Emerson Fisher 2503 User manual

www.Fisher.com

Fisher™2500 and 2503 Controllers and Transmitters

Contents

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

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

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

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

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

Installation 5....................................

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

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

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

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

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

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

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

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

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

Controller/Transmitter Output Connection 13..

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

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

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

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

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

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

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

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

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

Proportional Band Adjustment

(Except Transmitters and 2503

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

Specific Gravity Adjustment

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

Calibration 20...................................

Precalibration Requirements 20.................

Wet Calibration 20.........................

Dry Calibration 21.........................

Controller/Transmitter and Torque Tube Arm

Disassembly 21.........................

Determining the Amount of

Suspended Weight 21....................

Calibration Procedure 22.......................

2500 Controller and 2500T Transmitter 23.....

2500S and 2503 Controllers 25..............

Startup 27......................................

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

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

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

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

Figure 1. Fisher 2500 or 2503 Controller/Transmitter

on 249 Caged Sensor

2500 OR 2503

CONTROLLER/

TRANSMITTER

249 SENSOR

W8334

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

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

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

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

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

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

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

Removing Controller/Transmitter from Sensor 32..

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

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

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

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

Relay Deadband Testing (2500 Controller

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

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

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

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

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

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Introduction

Scope of Manual

This manual provides installation, operating, calibration, maintenance, and parts ordering information for 2500 and

2503 pneumatic controllers and transmitters used in combination with 249 displacer sensors.

Note

This manual does not include installation or maintenance procedures for the supply pressure regulator, sensor, or other devices.

For that information, refer to the appropriate instruction manual for the other device.

Do not install, operate, or maintain a 2500 or 2503 pneumatic controller/transmitter without being fully trained and

qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or

property damage, it is important to carefully read, understand, and follow all contents of this quick start guide,

including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson

sales office or Local Business Partner before proceeding.

Description

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

gravity). Each unit consists of a 249 displacer‐type fluid level sensor and a 2500 or 2503 pneumatic controller or

transmitter. Figure 1 shows a typical controller‐sensor combination.

Specifications

Refer to table 1 for specifications.

Educational Services

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

contact:

Emerson Automation Solutions

Educational Services - Registration

Phone: 1-641-754-3771 or 1-800-338-8158

E-mail: [email protected]

emerson.com/fishervalvetraining

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Table 1. Specifications

Available Configurations(1)

2500—Proportional‐only controller

2500C—Proportional‐only controller with indicator

(see figure 10)

2500R—Reverse acting proportional‐only controller

2500S—Differential gap (snap acting) controller. See

changing controller action procedure and figure 15

2500T—Transmitter

2503—Differential gap controller without

proportional valve; for applications requiring very

little adjustment

Input Signal

Fluid Level or Fluid‐to‐Fluid Interface Level: From 0 to

100% of displacer length—standard lengths for all

sensors are 356 mm or 812 mm

(14 inches or 32 inches). Other lengths available

depending on sensor construction.

Fluid Density: From 0 to 100% of displacement force

change obtained with given displacer volume.

Standard volume for displacers are listed in table 2.

Output Signal

2500 Controller and 2500T Transmitter: 0.2 to 1 bar

(3 to 15 psig) or 0.4 to 2 bar (6 to 30 psig)

2500S and 2503 Differential Gap Controllers: 0 bar (0

psig) when switched off and full supply [1.4 or 2.4 bar

(20 or 35 psig) nominal depending on controller

output pressure range] when switched on.

Area Ratio of Relay Diaphragms

3:1

Supply Pressure Data

See table 3(2)

Supply Medium

Air or Natural Gas

Supply medium must be clean, dry, and noncorrosive

Per ISA Standard 7.0.01

A maximum 40 micrometer particle size in the air

system is acceptable. Further filtration down to 5

micrometer particle size is recommended. Lubricant

content is not to exceed 1 ppm weight (w/w) or

volume (v/v) basis. Condensation in the air supply

should be minimized

Per ISO 8573-1

Maximum particle density size: Class 7

Oil content: Class 3

Pressure Dew Point: Class 3 or at least 10_C less than

the lowest ambient temperature expected

Maximum Supply Pressure(2,3)

3 bar (45 psig) to the controller or transmitter. If

controller or transmitter is equipped with an

integrally mounted 67CFR filter/regulator, typical

supply pressure to the regulator is from 2.5 bar (35

psig) to 17 bar (250 psig), maximum. For supply

pressures to the filter/regulator, refer to the

appropriate regulator instruction manual.

