) (displacer diameter)2 (length of displacer

submerged)

GR = Specific gravity of

the process fluid at operating

temperature.

For interface level measurement, the equation becomes:

Ws+Wd–[(0.0361)(Vt)(SP GRl)

) (0.0361)(Vh)(SP GRh* SP GRl)]

where:

Vt = Total volume, in cubic inches, of the displacer.

GRl = Specific gravity of the lighter of the fluids at oper

ating temperature.

Vh = Volume, in cubic inches, of the portion of the

displacer submerged in the heavier of the fluids.

before taking the controller/transmitter out of service.

Figure 12 shows adjustment locations, except as

otherwise indicated. In order to calibrate, open-loop conditions must exist. One way to obtain an open loop is to ensure that there is no flow through the final control element. Another way to obtain an open loop is to disconnect the controller/transmitter output signal line and plug the output connection with a test pressure gauge.

Several steps in these calibrating procedures require setting the process variable at its minimum and maximum limits, according to table 5.

Note

If the process cannot be varied readily or the Wet Calibration method cannot be used in the following steps, be sure to use the proper sequence of correct weights as found in the Determining Amount of Suspended Weight proce-

dure. Whenever the following steps require particular prestartup checks, refer to the appropriate procedures for: Type 2500 Controller or 2500T Transmitter, Type 2500S Controller, or Type 2503 Controller.

Or,

= (π/4) (displacer diameter)2 (length

er submerged)

GRh = Specific gravity of the heavier

erating temperature.

Calibration Procedure

WARNING

The following calibration procedures require taking the controller/transmitter out of service. To avoid personal injury and property damage caused by an uncontrolled process, provide some temporary means of control for the process

of the displac

of the fluids at op

Type 2500 Controller and 2500T Transmitter

1. Turn on the supply pressure and check that it is set according to the appropriate prestartup checks proce-

dure.

2. Make sure that the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment is at the setting determined according to the appropriate prestartup check procedure.

3. Adjust the RAISE LEVEL (Type 2500) or ZERO ADJUSTMENT (Type 2500T) to the appropriate value per table 4. 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 SPECIFIC GRAVITY setting.

Page 18

Type 2500

4. Set the process variable to the minimum value of the input range as shown in Table 5. For constructions with an indicator assembly, make sure that the pointer is over the LOW mark.

Note

In the following step, the alignment screw (key 33, figure 19) always must remain screwed in far enough to provide spring tension on the underside of the alignment screw head.

5. Adjust the flapper (key 32, figure 19) to obtain the appropriate pressure listed below. For coarse flapper adjustment, loosen the hex nut (key 40, figure 19) and rotate the flapper assembly about the torque tube shaft. For fine flapper adjustment, turn the flapper alignment screw (key 33, figure 19).

 For Direct Acting Type 2500, 2500T, 3 psig (0.2 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or 6 psig (0.4 bar) for a 6 to 30 psig (0.4 to 2.0 bar)output.

 For Reverse Acting Type 2500, 2500T, 15 psig (1.0 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or 30 psig (2.0 bar) for a 6 to 30 psig (0.4 to 2.0 bar) output.

the indicator plate screws (key 41, figure 19, detail of indicator assembly), slide the plate until the HIGH mark is under the pointer. Tighten the plate screws and go to the Startup section.

Note

Any sliding of the level set arm (key 28, figure 19) in the following step changes the zero as well as the output pressure span.

11. To adjust the output pressure span, loosen the two level set mounting screws (see figure 19) and slide the flexure strip base (key 27) right or left along the elongated slotted hole as follows:

 To increase the output pressure span, slide the

flexure strip base away from the torque tube shaft.

 To decrease the output pressure span, slide the

flexure strip base toward the torque tube shaft.

Retighten the screws. If the flexure strip base has been moved as far as possible and the output pressure span is still too large or too small, proceed to step

13.

6. Visually examine the nozzle and flapper to ensure the nozzle is as square as possible with the flapper. The nozzle can be realigned by loosening the Bourdon tube mounting screws (key 45, figure 19) and rotating the Bourdon tube slightly. If the nozzle is realigned, tighten the mounting screws and repeat step 5.

7. Set the process variable to the maximum value of the input range as shown in table 5.

8. The output pressure should be:

 For Direct Acting Type 2500, 2500T, 15 psig

1.0 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or 30 psig (2.0 bar) for a 6 to 30 psig (0.4 to 2.0 bar) output.

 For Reverse Acting Type 2500, 2500T, 3 psig (0.2 bar) for a 3 to 15 psig (0.2 to 1.0 bar) output or 6 psig (0.4 bar) for a 6 to 30 psig (0.4 to 2.0 bar) 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 an indicator assembly, go to the Startup section. If the unit contains an indicator assembly, change the pointer span by loosening

12. Repeat the procedure from step 4 until the required calibration points are obtained.

Note

Any change of the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment in the following step changes the zero as well as the output pressure span.

13. If the flexure strip base has been moved as 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:

 If the output pressure span is too large, slightly increase the PROPORTIONAL BAND or SPECIFIC GRAVITY setting.

