2500 and 2503 Series Level-Trol Controllers and Transmitters

Instruction Manual Form 1013 February 1997
Type 2500
2500 and 2503 Series Level-Trolr Controllers and Transmitters

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................................. 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
W3121-3/IL/A
2500 OR 2503 SERIES CONTROLLER/ TRANSMITTER 249 SERIES SENSOR
Prestartup Checks
...................... Type 2500 Controller or Type 2500T Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 2500S Controller . . . . . . . . . . . . . . . . . . . . . . Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level Adjustment (Controllers Only) . . . . . . . . . . . . . . . . . . . . . . Zero Adjustment (Transmitters Only) . . . . . . . . . . . . . . . . . . . . . Proportional Band Adjustment (Except Transmitters and 2503 Series Controllers) . . . . . . . . . . . . . . . . . . . . . . Specific Gravity Adjustment (Transmitters Only) . . . . . . . . . . . . . . . . . . . . . .
11 13 13 14 15 15 15 15 15 15
Figure 1. 2500 or 2503 Series Level-TrolR Controller/ Transmitter on Caged 249 Series Sensor
Controller/Transmitter and Torque Tube Arm Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining the Amount of Suspended Weight . . . . . . . . . . . . . . . . . . . . . Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . Type 2500 Controller and 2500T Transmitter . . . . . . . . . . . . . . . . . . . . . . Type 2500S and 2503 Controllers . . . . . . . . . . .
16 16 17 17 19
Calibration
Startup
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Precalibration Requirements . . . . . . . . . . . . . . . . . 15 Wet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Dry Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Type 2500 Controller . . . . . . . . . . . . . . . . . . . . . . . Type 2500T Transmitter . . . . . . . . . . . . . . . . . . . . Type 2500S Controller . . . . . . . . . . . . . . . . . . . . . . Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . . .
20 20 20 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. EFisher Controls International, Inc. 1977, 1997; All Rights Reserved
D200124X012
Type 2500
Contents (Continued)
Principle of Operation
.................. Type 2500 Controller or Type 2500T Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . Type 2500S Controller . . . . . . . . . . . . . . . . . . . . . . Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . . . ............................. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Controller/Transmitter from Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Mounting Methods . . . . . . . . . . . . . . . . Installing Controller/Transmitter on Sensor . . . . Replacing the Bourdon Tube . . . . . . . . . . . . . . . . Changing Action . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Deadband Testing (Type 2500 Controller or 2500T Transmitter Only) . . . . . . . . . . . . . . . . Replacing the Proportional Valve . . . . . . . . . . . . . Changing Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Assembly Maintenance . . . . . . . . . . . . . . 20 21 21 21 21 22 23 23 25 26 26 26 27 27 28 28 29 29
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 Series displacer-type fluid level sensor and a 2500 or 2503 Series pneumatic controller or transmitter. Figure 1 shows a typical controller-sensor combination.
Maintenance
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.
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor Assembly
Table 2 lists sensors recommended for use with controller/transmitters. For sensor installation and maintenance, 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.
Type 2500
Table 1. Specifications
Available Configurations(1) Type 2500Proportional-Only controller Type 2500CProportional-Only controller with indicator (see figure 12) Type 2500RReverse acting proportional-only controller Type 2500SDifferential gap (snap acting) controller. See changing controller action procedure and figure 17. Type 2500TTransmitter Type 2503Differential gap controller without proportional valve; for applications requiring very little adjustment. Input Signal(2) Fluid Level or Fluid-to-Fluid Interface Level: From 0 to 100% of displacer lengthstandard 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 supply [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(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 (ProportionalOnly Controllers) Full output pressure change adjustable over 10 to 100% of displacer length.(5) Differential Gap(2) Adjustment (Differential Gap 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.(5) Span(2) Adjustment (Type 2500T Transmitter) Full output pressure change adjustable from 20 to 100% of displacer length.(5) Set Point(2) (controllers only) or Zero(2) (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. 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 (2): 0.2% of displacer length or displacement force change. Deadband (2) (except differential gap controllers(4)): 0.05% of proportional band or span. Typical Frequency Response(2): 4 Hz and 90 degree 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)
Type 2500
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.
Supply and Output Connections 1/4-inch NPT female Maximum Working Pressure (sensors only) Refer to the appropriate sensor instruction manual.
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 100 60 120 80(1)
STANDARD VOLUME, Liters 1.6 1.0 1.9 1.3(1)
Table 3. Supply Pressure Data