Steady‐State Air Consumption

2500 Controllers and Transmitters (2500, 2500C,

2500R, 2500S, and 2500T): See table 3

2503 Controller: Vents only when relay is exhausting

Proportional Band Adjustment (Proportional‐Only

Controllers)

Full output pressure change adjustable over 10 to

100% of displacer length(4)

Differential Gap Adjustment (Differential Gap

Controllers)

2500S Controller: Full output pressure change

adjustable from 20 to 100% of displacer length.(4)

2503 Controller: Full output pressure change

adjustable over approximately 25 to 40% of displacer

length(4)

Span Adjustment (2500T Transmitter)

Full output pressure change adjustable from 20 to

100% of displacer length(4)

Set Point (controllers only) or Zero (transmitters

only) Adjustment

For proportional‐only controllers or transmitters,

level adjustment positions the set point or zero for

the fluid level, interface level, or displacer force

change (density) within the displacer length.

For differential gap controllers, level adjustment

simultaneously positions both ends of the gap within

the displacer length.

(continued)

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Table 1. Specifications (Continued)

Performance

Independent Linearity (transmitters only): 1% of

output pressure change for 100% span.

Hysteresis: 0.6% of output pressure change at 100%

proportional band, differential gap, or span

Repeatability: 0.2% of displacer length or

displacement force change

Deadband (except differential gap controllers(5)):

0.05% of proportional band or span

Typical Frequency Response: 4 Hz and 90 degree

phase shift at 100% proportional band with output

piped to typical instrument bellows using 6.1 meters

(20 feet) of 1/4‐inch tubing

Ambient Operating Temperature Limits(3)

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 71_C(‐40 to 160_F)

High‐Temperature Construction: ‐18 to 104_C

(0 to 220_F)

Typical Ambient Temperature Operating Influence

Output pressure changes 1.5% per 10_C (50_F)

change in temperature at 100% proportional band

when using a standard wall torque tube with 249

sensors

Hazardous Area Classification

2500 and 2503 controllers/transmitters comply with

the requirements of ATEX Group II Category 2 Gas

and Dust

Supply and Output Connections

1/4 NPT internal

Maximum Working Pressure (sensors only)

Refer to the appropriate sensor instruction manual

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

1. Controllers are field adjustable between direct or reverse action. The letter R in the type number indicates that the controller/transmitter shipped from the factory set for reverse action (see chang

ing controller action procedures). The letter C in the type number indicates that a pointer is attached to the torque tube shaft providing visual monitoring of torque tube motion.

2. Control and stability may be impaired if the maximum pressures are exceeded.

3. The pressure/temperature limits in this document, and any applicable standard or code limitation should not be exceeded.

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

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

Table 2. Standard Displacer Volumes

Sensor Standard Volume

Liters

Standard Volume

Cubic Inches

249, 249B, 249BF, 249BP, 249K, 249P, 249W

249C, 249CP, 249W

249L

249VS

1.6

1.0

1.9

1.3(3)

100(1)

60(2)

120

80(3)

1. For 249W, with standard 812 mm (32‐inch) displacer.

2. For 249W, with standard 356 mm (14‐inch) displacer.

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

Table 3. Supply Pressure Data

OUTPUT SIGNAL RANGE

STANDARD SUPPLY AND

OUTPUT

PRESSURE GAUGE

INDICATIONS(1)

NORMAL OPERATING

SUPPLY PRESSURE(2)

AIR CONSUMPTION AT

NORMAL OPERATING

SUPPLY PRESSURE MAXIMUM

SUPPLY PRESSURE

Bar Psig Minimum(3) Maximum(4)

0.2 to 1 bar (3 to 15 psig) 0 to 30 psig 1.4 20 4.2 scfh(5) 27 scfh(5) 3 bar (45 psig)

0.4 to 2 bar (6 to 30 psig) 0 to 60 psig 2.4 35 7 scfh(5) 42 scfh(5) 3 bar (45 psig)

1. Consult your Emerson Automation Solutions sales office about gauges in other units.

2. Control and stability may be impaired if this pressure is exceeded.

3. At zero or maximum proportional band or specific gravity setting.

4. At setting in middle of proportional band or specific gravity range.

5. If air consumption is desired in normal m3/hr at 0_C and 1.01325 bar, multiply scfh by 0.0258.

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

0 20 40 60 80 100 120 140 160

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE

PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT

MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)

01020

−18 −10 30 40 50 60 70

593

500

400

300

200

100

−40

400

800

1100

−20 NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (_C)

STANDARD CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (_F)

HEAT INSULATOR

REQUIRED

TOO

HOT

NOTE:

FOR APPLICATIONS BELOW -29_C (-20_F), BE SURE THE SENSOR MATERIALS OF CONSTRUCTION

ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.