 If the output pressure span is too small, slightly decrease the PROPORTIONAL BAND or SPECIFIC GRAVITY setting.

14. Repeat the procedure from step 4 until the required calibration points are obtained.

Page 19

Type 2500

Note

If you cannot calibrate the controller or transmitter, look for other problems as described in the Troubleshooting procedures, such as leaking connections, or a binding displacer rod. If none of these troubles are apparent, ensure that the displacer is sized correctly for the application.

Type 2500S and 2503 Controllers

1. Turn on the supply pressure and check that it is set according to the appropriate prestartup checks procedure.

2. Make sure that the PROPORTIONAL BAND adjustment (Type 2500S only) is at the setting determined according to the appropriate prestartup check procedure.

3. Perform one or the other of the following:  For direct acting controllers, set the RAISE

LEVEL adjustment between 1.0 and 1.5.

 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 5. For constructions with an indicator assembly, make sure that the pointer is over the LOW mark.

 For Reverse Acting Controllers, move the flap- per away from the nozzle until the output pressure switches to 0 psig, then carefully adjust the flapper toward the nozzle until the output pressure switches to full supply pressure.

7. Slowly increase the process variable until the output pressure switches:

 For Direct Acting Controllers, slowly increase the process variable until the output pressure switches to full supply pressure. The process variable should be at the maximum value of input range as shown in table

5. If the process variable agrees with table 5, proceed with step 8. If the process variable does not agree with table 5, proceed to step 9.

 For Reverse Acting Controllers, slowly in- crease the process variable until the output pressure switches to 0 psig. The process variable should be at the maximum value of input range as shown in table 5. If the process variable agrees with table 5, proceed with step 8. If the process variable does not agree with table 5, proceed to step 9.

8. If the unit does not contain an indicator assembly, go to the startup section. If the unit contains an indicator assembly, change the pointer span by loosening the indicator plate screws (key 41, figure 19, indicator assembly detail), slide the plate until the HIGH mark is under the pointer. Tighten the plate screws and go to the startup section.

Note

In the following step, the alignment screw (key 33, figure 19) always must remain screwed in far enough to provide spring tension on the underside of the alignment screw head.

5. Be sure the flapper is centered over the nozzle. If not, loosen the hex nut (key 40, figure 19) and reposition the flapper, tighten the hex nut.

6. Adjust the flapper (key 32, figure 19) as described below. For coarse flapper adjustment, loosen the hex nut (key 40, figure 19) and rotate the flapper assembly about the torque tube shaft. For fine flapper adjustment, turn the flapper alignment screw (key 33, figure

19).  For Direct Acting Controllers, move the flapper

toward the nozzle until the output pressure switches to full supply pressure, then carefully adjust the flapper away from the nozzle until the output pressure switches to 0 psig.

Note

Any sliding of the level set arm (key 28, figure 19) 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 19) and slide the flexure strip base (key 27) right or left along the elongated slotted hole as follows:

 To decrease the differential gap, slide the flexure

strip base away from the torque tube shaft.

 To increase the differential gap, slide the flexure

strip base toward the torque tube shaft. Retighten the screws. For the Type 2500S only, if the

flexure strip base has been moved as far as possible and the differential gap is still too low, proceed to step 11.

10. Repeat the procedure from step 4 until the required calibration points are obtained.

Page 20

Type 2500

Note

Any change in the PROPORTIONAL BAND adjustment in the following step changes the zero as well as the differential gap.

11. If the flexure strip base has been moved as far as

possible and the differential gap is still too large or too small, adjust the PROPORTIONAL BAND as follows:

 If the differential gap is too large, slightly de-

crease the PROPORTIONAL BAND setting.

 If the differential gap is too small, slightly in-

crease the PROPORTIONAL BAND setting.

12. Repeat the procedure from step 4 until the re-

quired calibration points are obtained.

Note

If you cannot calibrate the controller, look for other problems as described in the Troubleshooting procedures, such as a nozzle that is not perpendicular to the flapper, leaky connections, or a binding displacer rod. If none of these troubles are apparent, ensure the displacer is sized correctly for the application.

Startup

Adjustment locations are shown in figure 12. The prestartup or calibration procedures must be completed prior to startup.

Type 2500 Controller

1. Slowly open the upstream and downstream manual

control valves in the pipeline. If the pipeline has a bypass valve, close the valve.

2. If desired, adjust the proportional band to the nar-

rowest (lowest) setting that maintains stable control. Proportional band adjustments will affect the process level and may require a level adjustment. If adjusting proportional band, make the adjustments in small increments.

3. To confirm the optimum proportional band setting,

momentarily create a load upset. If cycling occurs, broaden (increase) the proportional band until process oscillations diminish rapidly. In general, the narrowest proportional band that does not produce cycling provides the best control.

Type 2500T Transmitter

1. Make sure that the SPECIFIC GRAVITY and ZERO ADJUSTMENT controls are set according to the Type 2500 Controller or 2500T Transmitter portion of the pre-startup 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.