OUTPUT SIGNAL RANGE 3 to 15 psig (0.2 to 1 bar) 6 to 30 psig (0.4 to 2 bar)
1. 2. 3. 4. 5.
STANDARD SUPPLY AND OUTPUT PRESSURE GAUGE INDICATIONS(1) 0 to 30 psig 0 to 60 psig
NORMAL OPERATING SUPPLY PRESSURE(2) Psig 20 35 Bar 1.4 2.4
AIR CONSUMPTION AT NORMAL OPERATING SUPPLY PRESSURE Minimum(3) Maximum(4) 4.2 scfh(5) 7 scfh(5) 27 scfh(5) 42 scfh(5)
MAXIMUM SUPPLY PRESSURE 45 psig (3 bar) 45 psig (3 bar)
Consult your Fisher Controls representative about gauges in other units. Control and stability may be impaired if this pressure is exceeded. At zero or maximum proportional band or specific gravity setting. At setting in middle of proportional band or specific gravity range. If air consumption is desired in normal m3/hr at 0_C and 1.01325 bar, multiply scfh by 0.0258.
Type 2500
PROCESS TEMPERATURE ( C) _ 800 TOO HOT 500 400 _ 300 200 100 18 29
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
PROCESS TEMPERATURE ( F)
HEAT INSULATOR REQUIRED
800
HEAT INSULATOR REQUIRED
TOO HOT
500 _ 400 300
400
400 NO INSULATOR NECESSARY 0

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
200 100 0
0 20 40
NO INSULATOR NECESSARY
40
20 160 0 20 40 60 80 100 120 140 160 180 200 220 AMBIENT TEMPERATURE (_F)
20
40
60
80
100
120
140
AMBIENT TEMPERATURE (_F)
STANDARD CONTROLLER OR TRANSMITTER

NOTE: FOR APPLICATIONS BELOW 20_F (29_C), BE SURE THE SENSOR MATERIALS OF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.
CV6190E B1413-2/IL
HIGHTEMPERATURE CONTROLLER OR TRANSMITTER
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. 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.
W01441/IL
DISPLACER CAGE
W21411B/IL
SCREWED CONNECTION
DAMPING PLATE
FLANGED CONNECTION
Figure 3. Damping Plate Location
PROCESS TEMPERATURE ( C)
PROCESS TEMPERATURE ( F)
18 1100
10
AMBIENT TEMPERATURE (_C) 10 20 30 40 50
60
71 70 593
18 10 1100
10
AMBIENT TEMPERATURE (_C) 20 30 40 50 60 70
80
90
100 105
593
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 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.
AH9150A A26131/IL
Figure 4. Cage Head Mounting Positions
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).
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-
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. 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.
CENTER OF LIQUID OR INTERFACE LEVEL SHUTOFF VALVES
A12712/IL
Figure 5. Cage Connection Styles
EQUALIZING LINE
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.
DRAIN VALVE
EQUALIZING LINE
DF5379-A A1883-2/IL
Figure 6. Caged Sensor Mounting
Type 2500
TOP MOUNTED
SIDE MOUNTED
CF5380-A A3893/IL W06451/IL
SIDE VIEW (SHOWING STILWELL)
SIDE VIEW (WITHOUT STILWELL)
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.
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
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
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-
Type 2500
DISPLACER STEM END PIECE
DISPLACER ROD DISPLACER STEM EXTENSION COTTER SPRING
COTTER SPRING LOCKING NUTS
DISPLACER SPUD
DISPLACER SPUD
W0229-1A/IL
W0228-1A/IL
DISPLACER ROD
TYPE 249V
ALL OTHER TYPES
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.
A07461/IL
Figure 9. Temperature-Compensated Displacer
Supply and Output Pressure Connections WARNING
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.
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.
Type 2500
10A1211A 22A9197B CD1700E A27081/IL
Figure 11. Controller/Transmitter Dimensions and Connections
A6620/IL
Figure 10. Piezometer-Ring Cage for Flow Line Mounting
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.
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-
10
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. Set the PROPORTIONAL BAND control on a Type 2500 or 2500S controller, or the SPECIFIC GRAVITY control on a Type 2500T transmitter, as follows: D Sensor with Both Standard Torque Tube and Standard Volume DisplacerIf 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. D Sensor with Nonstandard Torque Tube and/ or Displacer with Other than Standard VolumeIf 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 + ( L )(SP GR) V a (X) 100 Vr Required
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: D make sure there is no process flow through the final control element, or D 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.
where: L = 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 the process fluid (for interface 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).
11
Type 2500
W06411B/IL 1C9283B/DOC
BOURDON TUBE DETAIL OF TYPE 2500S ON-OFF CONTROLLER