PROCESS TEMPERATURE ( C)

PROCESS TEMPERATURE ( F)

0 20 40 60 80 100 120 140 200

010 20

−18 −10 30 40 50 60 70 105593

500

400

300

200

100

400

800

1100

−20

NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (_C)

HIGH‐TEMPERATURE CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (_F)

HEAT INSULATOR

REQUIRED

TOO

HOT

PROCESS TEMPERATURE ( C)

PROCESS TEMPERATURE ( F)

180160

80 90

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS

TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND

REDUCE INSULATOR EFFECTIVENESS.)

CV6190-E

B1413‐3

−40

−29

−18

100

220

thank

Table 4. Displacer and Torque Tube Materials

Part Standard Material Other Materials

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

Displacer Stem, Driver Bearing,

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

Torque Tube N05500(1) 316 Stainless Steel, N06600, N10276

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

Installation

2500 and 2503 controller/transmitters work in combination with 249 displacer‐type sensors. The factory attaches the

controller/transmitter to the sensor, unless it is ordered separately.

If using natural gas as the pneumatic supply medium, natural gas will be used in the pressure connections of the unit

to any connected equipment. The unit will vent natural gas into the surrounding atmosphere.

WARNING

Always wear protective clothing, gloves, and eyewear when performing any installation operations to avoid personal

injury.

Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this

instruction manual.

CAUTION

Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed

by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

WARNING

Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and

preventive measures are not taken. Preventive measures may include, but are not limited to, one or more of the following:

Remote venting of the unit, re‐evaluating the hazardous area classification, ensuring adequate ventilation, and the

removal of any ignition sources. For information on remote venting of this controller refer to page 13.

Sensor Assembly

Table 2 lists sensors recommended for use with controller/transmitters. Table 4 contains displacer and torque tube

materials. For sensor installation and maintenance, refer to the appropriate sensor instruction manual.

WARNING

When replacing the sensor assembly, the displacer may retain process fluid or pressure. Personal injury or property

damage may occur due to sudden release of the pressure. Contact with hazardous fluid, fire, or explosion can be caused by

puncturing, heating, or repairing a displacer retaining process pressure or fluid. This danger may not be readily apparent

when disassembling the sensor assembly or removing the displacer. Before disassembling the sensor or removing the

displacer, observe the more specific warning provided in the sensor instruction manual.

Uncrating

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

assembly.

CAUTION

Sensors used for interface or density control may be so large and heavy that the torque tube cannot fully support their

weight in air. On the 249VS, a travel stop is used to prevent damage. Do not remove this travel stop assembly without first

removing the displacer from the displacer rod. Refer to the appropriate instruction manual for 249 cageless sensors.

Note

Caged sensors have rods and blocks installed at each end of the displacers to protect the displacers in shipping. Remove these

parts before you install the sensor to allow the displacer to function properly.

Caged sensors come with the displacer installed in the cage. If a tubular gauge glass is ordered with the sensor, the

gauge glass is crated separately and must be installed at the site. A damping plate is installed in the lower screwed or

flanged connection (see figure 3) to provide more stable operation. Be certain that the cage equalizing connections

and the damping plate are not plugged by foreign material.

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

W0144-1

W2141-1B

DISPLACER

CAGE

SCREWED

CONNECTION

FLANGED

CONNECTION

DAMPING PLATE

Figure 3. Damping Plate Location

A cageless sensor comes with its displacer separated from the sensor assembly. Displacers longer than 813 mm (32

inches) come in a separate crate. Shorter displacers come in the same crate as the sensor, but are not attached to their

displacer rods. Inspect the displacer to ensure it is not dented. A dent may reduce the pressure rating of the displacer.

If a displacer is dented, replace it.