Type 2500S Controller

1. Set the switching points according to the Type 2500S Controller 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 is still switching correctly at both switching points.

Type 2503 Controller

1. Set the switching points according to the Type 2503 Controller 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, reposition the switching points by adjusting the RAISE LEVEL control. For example, if the differential gap is set for 4-inches (102 mm) of level change, this 4-inches (102 mm) can be set anywhere within the length of the displacer. After readjustment, confirm the controller is still switching correctly at both switching points.

Principle of Operation

The controller/transmitter receives the change 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.

All 2500 and 2503 Series controller/transmitters use the same basic pressure-balanced relay assembly.

Page 21

Type 2500

The following descriptions explain how the relay action produces the output signal with the various controller/ transmitter constructions.

Type 2500 Controller or 2500T Transmitter

Full supply pressure comes to the relay from the regulator, as shown in figure 14. The relay has a fixed restriction through which supply pressure bleeds before entering the large diaphragm area and the inner Bourdon tube channel. In a steady-state condition, the process level holds the torque tube and attached flapper steady in relation to the nozzle. This allows pressure to escape between the nozzle and flapper at the same rate it bleeds into the large diaphragm area. The large diaphragm holds the inlet end of the relay valve slightly open to compensate for the venting of output pressure through the proportional valve as it maintains a steady-state position of the final control element. The output pressure, through the three-way proportional valve, affects the Bourdon tube outer channel, holding the Bourdon tube in a steady-state position.

A process level change raises or lowers the displacer, moving the flapper with respect to the nozzle. If the process level change increases nozzle pressure, the large diaphragm moves down; this closes the exhaust end and opens the inlet end of the relay valve (see figure 14). This action of the relay valve increases the output pressure to the final control element. Since the area ratio of the large diaphragm to the small diaphragm is three-to-one, the small diaphragm action amplifies the output pressure change. The three-way proportional valve lets the increase 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 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 subsection.

Proportional Valve

The three-way proportional valve is adjustable to allow some or all of the output pressure change to feed back to the Bourdon tube outer channel, providing proportional band control (see figure 14). The Bourdon tube

moves to counteract the pressure changes in the nozzle, equaling the relay diaphragm pressure differential. The relay valve maintains a new output pressure according to the change in the process variable.

A wide-open proportional valve (fully counterclockwise) permits feedback of the output pressure signal change and produces 100 percent proportional response. A closed (fully clockwise) proportional valve produces smaller proportional responses, because 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 14) 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 completely opens the relay valve for full output pressure or completely closes the relay valve for full exhaust of the output pressure, allowing no in-between throttling.

Type 2503 Controller

This construction has the same flapper and sensor arrangement as the Type 2500 controller, but its Bourdon tube has a three way valve operated by a plunger (see figure 15). 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 level. The differential gap of the 2503 either completely opens the relay valve for full output pressure or completely closes the relay valve for full exhaust of the output pressure, allowing no in-between throttling.

For a direct-acting controller, as long as the process variable remains above the switch point, the flapper does not depress the plunger of the Bourdon tube valve. In this condition, the Bourdon tube valve remains closed, providing full loading pressure to the Bourdon tube. This loading pressure moves the Bourdon tube away from the flapper. Also, in this condition, full loading pressure is on the upper diaphragm of the relay. The loading pressure moves the diaphragm down, closing the exhaust end and opening the inlet end of the relay valve, allowing full output pressure.

When the process level sufficiently decreases, the flapper pushes in the plunger of the Bourdon tube valve enough to release the loading pressure and seal the inner Bourdon tube channel (see figure 15). This decrease in the loading pressure moves the Bourdon tube toward the flapper, producing the snap action. Also, this decrease in loading pressure allows relay spring pressure to move the large diaphragm up, closing the inlet end and opening the exhaust end of the relay valve,

Page 22

Type 2500

CD2114–E BO998–1/IL

Figure

14. Direct-Acting, Right-Hand-Mounted 2500-249 Series Controller/Transmitter

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.

Maintenance

The 2500 and 2503 Series controllers/transmitters work in combination with 249 Series displacers. Refer to figure 19 for key number locations, unless otherwise indicated.

Due to the care Fisher Controls takes in meeting all manufacturing requirements (heat treating, dimension-

Page 23

Type 2500

BD4466–A CD2114–E A1890–1/IL

Figure

15. Direct-Acting Left-Hand-Mounted Type 2503 Controller

al tolerances, etc.), use only replacement parts manufactured or furnished by Fisher Controls.

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 that is 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.

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 6 lists some common operating faults, their probable causes, and corrective action.

Removing Controller/Transmitter from Sensor

WARNING

To avoid injury in the following steps, turn off the supply pressure and carefully release any pressure trapped in the controller/transmitter before breaking any pressure connection. Provide a bypass for the control device if continuous operation is required during maintenance.

1. Disconnect the supply and output pressure tubing from the controller or transmitter. For a controller/ transmitter with an indicator, remove the pointer assembly by referring to the section entitled Replacing the Bourdon Tube.