LEVEL SET ARM MOUNTING SCREWS LEVEL SET ARM 3WAY VALVE FLAPPER ALIGNMENT SCREW SHAFT CLAMP NUT NOZZLE PLUNGER
RAISE LEVEL DIAL FOR LEFT-HAND MOUNTING
LEVEL ADJUSTMENT PROPORTIONAL BAND ADJUSTMENT
W06711/IL
W06561/IL
VENT
RELAY
FLAPPER
SPAN ADJUSTMENT
RIGHT-HAND MOUNTED TYPE 2503R ON-OFF CONTROLLER
RIGHT-HAND MOUNTED TYPE 2500 PROPORTIONAL CONTROLLER
SPECIFIC GRAVITY ADJUSTMENT ZERO ADJUSTMENT
POINTER ASSEMBLY
W06472B/IL
W06481B/IL
1E8731 1E8732 A18971/IL
DETAIL OF TRANSMITTER ADJUSTMENTS
INDICATOR ASSEMBLY WITH RIGHT-HAND MOUNTING
TRAVEL INDICATOR PLATE FOR LEFT-HAND MOUNTING
Figure 12. Adjustment Locations
12
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.
NOTE: EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.

1C9259G A38911/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 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.
13
Type 2500
Table 4. Recommended Settings For Pre-Startup Checks
RECOMMENDED RAISE LEVEL SETTING FOR TYPE 2500 CONTROLLER MOUNTING O G ACTION C O For Predetermined PROPORTIONAL BAND Dial Setting of 10 3.0 to 3.5 6.5 to 7.0 3.0 to 3.5 6.5 to 7.0 For Predetermined PROPORTIONAL BAND Dial Setting of 0 4.0 to 4.5 0.5 to 1.0 4.0 to 4.5 0.5 to 1.0 RECOMMENDED ZERO ADJUSTMENT SETTING FOR TYPE 2500T TRANSMITTER For Predetermined SPECIFIC GRAVITY Dial Setting of 1.0 1.5 to 2.0 to right 1.5 to 2.0 to left 1.5 to 2.0 to left 1.5 to 2.0 to right For Predetermined SPECIFIC GRAVITY Dial Setting of 0 0.5 to 1.0 to right 4.0 to 4.5 to right 0.5 to 1.0 to left 4.0 to 4.5 to left
Right-hand Left-hand
Direct Reverse Direct Reverse
1. For proportional band dial settings between 10 and 0 or for specific gravity dial settings between 1.0 and 0, interpolate the 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. 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.
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.
Type 2503 Controller

Note In the following steps the output pressure can go as high as the controller supply pressure.
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.
14
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.
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.
Adjustments
This section explains controller/transmitter action and adjustments. Figure 12 shows adjustment locations.
Control Action
The following is a definition of control action. D Direct ActionIncreasing fluid level, interface level, or density, increases the output signal. D Reverse ActionIncreasing 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. 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.
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.
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.
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.
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).
Note The raise level dial does not reflect actual fluid level in the tank or fluid level position on the displacer.
15
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. 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
Controller/Transmitter and Torque Tube Arm Disassembly
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: W s + W d[(0.0361)(V)(SP GR)] where: Ws = Total suspended weight in pounds (should never be less than 0.5 pounds). For a unit with a horizontal displacer, make sure the center of gravity of the substitute weight is where it would be on the actual displacer.
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
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).
16
Type 2500
Table 5. Minimum and Maximum Limits for Setting Process Variables
APPLICATION Liquid Level Interface Density MINIMUM LIMIT Displacer must be completely out of liquid Displacer must be completely submerged in lighter of two process liquids Displacer must be completely submerged in liquid having specific gravity of lowest range point MAXIMUM LIMIT Displacer must be completely submerged in liquid 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. V = Volume, in cubic inches, of the portion of the displacer submerged. Or, V = (/4) (displacer diameter)2 (length of displacer submerged) SP GR = Specific gravity of the process fluid at operating temperature. For interface level measurement, the equation becomes: W s + W d[(0.0361)(V t)(SP GR l) ) (0.0361)(V h)(SP GRh * SP GR l)] where: Vt = Total volume, in cubic inches, of the displacer. SP GRl = Specific gravity of the lighter of the fluids at operating temperature. Vh = Volume, in cubic inches, of the portion of the displacer submerged in the heavier of the fluids. Or, V = (/4) (displacer er submerged) diameter)2 (length of the displac-
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 procedure. 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.
Type 2500 Controller and 2500T Transmitter

