Fisher 2500 Series, 2500R Series, 2503 Series, 2500S Series, 2500T Series Instruction Manual
...
Instruction Manual
Form 1013
February 1997
Type 2500
2500 an
d 2
50
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
2.
2
W3121-3/IL/A
11.
15
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
nd
2500 OR 2503 SERIES
CONTROLLER/
TRANSMITTER
Controller/
. . . . . . . . . .
20
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.
Fisher Controls International, Inc. 1977, 1997; All Rights Reserved
D200124X012
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
22
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.
2
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)
(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 160F (-40 to
71C)
High-Temperature Construction: 0 to 220F (-18
to 104C)
(continued)
(2)
(transmit-
(2)
: 4 Hz and 90 de-
3
Type 2500
PRESSURE GAUGE
SUPPLY PRESSURE
Table 1. Specifications (Continued)
Typical Ambient Temperature Operating Influence
Output pressure changes 1.5% per 50F
(10C)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
60
120
80
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 0C 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)
4
Type 2500
AMBIENT TEMPERATURE (C)
01020
–10
–18
1100
800
400
–20
–40
PROCESS TEMPERATURE ( F)
HEAT INSULATOR
REQUIRED
0
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
71
NOTE:
FOR APPLICATIONS BELOW –20F (–29C), 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
0
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)
0
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
5
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 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 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).
6
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.
7
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-
8
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.
9
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.
10
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