Page 24

Type 2500

FAULT POSSIBLE CAUSE CHECK CORRECTION

1. Process wanders or cycles around set point.

2. Controller/transmitter controlling off set point or switching point.

3. Controller/transmitter cannot attain full output range.

4. Controller/transmitter remains at full or zero output pressure.

Table

6. Troubleshooting Chart for 2500 Series Controller/Transmitters

1.1 Proportional band or specific gravity adjustment incorrect or improperly tuned control loop.

1.2 Supply pressure varying or incorrect supply pressure setting.

1.3 Sensor not plumb and is in contact with sidewall or leak in displacer.

1.4 Relay malfunction. Check for relay malfunction by

2.1 Supply pressure not set correctly.

2.2 Leak in the controller/transmitter loop.

2.3 Leaking displacer. Ensure the displacer is not filling

2.4 Flapper adjustment. Ensure the flapper is not loose on

2.5 Process variable changed. Ensure the process variable has

3.1 Supply pressure not set correctly.

3.2 Flapper adjustment. Ensure the flapper is not loose on

3.3 Process variable changed. Ensure the process variable has

3.4 Relay malfunction Check for relay malfunction by

3.5 Leak in the controller/transmitter loop.

4.1 Supply or output pressure gauge malfunction.

4.2 Flapper adjustment. Ensure the flapper is not loose on

Ensure the prestartup procedures are completed correctly. Tune control loop.

Use input pressure gauge to monitor stability. Make sure regulator IN supply pressure is within limits.

Check cage vessel and stillwell installation, or for leaking displacer.

using the testing relay deadband procedure.

Make sure regulator supply pressure is set correctly. Make sure regulator IN supply pressure is within limits.

Use soap and water to check for internal and external leaks.

with process fluid.

the torque tube shaft and is centered on the nozzle.

not changed from original calibration settings, or displacer not designed for specific gravity of process.

Make sure supply pressure is set correctly. Make sure regulator IN supply pressure is within limits.

the torque tube shaft and is centered on the nozzle.

not changed from original calibration settings, or from displacer’s designed specific gravity.

using the testing relay deadband procedure.

Use soap and water to check for internal and external leaks.

Ensure the pressure gauges are registering correctly.

the torque tube shaft and is centered on the nozzle.

If stable control cannot be attained and all other elements are functionally correct, examine other possible causes related to the controller/transmitter.

Apply correct supply pressure. Use one regulator per instrument.

Make sure the displacer and displacer rod hangs freely. Make sure linkage is tight. Replace displacer if leaking.

Depress plunger to clean out the fixed restriction. Replace or repair relay using the procedure in the Maintenance section.

Reset the supply regulator pressure. If the condition occurs again, rebuild or replace regulator. Provide a regulator input pressure within regulator limits.

Replace or repair leaking parts as necessary.

Refer to sensor maintenance procedures in the appropriate sensor instruction manual.

Replace or tighten flapper assembly as necessary and/or center flapper on nozzle.

Change process variable back to original specification or recalibrate. If necessary, provide replacement displacer of correct size and recalibrate.

Reset the regulator pressure. If problem reoccurs, replace or rebuild the regulator. Ensure regulator IN supply pressure is within limits at all operating levels.

Replace or tighten flapper assembly as necessary and/or center flapper on nozzle.

Change process variable back to original specification or recalibrate. If necessary, provide replacement displacer of correct size and recalibrate.

Depress plunger to clean out the fixed restriction. Replace or repair relay using the procedure in the Maintenance section.

Replace or repair leaking parts as necessary.

Replace pressure gauges. Use corrective action given in section 3 of this table.

Replace or tighten flapper assembly as necessary and/or center flapper on nozzle.

Page 25

2. Loosen the top hex clamp nut (key 40, figure 19)

and remove the flapper base (key 30, figure 19) from the torque tube rotary shaft.

CAUTION

If the hex clamp nut has not been loosened or the pointer removed according to step 2, attempting to remove the controller/transmitter from the sensor may bend the flapper or rotary shaft. Be careful that the back of the controller/transmitter case or the heat insulator does not drop down and bend the rotary shaft or shaft extension.

3. Remove any insulating tape from the joint between

the controller/transmitter case and the torque tube arm. Remove the four cap screws (key 39, figure 16) 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 16) if one is installed.

Type 2500

4. If the controller/transmitter has a heat insulator,

remove the four button head cap screws and washers (keys 40 and 53, figure 16) and remove the insulator assembly.

Changing Mounting Methods

WARNING

To avoid personal injury from contact with the process fluid, lower the vessel fluid level below the torque-tube arm before proceeding. For closed vessels, release any pressure that may be above the fluid. Also, be careful to avoid overloading a thin-wall torque tube with an overweight displacer.

Refer to figure 19 for key number locations.

1. Remove the controller/transmitter as described pre-

viously.

2. A controller/transmitter is attached to the sensor in

one of the mounting positions shown in figure 4. Righthand mounting is with the controller/transmitter case (key 1) to the right of the displacer (FLOAT), as you look at the front of the case, left-hand mounting is with with the case to the left of the displacer. For a 249 Series sensor, remove the torque tube arm from the sensor or vessel and reinstall the torque tube arm in the

20A7423–C/DOC

Figure

16. Heat Insulator for 249 Series Sensor

opposite position according to the appropriate instruction manual. Note that the term FLOAT is marked on the RAISE LEVEL dial and the indicator plate, if one is used.