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 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.
SP GRh = Specific gravity of the heavier of the fluids at operating 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
17
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. 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 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). D 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. D 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. 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: D 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. D 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
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: D To increase the output pressure span, slide the flexure strip base away from the torque tube shaft. D 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. 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: D If the output pressure span is too large, slightly increase the PROPORTIONAL BAND or SPECIFIC GRAVITY setting. D 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.
18
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. D For Reverse Acting Controllers, move the flapper 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: D 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. D For Reverse Acting Controllers, slowly increase 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.
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: D For direct acting controllers, set the RAISE LEVEL adjustment between 1.0 and 1.5. D 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. 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). D 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: D To decrease the differential gap, slide the flexure strip base away from the torque tube shaft. D 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.
19
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: D If the differential gap is too large, slightly decrease the PROPORTIONAL BAND setting. D If the differential gap is too small, slightly increase the PROPORTIONAL BAND setting. 12. Repeat the procedure from step 4 until the required 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.
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.

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.

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

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 narrowest (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.
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.
20
Type 2500
The following descriptions explain how the relay action produces the output signal with the various controller/ transmitter constructions. 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 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.

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.

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,
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
21
Type 2500
CD2114E BO9981/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-
22
Type 2500
BD4466A CD2114E A18901/IL
Figure 15. Direct-Acting Left-Hand-Mounted Type 2503 Controller
al tolerances, etc.), use only replacement parts manufactured or furnished by Fisher Controls.
available. The output signal measuring device should have corresponding accuracy. Table 6 lists some common operating faults, their probable causes, and corrective action.
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.
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.
Troubleshooting
When troubleshooting, open loop conditions must exist unless otherwise stated. When monitoring the process variable, use the most accurate level indicating device
23
Type 2500
Table 6. Troubleshooting Chart for 2500 Series Controller/Transmitters
FAULT 1. Process wanders or cycles around set point. POSSIBLE CAUSE 1.1 Proportional band or specific gravity adjustment incorrect or improperly tuned control loop. CHECK Ensure the prestartup procedures are completed correctly. Tune control loop. CORRECTION 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.
1.2 Supply pressure varying or incorrect supply pressure setting.
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. Check for relay malfunction by 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. Ensure the displacer is not filling with process fluid. Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle. Ensure the process variable has 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.
1.3 Sensor not plumb and is in contact with sidewall or leak in displacer. 1.4 Relay malfunction.
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.
2. Controller/transmitter controlling off set point or switching point.
2.1 Supply pressure not set correctly.
2.2 Leak in the controller/transmitter loop. 2.3 Leaking displacer.
2.4 Flapper adjustment.
2.5 Process variable changed.
3. Controller/transmitter cannot attain full output range.
3.1 Supply pressure not set correctly.
3.2 Flapper adjustment.
3.3 Process variable changed.
3.4 Relay malfunction
Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle. Ensure the process variable has not changed from original calibration settings, or from displacers designed specific gravity. Check for relay malfunction by using the testing relay deadband procedure. Use soap and water to check for internal and external leaks. Ensure the pressure gauges are registering correctly. Ensure the flapper is not loose on the torque tube shaft and is centered on the nozzle.
3.5 Leak in the controller/transmitter loop. 4. Controller/transmitter remains at full or zero output pressure. 4.1 Supply or output pressure gauge malfunction. 4.2 Flapper adjustment.
24
Type 2500
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. 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.
20A7423C/DOC
Figure 16. Heat Insulator for 249 Series Sensor
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 previously. 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 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.
25
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 extension (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. 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.
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. 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).
Changing Action
Note 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.
26
Type 2500
AC9554 AR8148 BO9961/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 direction 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
27
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 assembly 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 assembly, 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).
15A3519B A6016
Figure 18. Relay Alignment Tool
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 Calibration section. If the deadband is not within tolerance, perform the Relay Assembly Maintenance procedure 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.
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.
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.
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
28
Type 2500
3. Install the machine screws (key 96) and, for standard 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. Remove 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 replacement 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 Calibration section.
Key Description 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 High temperature Relay Replacement Kit Contains keys 22, 43, and the relay assembly Standard temperature High temperature Heat Insulator Retrofit Kit Contains the heat insulator parts shown in figure 16 and listed under Heat Insulator in this parts list Part Number
R2503 X00022
RRELAYX0L12 RRELAYX0H12
RRELAYX0L22 RRELAYX0H22
R2500XH0012
Common Controller/Transmitter Parts (figure 19)