Controller/Transmitter Orientation

The controller/transmitter attaches to the sensor in one of the mounting positions shown in figure 4. Right‐hand

mounting is with the controller or transmitter case to the right of the displacer when you look at the front of the case;

left‐hand mounting is with the case to the left of the displacer. The mounting position can be changed in the field.

Changing this mounting position changes the control action from direct to reverse, or vice versa.

All caged sensors have a rotatable head. That is, the controller/transmitter may be positioned at any of eight alternate

positions around the cage as indicated by the numbers 1 through 8 in figure 4. To rotate the head, remove the head

flange bolts and nuts and position the head as desired.

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Figure 4. Cage Head Mounting Positions

RIGHT‐HAND MOUNTING LEFT‐HAND MOUNTING

1 67CFR FILTER/REGULATOR.

AH9150-A

A2613-2

Mounting Caged Sensor

Note

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

transmit an erroneous output signal.

Note

If the controller/transmitter is not mounted on the sensor, refer to the Installing Controller/Transmitter on Sensor procedures in

the Maintenance section. This section also provides instructions for adding a heat insulator to a unit.

Cage connections normally are either NPS 1‐1/2 or 2, screwed or flanged. Figure 5 shows the combinations. With

flanged connections, use standard gaskets or other flat‐sheet gaskets compatible with the process fluid. Spiral‐wound

gaskets without compression‐controlling centering rings cannot be used for flange connections.

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

Figure 5. Cage Connection Styles

A1271-2

STYLE 1: TOP

AND BOTTOM

STYLE 2: TOP

AND LOWER SIDE

STYLE 3: UPPER

AND LOWER SIDE

STYLE 4: UPPER

SIDE AND BOTTOM

SCREWED: S3

FLANGED: F3

SCREWED: S2

FLANGED: F2

SCREWED: S1

FLANGED: F1

SCREWED: S4

FLANGED: F4

As shown in figure 6, mount the cage by running equalizing lines between the cage connections and the vessel. A

shutoff or hand valve with a 1‐1/2 inch diameter or larger port should be installed in each of the equalizing lines. Also

install a drain between the cage and shutoff or hand valve whenever the bottom cage line has a fluid‐trapping low

point.

Figure 6. Caged Sensor Mounting

EQUALIZING LINE

DRAIN VALVE

EQUALIZING LINE

CENTER OF LIQUID

OR INTERFACE LEVEL

DF5379‐A

A1883‐2

SHUTOFF

VALVES

Instruction Manual

D200124X012

2500 and 2503 Controllers/Transmitters

June 2017

On fluid or interface level applications, position the sensor so that the center line on the cage (see figure 6) is as close

as possible to the center of the fluid level or interface level range being measured. Also consider installing a gauge

glass on the vessel, or on the sensor cage (if the cage is tapped for a gauge).

Mounting Cageless Sensor

Note

If a stillwell is used, install it plumb so that the displacer does not touch the wall of the stillwell. If the displacer touches the wall,

the unit will transmit an erroneous output signal.

Since the displacer hangs inside the vessel, provide a stillwell around the displacer if the fluid is in a state of continuous

agitation to avoid excessive turbulence around the displacer.

Note

Displacers used in an interface level application must be completely submerged during operation. If displacers aren't completely

submerged, they will not calibrate or perform properly. To obtain the desired controller or transmitter sensitivity may require

using either a thin‐wall torque tube, an oversized displacer, or both.

Note

If the controller/transmitter is not mounted on the sensor, refer to the Installing Controller/Transmitter on Sensor procedures in

the Maintenance section. This section also provides instructions for adding a heat insulator to a unit.

Attach a cageless sensor to a flanged connection on the vessel as shown in figure 7. For interface or fluid level

applications, install a gauge glass on the vessel.

Side‐Mounted Sensor

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

Connect the displacer as shown in figure 8, locking the assembly with the cotter spring provided. If a stillwell is not

required, attach the displacer rod before mounting the sensor on the vessel. Then, you can swing the displacer out

horizontally for insertion into the vessel. However, once the sensor is installed and the displacer drops to a vertical

position, the displacer may not be capable of being withdrawn for servicing later. Be sure there is another access to the

displacer to permit swinging it to a horizontal position or to permit disconnecting it from the displacer rod.

If an extension is used between the displacer spud and the displacer stem end piece, make sure the nuts are tight at

each end of the displacer stem extension. Install and tighten suitable bolting or cap screws in the flanged connection

to complete the installation.

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