3. Check the desired control action. If the control action is not correct, refer to the changing action procedures to change it. Mount the Bourdon tube in one of the positions shown in figure 17.

4. The arrow on the RAISE LEVEL dial under the word FLOAT should point toward the displacer. If not, remove the dial from the controller, turn it over, and install it in the correct position.

5. For a controller/transmitter with an indicator assembly, the arrow near the word FLOAT on the indicator plate should point toward the displacer. If it does not, remove the two screws (key 41, see detail of indicator assembly in figure 19), turn the front plate (key 54) to the side with the FLOAT arrow pointing toward the displacer, and secure the plate with the screws.

6. Install the controller/transmitter according to the next section.

Page 26

Type 2500

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 torque tube arm in the shop; then calibrate and return the controller/transmitter with the torque tube arm assembly attached for installation.

Perform step 1 only if adding a heat insulator to a unit that does not have one. Key numbers in this step are shown in figure 16.

1. To install the heat insulator, secure the shaft exten-

sion (key 37) to the torque tube assembly rotary shaft with the shaft coupling (key 36). Tighten both set screws (key 38), with the coupling centered as shown in figure 16. 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 loading of this shaft could cause erroneous readings. Additionally, make sure the ball bearing assembly (key 12, figure 19) is removed from the case (key 1, figure 19) to provide clearance when installing the case on the sensor.

5. Install the flapper base (key 30, figure 19) on the torque tube rotary shaft, making sure the flapper is centered over the nozzle or Bourdon tube valve. Secure the base with the hex nut (key 40, figure 19). For a controller/transmitter with an indicator assembly, install the pointer assembly according to the section entitled Replacing the Bourdon Tube.

6. Connect the supply and output pressure tubing and perform the calibration procedure.

Replacing the Bourdon Tube

Refer to figure 19 for key number locations.

1. Disconnect the tubing (key 10 for Type 2503 and key 11 for Type 2500) from the Bourdon tube base. For a controller/transmitter with indicator assembly, loosen the side hex clamp nut (key 40) and remove the pointer assembly (key 51) from the torque tube rotary shaft.

2. Remove the mounting screws (key 45) and Bourdon tube assembly (key 16).

3. Inspect the Bourdon tube. Replace it if necessary, using a tube with a black color code for a 3 to 15 psig or 0 to 20 psig (0.2 to 1 bar or 0 to 1.4 bar) range. Use a tube with a red color code for a 6 to 30 psig or 0 to 35 psig (0.4 to 2 bar or 0 to 2.4 bar) 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 17. Connect the tubing to the tube base, with tubing from the R connection on the relay (key 34) going to the marked 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

2. Remove the bearing assembly (key 12, figure 19)

from the case (key 1, figure 19).

3. Carefully slide the controller/transmitter case

straight in. Secure the case on the torque arm or insulator with the four cap screws (key 39).

Note

If a heat insulator is used, do not insulate its exterior.

4. Slide the bearing assembly (key 12, figure 19) onto

the shaft or shaft extension of the insulator, and install the bearing assembly (key 12, figure 19) into the case (key 1, figure 19).

The following procedure is necessary to restore previous action if the mounting method has been changed. Figure 19 shows key numbers.

1. Reposition the Bourdon tube (and indicator assembly, if used) according to steps 1 through 4 of the section entitled Replacing the Bourdon Tube.

2. Loosen the hex nut (key 40) and remove the flapper base (key 30) from the torque tube rotary shaft. Turn the flapper base over and install it on the rotary shaft, using the proper orientation as shown in figure 17 and making sure the flapper is centered over the nozzle or Bourdon tube valve.

3. Perform the calibration procedure.

Page 27

Type 2500

AC9554 AR8148 BO996–1/IL

Figure

17. Bourdon Tube-Flapper Arrangements for Various Actions and Mountings

Relay Deadband Testing (Type 2500 Controller or 2500T Transmitter Only)

1. Replace the appropriate (proportional or specific

gravity) adjustment assembly with the 1/8-inch NPT pipe plug according to the section entitled Replacing the Proportional Valve.

2. Turn on the supply pressure and set it to 20 or 35

psig (1.4 to 2.4 bar), 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 15 or 30 psig (1.0 or 2.0 bar). While monitoring the output pressure, slowly change the process variable until the output pressure just changes, and record the value of the process variable at the detection point.

4. Change the process variable in the opposite direc-

tion until the output pressure just changes and again record the value of the process variable. If the differ-

ence between the two recorded values (the deadband) is more than 0.2% of the maximum displacer length, the relay must be replaced or repaired according to the Changing Relay section.

5. Turn off the supply pressure, remove the pipe plug, and install the appropriate adjustment assembly.

Replacing the Proportional Valve

Note

The following procedure, to convert to or from the pipe plug or the desired adjustment assembly, can be used for any type number covered in this manual.