1 2 3 4 5 6 7 8 9 10 Case back Case cover, aluminum Door handle, pl steel Door handle shaft (not shown), brass Machine screw, steel Spring washer, stainless steel Door hook, pl steel Stop nut, pl steel Drive-lock pin, (2 reqd) Tubing assembly, For all 2500 Series except Type 2503 Copper Stainless steel For Type 2503 only Copper Stainless steel Relay tubing Copper Stainless steel Ball bearing assembly, Brass, pl Retaining ring, pl steel (2 reqd) Gauge glass (2 reqd) Gauge glass gasket, neoprene (2 reqd) Bourdon tube assembly, Brass Type 2500 and 2500T 3 to 15 psig 6 to 30 psig Type 2500S 0 to 20 psi 0 to 35 psig Type 2503 0 to 20 psig 0 to 35 psig Stainless steel Type 2500 and 2500T 3 to 15 psig 6 to 30 psig 57A0953 X012 50B9454 X012 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
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.
11
12 13 14 15 16*
Parts List
Key Description Type 2500 Controller Repair Kits Contains keys 12, 15, 21, 24, 38, and the flapper assembly Standard temperature High temperature Part Number
32B1231 X012 32B1231 X022 32B1233 X012 32B1233 X022 32B1234 X012 32B1234 X022
Controller Parts Kits

R2500 X00L32 R2500 X00H32
32B1232 X032 32B1232 X042
*Recommended spare parts
29
Type 2500
LEVEL SET MOUNTING SCREWS SEE VIEW A
30A8865D/DOC
TYPICAL CONTROLLER
32B0465B/DOC
TYPE 2503 CONNECTOR DETAIL ORIFICE ASSEMBLY (SEE FIGURE 21)
30A8866C/DOC
TYPE 2503R CONTROLLER CONSTRUCTION
30A8869D/DOC
NOTE: PARTS NOT SHOWN 4, 24, 38, 39, 47, AND 48.
DETAIL OF INDICATOR ASSEMBLY ON C VERSIONS
Figure 19. 2500 Series Controller / Transmitter Constructions
30
Type 2500
Key 19* Description Triple scale gauge (2 reqd) Brass 0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar Stainless steel 0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar Dual scale gauge (2 reqd) Brass 0 to 30 psig / 0 to 2 kg/cm2 0 to 60 psig / 0 to 4 kg/cm2 Stainless steel 0 to 30 psig / 0 to 2 kg/cm2 Cover gasket, nitrile Relay gasket Standard temperature, neoprene High temperature, silicon Relay base Relay base gasket (not shown) Standard temperature, neoprene High temperature, silicon Flexure strip, stainless steel, Part Number
MACHINE SCREW (KEY 97, 4 REQUIRED) SPRING PLATE (KEY 95)
11B8577 X012 11B8577 X022 11B8583 X012 11B8583 X022
PLATE GASKET (KEY 94)
VALVE SPRING (KEY 93) INNER VALVE (KEY 87)
19*
11B8577 X042 11B8577 X052 11B8583 X032 1C9198 06342
RELAY BODY (KEY 83)
21* 22*
RELAY SPRING (KEY 92)
23 24*
1C8974 03012 1N8738 04142 47A0950 X012 1C8973 03012 1N8739 04142 1C8978 36012
DIAPHRAGM ASSEMBLY (KEY 86)
25 26 27 28 29 30 31 32 33 34
SPACER RING (KEY 84)
Flexure strip nut, pl steel (2 reqd) 1C8975 25082 Flexure strip base, pl steel 1C8977 25082 Level set arm, pl steel 1C8976 25082 Drivelok pin, pl steel 1C8989 X0012 Flapper base, brass, pl 1C9261 14022 Shaft clamp screw, SST (2 reqd for C version only, 1 reqd for all others) 1B4514 35172 Flapper, stainless steel 1C9262 38992 Alignment screw, brass, pl 1B4517 14022 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 Level adjustment assembly (controllers only) 10A8939 X0A2 Zero adjustment assembly (transmitters only) 10A8939 X0C2 Proportional band adjustment assembly (except transmitters and Type 2503 controllers, see key 90) Standard and high temperature 10A9122 X032 Corrosive service 10A9122 X082 Type 67FR regulator Filter gasket (not shown) Standard temperature, neoprene High temperature, silicon Cap screw (not shown), pl steel (2 reqd) Hex nut, pl steel (2 reqd for C versions, 1 reqd for all others) Screw, pl steel (2 reqd for C versions only) Machine screw, pl steel (8 reqd) Machine screw, pl steel (2 reqd) Machine screw, pl steel (6 reqd) Machine Screw, pl steel (2 reqd) Machine Screw, pl steel (4 reqd) Spring (not shown), stainless steel Cap screw, pl steel (4 reqd)
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 35 36
Key 49 50 51 52
Description Machine screw, pl steel (13 reqd) Screen, alloy 400 Pointer assembly (C versions only), Stainless steel/brass, pl Washer (C versions only), steel (2 reqd) Base plate (C versions only), aluminum Front plate (C versions only), aluminum Pipe plug (Type 2503 only), brass (not shown) Specific gravity adjustment assembly Standard and high temperature Corrosive service Nameplate
Part Number 1B7839 X0012 0L0783 43062 1E8735 000A2 1E8730 X0012 1E8731 11992 1E8732 11992 1A6219 14012 10A8870 X0A2 10A8870 X022
37 38*
39 40 41 42 43 44 45 46 47 48
1C8986 03012 1N8740 04142 1C3988 X0022 1L2863 38992 16A6938 X022 1V7435 X0022 1A3776 X0012 1A5733 X0012 1H1581 X0012 1C8990 X0012 1J4234 37022 1A3816 K0012
53 54 73 90
215
Relay (figure 20 and 21)