1. Remove the tubing (key 10) from the proportional band valve assembly.

2. Unscrew the base of the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment assembly (key 36

Page 28

Type 2500

or 90, figure 19), or the 1/8-inch NPT pipe plug (key 73, not shown), from the relay base (key 23, figure

19).

3. Install the pipe plug or the desired adjustment as-

sembly 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, repair, or replacement.

Removal

1. For a controller or transmitter with indicator assem-

bly, 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, slide the base plate under the two lower screws of the relay case, align the plate so the pointer will read properly, and tighten the screws.

2. Connect the tubing (key 10 or 11) to the relay.

3. Test the relay deadband, according to the Relay

Deadband Testing procedure in this section.

4. If the deadband is within tolerance, go to the Cal-

ibration section. If the deadband is not within tolerance, perform the Relay Assembly Maintenance procedure

Relay Assembly Maintenance

The alignment tool shown in figure 18 is not essential for assembly of the relay, but its use does prevent excessive air consumption and deadband. If low air consumption and minimum deadband are required, make or purchase the alignment tool before disassembling the relay.

Refer to figures 20 and 21 for key number locations.

Disassembly

1. Remove the relay according to the Changing Relay

procedure in this section.

2. Remove the orifice assembly or connector (key

88), check to see if the orifice is plugged or damaged,

and inspect the O-ring (key 90).

3. Remove six casing screws and washers (keys 96

and 98) and, remove the top diaphragm (key 91). For

15A3519–B A6016

Figure

18. Relay Alignment Tool

a high temperature relay, also remove the gasket (key 100, figure 21) that covers the diaphragm.

4. Remove the spacer ring (key 84), diaphragm assembly (key 86), and relay spring (key 92) from the relay body (key 83). On a high temperature relay, also remove the gasket (key 99, figure 21) from underneath the diaphragm assembly.

5. Remove the four screws (key 97), spring plate (key

95), spring plate gasket (key 94), spring (key 92), and inner valve (key 87).

6. Inspect the valve seats for roughness due to corrosion. One seat is in the diaphragm assembly; the other is in the relay body (key 83). If necessary, replace the parts.

7. Inspect the diaphragms and gaskets, and replace them if necessary. Also, replace the spring and inner valve (keys 92 and 87) if they show signs of corrosion. The lower diaphragm comes as part of an assembly; it must be installed as an assembly.

8. Clean all parts thoroughly before assembly.

Assembly

1. Place the relay spring in the relay body and, for a high temperature relay, install a bottom gasket. Install the diaphragm assembly, spacer ring, and top diaphragm on the body so that all flow passage holes are in line. For a high temperature relay, also install a gasket over the top diaphragm.

2. Place the casing assembly on the top diaphragm so that the lugs on the casing and spacer ring line up and are also in line with the body lug.

Page 29

Type 2500

3. Install the machine screws (key 96) and, for stan-

dard relays, the washers (key 98), but do not tighten the screws.

4. If the optional alignment tool (figure 18) is available,

insert the small end of the tool into the opening in the relay body. If the tool does not engage in the hole of the diaphragm assembly, move the parts slightly to reposition the diaphragm so the alignment tool does engage the hole in the diaphragm assembly. Do not remove the alignment tool until the machine screws (key 96) are tightened.

5. Tighten the machine screws (key 96) evenly. Re-

move the alignment tool, if one is used.

6. Install the inner valve, spring, gasket, and cover

plate (keys 87, 92, 94, and 95). Secure them with the four machine screws (key 97).

7. Install the O-ring (key 90) on the orifice assembly

(key 88), and install the orifice assembly into the relay casing.

8. Install the relay according to the Changing Relay

procedure.

9. Install a new gasket (key 22, figure 19), the re-

placement relay (key 34, figure 19), and secure them with two mounting screws (key 43, figure 19).

10. Connect the tubing (key 11, figure 19) to the relay.

11. Test the relay deadband according to procedures

in this section.

12. If the deadband is within tolerance, go to the Cal-

ibration section.

Parts Ordering

Whenever corresponding with the sales representative about this equipment, use the controller/transmitter type number and the serial number. The serial number is found on the nameplate (key 215, figure 19). When ordering replacement parts, also state the complete 11-character part number of each part required as found in the following parts list.

Parts

Key Description Part Number

Controller Parts Kits

List

Type 2500 Controller Repair Kits

Contains keys 12, 15, 21, 24, 38, and

the flapper assembly

Standard temperature High temperature

R2500 X00L32

R2500 X00H32

Key Description Part Number

Type 2503 Controller and Relay Repair Kit

Standard temperature only

For the controller, the kit contains

keys 12, 21, 22, 24, 38, and the

flapper assembly. For the relay, the

kit contains keys 86, 90, 91, and 94

Relay Repair Kits

Contains keys 22, 85, 86, 87, 88, 90, 91, 92,

93, 94, (99 and 100 high temperature only)

and the plug and wire assembly

Standard temperature RRELAYX0L12 High temperature RRELAYX0H12

Relay Replacement Kit

Contains keys 22, 43, and the relay assembly

Standard temperature RRELAYX0L22 High temperature RRELAYX0H22

Heat Insulator Retrofit Kit

Contains the heat insulator parts shown

in figure 16 and listed under Heat

Insulator in this parts list R2500XH0012

R2503 X00022

Common Controller/Transmitter Parts (figure 19)

1 Case back 57A0953 X012 2 Case cover, aluminum 50B9454 X012 3 Door handle, pl steel 4 Door handle shaft (not shown), brass

5 Machine screw, steel 6 Spring washer, stainless steel 7 Door hook, pl steel 8 Stop nut, pl steel 9 Drive-lock pin, (2 req’d) 10 Tubing assembly,

For all 2500 Series except Type 2503

Copper Stainless steel

For Type 2503 only

Copper Stainless steel

11 Relay tubing

Copper Stainless steel

12 Ball bearing assembly, Brass, pl

13 Retaining ring, pl steel (2 req’d) 14 Gauge glass (2 req’d) 15 Gauge glass gasket, neoprene (2 req’d) 16* Bourdon tube assembly,

Brass

Type 2500 and 2500T

3 to 15 psig 32B1231 X012 6 to 30 psig 32B1231 X022

Type 2500S

0 to 20 psi 32B1233 X012 0 to 35 psig 32B1233 X022

Type 2503

0 to 20 psig 32B1234 X012 0 to 35 psig 32B1234 X022

Stainless steel

Type 2500 and 2500T

3 to 15 psig 32B1232 X032 6 to 30 psig 32B1232 X042

1C8972 25082 1C8984 14012

1C8958 X0022

1C8970 36032

1C8971 25082 1C8959 X0012 1C8991 X0022

1C9154 000A2 1N7983 X0012

1H3093 17052 1H3093 X0012

1H2738 000A2 1N7984 X0012 1C8983 000A2

1A4658 28992

0T0192 06042 0T0191 04082

*Recommended spare parts

Page 30

Type 2500

LEVEL SET MOUNTING SCREWS

SEE VIEW A

30A8865–D/DOC

32B0465–B/DOC

TYPE 2503 CONNECTOR DETAIL

ORIFICE ASSEMBLY

(SEE FIGURE 21)

NOTE: PARTS NOT SHOWN 4, 24, 38, 39, 47, AND 48.

TYPICAL CONTROLLER

30A8866–C/DOC

TYPE 2503R CONTROLLER

CONSTRUCTION

30A8869–D/DOC

DETAIL OF INDICATOR

ASSEMBLY ON C VERSIONS

Figure 19. 2500 Series Controller / Transmitter Constructions

Page 31

Type 2500

Key Description Part Number

19* Triple scale gauge (2 req’d)

Brass

0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8577 X012 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8577 X022

Stainless steel

0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8583 X012 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8583 X022

19* Dual scale gauge (2 req’d)

Brass

0 to 30 psig / 0 to 2 kg/cm 0 to 60 psig / 0 to 4 kg/cm

Stainless steel

0 to 30 psig / 0 to 2 kg/cm

21* Cover gasket, nitrile

2 2

11B8577 X042 11B8577 X052

11B8583 X032 1C9198 06342

22* Relay gasket

Standard temperature, neoprene High temperature, silicon

1C8974 03012

1N8738 04142 23 Relay base 47A0950 X012 24* Relay base gasket (not shown)

Standard temperature, neoprene High temperature, silicon

25 Flexure strip, stainless steel,

26 Flexure strip nut, pl steel (2 req’d) 27 Flexure strip base, pl steel 28 Level set arm, pl steel 29 Drivelok pin, pl steel 30 Flapper base, brass, pl

1C8973 03012

1N8739 04142

1C8978 36012

1C8975 25082

1C8977 25082

1C8976 25082

1C8989 X0012

1C9261 14022 31 Shaft clamp screw, SST

(2 req’d for C version only, 1 req’d for all others) 32 Flapper, stainless steel 33 Alignment screw, brass, pl

1B4514 35172

1C9262 38992

1B4517 14022

34 Relay assembly

(For individual parts see following list and figure 21),

For all 2500 Series except Type 2503

Standard temperature 22B0463 X012 High temperature 22B0462 X012 Corrosive service 22B0463 X032

Type 2503 only

Standard temperature 32B0464 X012 High temperature 32B0465 X012

MACHINE SCREW (KEY 97, 4 REQUIRED)

SPRING PLATE (KEY 95)

PLATE GASKET (KEY 94)

VALVE SPRING (KEY 93)

INNER VALVE (KEY 87)

RELAY BODY (KEY 83)

RELAY SPRING (KEY 92)

DIAPHRAGM ASSEMBLY (KEY 86)

SPACER RING (KEY 84)

DIAPHRAGM (KEY 91)

CASING ASSEMBLY (KEY 85)

O-RING (KEY 90)

ORIFICE ASSEMBLY (KEY 88)

CORE ASSEMBLY (INCLUDED WITH KEY 88)