83 84 85 Relay body, Standard and high-temp., aluminum/brass Corrosive service, aluminum/stainless steel Spacer ring, aluminum Casing assembly, aluminum/steel 48A3776 X012 48A3776 X032 38A3778 X012 12B0460 X012
*Recommended spare parts
31
Type 2500
j APPLY LUB
22B0463-B / DOC
Figure 21. Typical Relay Assembly
Key 86*
Description Diaphragm assembly Standard temperature, nitrile/nylon High temperature, polyacrylate/nylon Corrosive service, nitrile/nylon Inner valve, brass Standard temperature Corrosive service Orifice assembly(1) (all except Type 2503), brass Connector (Type 2503 only), brass O-Ring (2 reqd) Standard temperature, nitrile High temperature, fluoroelastomer Top diaphragm Standard temperature, nitrile/nylon High temperature, polyacrylate/nylon Relay spring, pl steel Valve spring, stainless steel Spring plate gasket Standard temperature, neoprene High-temperature, silicon
Part Number 18A2451 X012 18A2451 X092 18A2451 X042
Key 95 96 97 98 99* 100* 168 169 ---
87*
88* 88 90*
0Y0617 14012 0Y0617 X0022 12B0468 X012 22B0461 X012 1D6875 06992 1N4304 06382
Description Part Number Spring plate, pl steel 1H2697 25072 Machine screw, pl steel (6 reqd) 1A3294 X0022 Machine screw, pl steel (4 reqd) 1A8664 X00A2 Washer (standard temperature only), pl steel (6 reqd) 1P8261 X0012 1K7001 04142 Bottom gasket (high-temperature only), silicon Top gasket (high-temperature only), silicon 1K7002 04142 Lubricant, Lubriplate Mag-1 (not furnished with controller) Lubricant, Dow Corning Compound 111 (not furnished with controller) Relay alignment tool (see figure 18) 15A3519 X012
Heat Insulator (figure 16)

35 36 37 38 39 40 53 Heat Insulator Assembly, stainless steel Shaft Coupling, stainless steel Shaft extension, alloy K500 Set screw, stainless steel (2 reqd) Cap screw, pl steel (4 reqd) Cap screw, pl steel (4 reqd) Washer, carbon steel, pl (4 reqd) 22A0033 X012 1A5779 35032 1B6815 40022 1E6234 X0022 1A3816 24052 1V2395 28982 1B8659 28982
91*
92 93 94*
1L5556 02042 1K6999 X0012 1C8961 27012 0X0836 37022 1H2696 03012 1K7000 04142
*Recommended spare parts 1. Key 88, orifice assembly, now includes the core assembly. Key 89, core assembly, has been deleted from the parts list.
Thecontentsofthispublicationarepresentedforinformationalpurposesonly,andwhileeveryefforthasbeenmadetoensuretheiraccuracy,theyarenottobeconstruedaswarrantiesorguarantees,expressorimplied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 0512
32
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2500 and 2503 Series Level-Trol Controllers and Transmitters

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Instruction Manual Form 1013 February 1997

2500 and 2503 Series Level-Trolr Controllers and Transmitters

2500 OR 2503 SERIES CONTROLLER/ TRANSMITTER 249 SERIES SENSOR

Precalibration Requirements . . . . . . . . . . . . . . . . . 15 Wet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Dry Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 2. Standard Displacer Volumes

STANDARD VOLUME, Cubic Inches 100 60 120 80(1)

STANDARD VOLUME, Liters 1.6 1.0 1.9 1.3(1)

Table 3. Supply Pressure Data

STANDARD SUPPLY AND OUTPUT PRESSURE GAUGE INDICATIONS(1) 0 to 30 psig 0 to 60 psig

NORMAL OPERATING SUPPLY PRESSURE(2) Psig 20 35 Bar 1.4 2.4

MAXIMUM SUPPLY PRESSURE 45 psig (3 bar) 45 psig (3 bar)

HEAT INSULATOR REQUIRED

HEAT INSULATOR REQUIRED

500 _ 400 300

400 NO INSULATOR NECESSARY 0

AMBIENT TEMPERATURE (_F)

STANDARD CONTROLLER OR TRANSMITTER

HIGHTEMPERATURE CONTROLLER OR TRANSMITTER

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

Figure 3. Damping Plate Location

AMBIENT TEMPERATURE (_C) 10 20 30 40 50

AMBIENT TEMPERATURE (_C) 20 30 40 50 60 70

Mounting Caged Sensor CAUTION

Figure 4. Cage Head Mounting Positions

Figure 5. Cage Connection Styles

Figure 6. Caged Sensor Mounting

CF5380-A A3893/IL W06451/IL

SIDE VIEW (SHOWING STILWELL)

SIDE VIEW (WITHOUT STILWELL)

Figure 7. Cageless Sensor Mounting

DISPLACER ROD DISPLACER STEM EXTENSION COTTER SPRING

COTTER SPRING LOCKING NUTS

ALL OTHER TYPES

Figure 8. Displacer and Displacer Rod Connections

Figure 9. Temperature-Compensated Displacer

Supply and Output Pressure Connections WARNING

10A1211A 22A9197B CD1700E A27081/IL

Figure 11. Controller/Transmitter Dimensions and Connections

Figure 10. Piezometer-Ring Cage for Flow Line Mounting

BOURDON TUBE DETAIL OF TYPE 2500S ON-OFF CONTROLLER

RAISE LEVEL DIAL FOR LEFT-HAND MOUNTING

LEVEL ADJUSTMENT PROPORTIONAL BAND ADJUSTMENT

RIGHT-HAND MOUNTED TYPE 2503R ON-OFF CONTROLLER

RIGHT-HAND MOUNTED TYPE 2500 PROPORTIONAL CONTROLLER

SPECIFIC GRAVITY ADJUSTMENT ZERO ADJUSTMENT

1E8731 1E8732 A18971/IL

DETAIL OF TRANSMITTER ADJUSTMENTS

INDICATOR ASSEMBLY WITH RIGHT-HAND MOUNTING

TRAVEL INDICATOR PLATE FOR LEFT-HAND MOUNTING

Figure 12. Adjustment Locations

NOTE: EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.

Type 2500 Controller or 2500T Transmitter

Type 2500S Controller

Direct Reverse Direct Reverse

Type 2503 Controller

Zero Adjustment (Transmitters Only)

Proportional Band Adjustment (Except Transmitters and 2503 Series Controllers)