CP1885-C A3892-2/IL

MACHINE SCREW (KEY 96, 6 REQUIRED)

Figure 20. Relay Assembly (Standard Temperature Shown)

35 Level adjustment assembly (controllers only) 10A8939 X0A2 35 Zero adjustment assembly (transmitters only) 10A8939 X0C2 36 Proportional band adjustment assembly

(except transmitters and Type 2503 controllers, see key 90)

Standard and high temperature 10A9122 X032 Corrosive service 10A9122 X082

37 Type 67FR regulator 38* Filter gasket (not shown)

Standard temperature, neoprene

High temperature, silicon 39 Cap screw (not shown), pl steel (2 req’d) 40 Hex nut, pl steel

(2 req’d for C versions, 1 req’d for all others) 41 Screw, pl steel

(2 req’d for C versions only) 16A6938 X022 42 Machine screw, pl steel (8 req’d) 1V7435 X0022 43 Machine screw, pl steel (2 req’d) 1A3776 X0012 44 Machine screw, pl steel (6 req’d) 1A5733 X0012 45 Machine Screw, pl steel (2 req’d) 46 Machine Screw, pl steel (4 req’d) 47 Spring (not shown), stainless steel 48 Cap screw, pl steel (4 req’d) 1A3816 K0012

*Recommended spare parts

1C8986 03012 1N8740 04142 1C3988 X0022

1L2863 38992

1H1581 X0012 1C8990 X0012

1J4234 37022

Key Description Part Number

49 Machine screw, pl steel (13 req’d) 1B7839 X0012 50 Screen, alloy 400

0L0783 43062

51 Pointer assembly (C versions only),

Stainless steel/brass, pl 1E8735 000A2

52 Washer (C versions only), steel (2 req’d) 1E8730 X0012

53 Base plate (C versions only), aluminum 54 Front plate (C versions only), aluminum 73 Pipe plug (Type 2503 only), brass (not shown)

1E8731 11992 1E8732 11992 1A6219 14012

90 Specific gravity adjustment assembly

Standard and high temperature 10A8870 X0A2 Corrosive service 10A8870 X022

215 Nameplate – – – – – – – –

Relay (figure 20 and 21)

83 Relay body,

Standard and high-temp., aluminum/brass 48A3776 X012

Corrosive service, aluminum/stainless steel 48A3776 X032 84 Spacer ring, aluminum 38A3778 X012 85 Casing assembly, aluminum/steel 12B0460 X012

Page 32

Type 2500

 APPLY LUB

22B0463-B / DOC

Figure 21. Typical Relay Assembly

Key Description Part Number

86* Diaphragm assembly

Standard temperature, nitrile/nylon 18A2451 X012 High temperature, polyacrylate/nylon 18A2451 X092 Corrosive service, nitrile/nylon 18A2451 X042

87* Inner valve, brass

Standard temperature Corrosive service 0Y0617 X0022

88* Orifice assembly

(1)

(all except Type 2503), brass 12B0468 X012

0Y0617 14012

88 Connector (Type 2503 only), brass 22B0461 X012 90*

O-Ring (2 req’d)

Standard temperature, nitrile High temperature, fluoroelastomer

91*

Top diaphragm

Standard temperature, nitrile/nylon

1D6875 06992 1N4304 06382

1L5556 02042

High temperature, polyacrylate/nylon 1K6999 X0012 92 Relay spring, pl steel 93 Valve spring, stainless steel

1C8961 27012

0X0836 37022

94* Spring plate gasket

Standard temperature, neoprene

High-temperature, silicon

1H2696 03012

1K7000 04142

Key Description Part Number

95 Spring plate, pl steel

1H2697 25072 96 Machine screw, pl steel (6 req’d) 1A3294 X0022 97 Machine screw, pl steel (4 req’d) 1A8664 X00A2 98 Washer (standard temperature only),

pl steel (6 req’d) 1P8261 X0012 99* Bottom gasket (high-temperature only), silicon 100* Top gasket (high-temperature only), silicon

1K7001 04142

1K7002 04142 168 Lubricant, Lubriplate Mag-1 (not furnished with controller) 169 Lubricant, Dow Corning Compound 111

(not furnished with controller)

--- Relay alignment tool (see figure 18) 15A3519 X012

Heat Insulator (figure 16)

35 Heat Insulator Assembly, stainless steel 22A0033 X012 36 Shaft Coupling, stainless steel 37 Shaft extension, alloy K500 38 Set screw, stainless steel (2 req’d) 1E6234 X0022

39 Cap screw, pl steel (4 req’d) 40 Cap screw, pl steel (4 req’d) 53 Washer, carbon steel, pl (4 req’d)

1A5779 35032

1B6815 40022

1A3816 24052

1V2395 28982

1B8659 28982

                                        

For information, contact Fisher Controls:

Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 0512

Printed in U.S.A.





*Recommended spare parts

1. Key 88, orifice assembly, now includes the core assembly. Key 89, core assembly, has been deleted from the parts list.

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Fisher 2500 Series, 2500R Series, 2503 Series, 2500S Series, 2500T Series Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual