controlador 2500

7/29/2019 controlador 2500

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2500 and 2503 Series Controllers and

TransmittersContentsIntroduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope of Manual 2. . . . . . . . . . . . . . . . . . . . . . . . . .Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Educational Services 2. . . . . . . . . . . . . . . . . . . . . .

Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor Assembly 5. . . . . . . . . . . . . . . . . . . . . . . . .Uncrating 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controller/Transmitter Orientation 6. . . . . . . . . . .Mounting Caged Sensor 7. . . . . . . . . . . . . . . . . . .Mounting Cageless Sensor 7. . . . . . . . . . . . . . . . .

Side-Mounted Sensor 8. . . . . . . . . . . . . . . . . . . .Top-Mounted Sensor 9. . . . . . . . . . . . . . . . . . . . .

Supply and Output Pressure Connection 9. . . . .Supply Pressure 10. . . . . . . . . . . . . . . . . . . . . . . .Controller/Transmitter Output Connection 10. .

Vent Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . .Prestartup Checks 11. . . . . . . . . . . . . . . . . . . . . . . .

2500 Controller or 2500T Transmitter 13. . . . . . .2500S Controller 14. . . . . . . . . . . . . . . . . . . . . . . . .2503 Controller 14. . . . . . . . . . . . . . . . . . . . . . . . . .Adjustments 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Action 15. . . . . . . . . . . . . . . . . . . . . . . . . .Level Adjustment (Controllers Only) 15. . . . . . .Zero Adjustment (Transmitters Only) 15. . . . . .

Proportional Band Adjustment(Except Transmitters and 2503Series Controllers) 15. . . . . . . . . . . . . . . . . . . .

Specific Gravity Adjustment(Transmitters Only) 15. . . . . . . . . . . . . . . . . . .

Calibration 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Precalibration Requirements 16. . . . . . . . . . . . . . .

Wet Calibration 16. . . . . . . . . . . . . . . . . . . . . . . . .Dry Calibration 16. . . . . . . . . . . . . . . . . . . . . . . . .Controller/Transmitter and Torque Tube Arm

Disassembly 16. . . . . . . . . . . . . . . . . . . . . . . . .Determining the Amount of

Suspended Weight 17. . . . . . . . . . . . . . . . . . .Calibration Procedure 17. . . . . . . . . . . . . . . . . . . .

2500 Controller and 2500T Transmitter 18. . . .2500S and 2503 Controllers 19. . . . . . . . . . . . . .

Startup 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2500 Controller 21. . . . . . . . . . . . . . . . . . . . . . . . . .2500T Transmitter 21. . . . . . . . . . . . . . . . . . . . . . .2500S Controller 21. . . . . . . . . . . . . . . . . . . . . . . . .

2500 OR 2503 SERIESCONTROLLER/

TRANSMITTER

249 SERIES SENSOR

W8334

Figure 1. 2500 or 2503 Series Controller/Transmitter on Caged 249 Series Sensor

2503 Controller 21. . . . . . . . . . . . . . . . . . . . . . . . . .Principle of Operation 21. . . . . . . . . . . . . . . . . . . . . .

2500 Controller or 2500T Transmitter 21. . . . . . .Proportional Valve 22. . . . . . . . . . . . . . . . . . . . . . .2500S Controller 22. . . . . . . . . . . . . . . . . . . . . . . . .2503 Controller 22. . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . .Removing Controller/Transmitter from

Sensor 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Mounting Methods 27. . . . . . . . . . . . . .Installing Controller/Transmitter on Sensor 27. . .Replacing the Bourdon Tube 28. . . . . . . . . . . . . .Changing Action 28. . . . . . . . . . . . . . . . . . . . . . . . .

Relay Deadband Testing (2500 Controlleror 2500T Transmitter Only) 28. . . . . . . . . . . . .

Replacing the Proportional Valve 28. . . . . . . . . . .Changing Relay 29. . . . . . . . . . . . . . . . . . . . . . . . .

Parts Ordering 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts List 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instruction ManualD200124X012September 2008 2500 and 2503 Controllers/Transmitters


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2500 and 2503 Controllers/Transmitters

Instruction Manual

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Introduction

Scope of Manual

This manual provides installation, operating,calibration, maintenance, and parts orderinginformation for the 2500 and 2503 Series pneumaticcontrollers and transmitters used in combination with249 Series displacer sensors.

Note

This manual does not includeinstallation or maintenanceprocedures for the supply pressureregulator, sensor, or other devices. Forthat information, refer to the

appropriate instruction manual for theother device.

Do not install, operate or maintain a 2500 or 2503Series pneumatic controller/transmitter without first Dbeing fully trained and qualified in valve, actuatorand accessory installation, operation andmaintenance, and D carefully reading andunderstanding the contents of this manual. If youhave any questions about these instructions, contactyour Emerson Process Management sales office.

Description

These instruments control or transmit the fluid level,the level of interface between two fluids, or thedensity (specific gravity). Each unit consists of a 249Series displacer-type fluid level sensor and a 2500or 2503 Series pneumatic controller or transmitter.Figure 1 shows a typical controller-sensorcombination.

Specifications

Refer to table 1 for specifications.

Educational ServicesFor information on available courses for the 2500 or2503 Series as well as a variety of other products,contact:

Emerson Process ManagementEducational Services, RegistrationP.O. Box 190; 301 S. 1st Ave.Marshalltown, IA 501582823Phone: 8003388158 or

Phone: 6417543771FAX: 6417543431e-mail: [email protected]

Installation

The 2500 and 2503 Series controller/transmitterswork in combination with 249 Series displacer-typesensors. The factory attaches thecontroller/transmitter to the sensor, unless it isordered separately.

If using natural gas as the pneumatic supplymedium, natural gas will be used in the pressureconnections of the unit to any connected equipment.The unit will vent natural gas into the surrounding

atmosphere.

WARNING

Always wear protective clothing,gloves, and eyewear when performingany installation operations to avoidpersonal injury.

Check with your process or safetyengineer for any additional measures

that must be taken to protect againstprocess media.

If installing into an existingapplication, also refer to the WARNINGat the beginning of the Maintenancesection in this instruction manual.

WARNING

Personal injury or property damagemay result from fire or explosion ifnatural gas is used as the supplymedium and preventative measuresare not taken. Preventative measuresmay include: Remote venting of theunit, re-evaluating the hazardous areaclassification, ensuring adequateventilation, and the removal of anyignition sources. For information onremote venting of this controller referto page 10.


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Table 1. Specifications

Available Configurations(1)

2500Proportional-Only controller

2500CProportional-Only controller withindicator (see figure 10)2500RReverse acting proportional-onlycontroller2500SDifferential gap (snap acting) controller.See changing controller action procedure andfigure 152500TTransmitter2503Differential gap controller withoutproportional valve; for applications requiring verylittle adjustment

Input Signal

Fluid Level or Fluid-to-Fluid Interface Level:From 0 to 100% of displacer lengthstandardlengths for all sensors are 356 mm or 812 mm(14 inches or 32 inches). Other lengths availabledepending on sensor construction.

Fluid Density: From 0 to 100% of displacementforce change obtained with given displacervolume. Standard volume for displacers are listedin table 2.

Output Signal

2500 Controller and 2500T Transmitter: 0.2 to 1bar (3 to 15 psig) or 0.4 to 2 bar (6 to 30 psig)

2500S and 2503 Differential Gap Controllers: 0bar (0 psig) when switched off and full supply [1.4or 2.4 bar (20 or 35 psig) nominal depending oncontroller output pressure range] when switchedon.

Area Ratio of Relay Diaphragms

3:1

Supply Pressure Data

See table 3(2)

Supply Medium

Air or natural gas

Air Quality:Supply pressure must be clean, dryair that meets the requirements of ISA Standard7.0.01. A maximum 40 micrometer particle size inthe air system is acceptable. Further filtrationdown to 5 micrometer particle size isrecommended. Lubricant content is not to exceed1 ppm weight (w/w) or volume (v/v) basis.

Condensation in the air supply should beminimized

Natural Gas:Natural gas must be clean, dry,oil-free, and noncorrosive. H2S content should notexceed 20 ppm.

Maximum Supply Pressure(2,3)

3 bar (45 psig) to the controller or transmitter. Ifcontroller or transmitter is equipped with anintegrally mounted 67CFR filter/regulator, typicalsupply pressure to the regulator is from 2.5 bar(35 psig) to 17 bar (250 psig), maximum. Forsupply pressures to the filter/regulator, refer to theappropriate regulator instruction manual.

Steady-State Air Consumption

2500 Series Controllers and Transmitters(2500, 2500C, 2500R, 2500S, and 2500T): Seetable 3

2503 Controller: Vents only when relay isexhausting

Proportional Band Adjustment(Proportional-Only Controllers)

Full output pressure change adjustable over 10 to100% of displacer length(4)

Differential Gap Adjustment (Differential GapControllers)

2500S Controller: Full output pressure changeadjustable from 20 to 100% of displacer length.(4)

2503 Controller: Full output pressure changeadjustable over approximately 25 to 40% ofdisplacer length(4)

Span Adjustment (2500T Transmitter)

Full output pressure change adjustable from 20 to100% of displacer length(4)

Set Point (controllers only) or Zero (transmittersonly) Adjustment

For proportional-only controllers or transmitters,level adjustment positions the set point or zero forthe fluid level, interface level, or displacer forcechange (density) within the displacer length.For differential gap controllers, level adjustmentsimultaneously positions both ends of the gapwithin the displacer length.

(continued)


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Table 1. Specifications (Continued)

Performance

Independent Linearity (transmitters only): 1%

of output pressure change for 100% span.Hysteresis: 0.6% of output pressure change at100% proportional band, differential gap, or span

Repeatability: 0.2% of displacer length ordisplacement force changeDeadband (except differential gapcontrollers(5)): 0.05% of proportional band orspanTypical Frequency Response: 4 Hz and 90degree phase shift at 100% proportional bandwith output piped to typical instrument bellowsusing 6.1 meters (20 feet) of 1/4-inch tubing

Ambient Operating Temperature Limits(3)

For ambient temperature ranges and guidelinesfor use of the optional heat insulator assembly,see figure 2. Relay temperature limits are:Standard Construction: -40 to 71_C(-40 to160_F)High-Temperature Construction: -18 to 104_C(0 to 220_F)

Typical Ambient Temperature OperatingInfluence

Output pressure changes1.5% per 10_C(50_F) change in temperature at 100%proportional band when using a standard walltorque tube with 249 Series sensors

Hazardous Area Classification

2500 and 2503 Series controllers/transmitterscomply with the requirements of ATEX Group IICategory 2 Gas and Dust

Supply and Output Connections

1/4 NPT internal

Maximum Working Pressure (sensors only)

Refer to the appropriate sensor instructionmanual

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 Process Instrument Terminology.1. Controllers are field adjustable between direct or reverse action. The letter R in the type number indicates that the controller/transmitter shipped from the factory set for reverse action (seechanging controller action procedures). The letter C in the type number indicates that a pointer is attached to the torque tube shaft providing visual monitoring of torque tube motion.2. Control and stability may be impaired if the maximum pressures are exceeded.3. The pressure/temperature limits in this document, and any applicable standard or code limitation should not be exceeded.4. These statements apply only to units sized to produce a full output change for a 100% level change at the maximum proportional band dial setting.5. Adjusting the span of the differential gap controller is equivalent to adjusting the deadband.

Table 2. Standard Displacer Volumes

SENSOR TYPESTANDARD VOLUME,

LitersSTANDARD VOLUME,

Cubic Inches

249, 249B, 249BP, 249K, 249W249C, 249CP, 249W249L249VS

1.61.01.91.3(3)

100(1)

60(2)

12080(3)

1. For 249W, with standard 812 mm (32-inch) displacer.2. For 249W, with standard 356 mm (14-inch) displacer.3. With standard 305 mm (12-inch) flange-face-to-displacer centerline dimension only.

Table 3. Supply Pressure Data

OUTPUT SIGNAL RANGE

STANDARD SUPPLYAND OUTPUT

PRESSURE GAUGEINDICATIONS(1)

NORMAL OPERATINGSUPPLY PRESSURE(2)

AIR CONSUMPTION ATNORMAL OPERATINGSUPPLY PRESSURE

MAXIMUMSUPPLY PRESSURE

Bar Psig Minimum(3) Maximum(4)

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

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

1. Consult your Emerson Process Management sales office about gauges in other units.2. Control and stability may be impaired if this pressure is exceeded.3. At zero or maximum proportional band or specific gravity setting.4. At setting in middle of proportional band or specific gravity range.5. If air consumption is desired in normal m3/hr at 0_C and 1.01325 bar, multiply scfh by 0.0258.


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0 20 40 60 80 100 120 140 160

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE

PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENTMALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)

0 10 2018 10

30 40 50 60 70

71

593

500

400

300200

100

40

0

400

800

1100

20NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (_C)

STANDARD CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (_F)

HEAT INSULATORREQUIRED

TOOHOT

NOTE:FOR APPLICATIONS BELOW 29_C (20_F), BE SURE THE SENSOR MATERIALSOF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.

PROCESSTEMPERATU

RE(C)

_

PROCESSTEMPERATURE(F)

_

0 20 40 60 80 100 120 140 200

0 10 2018 10 30 40 50 60 70 105

593

500

400

300

200

100

00

400

800

1100

20

NO INSULATOR NECESSARY

AMBIENT TEMPERATURE (_C)

HIGH-TEMPERATURE CONTROLLER OR TRANSMITTER

AMBIENT TEMPERATURE (_F)

HEAT INSULATOR

REQUIRED

TOOHOT

PROCESSTEMPERATU

RE(C)

_

PROCESSTEMPERATU

RE(F)

_

180160

80 90

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESSTEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTIONAND REDUCE INSULATOR EFFECTIVENESS.)

CV6190EB1413-3/IL

40

29

18

100

220

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

Table 4.Displacer and Torque Tube Materials

Part Standard Material Other Materials

Displacer 304 Stainless Steel

316 Stainless Steel,

N10276, N04400,

Plastic, and Special

Alloys

Displacer Stem

Driver Bearing,

Displacer Rod

and Driver

316 Stainless Steel

N10276, N04400,

other Austenitic

Stainless Steels, and

Special Alloys

Torque Tube N05500(1)316 Stainless Steel,

N06600, N10276

1. N05500 is not recommended for spring applications above232_C (450_F). Contact your Emerson Process Managementsales office or application engineer if temperatures exceeding thislimit are required.

Sensor Assembly

Table 2 lists sensors recommended for use withcontroller/transmitters. Table 4 contains displacerand torque tube materials. For sensor installationand maintenance, refer to the appropriate sensorinstruction manual.

WARNING

When replacing the sensor assembly,the displacer may retain process fluidor pressure. Personal injury orproperty damage may occur due tosudden release of the pressure.Contact with hazardous fluid, fire, orexplosion can be caused bypuncturing, heating, or repairing a

displacer retaining process pressureor fluid. This danger may not bereadily apparent when disassemblingthe sensor assembly or removing thedisplacer. Before disassembling thesensor or removing the displacer,observe the more specific warningprovided in the sensor instructionmanual.

Uncrating

Unless ordered separately, the controller/transmitteris attached to the sensor when shipped. Carefullyuncrate the assembly.

CAUTION

Sensors used for interface or densitycontrol may be so large and heavy thatthe torque tube cannot fully supporttheir weight in air. On the 249VS, atravel stop is used to prevent damage.Do not remove this travel stopassembly without first removing thedisplacer from the displacer rod. Refer

to the appropriate instruction manualfor cageless 249 Series sensors.

Note

Caged sensors have rods and blocksinstalled at each end of the displacersto protect the displacers in shipping.Remove these parts before you installthe sensor to allow the displacer tofunction properly.


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W01441/IL

W21411B/IL

DISPLACER

CAGE

SCREWEDCONNECTION

FLANGEDCONNECTIONDAMPING PLATE

Figure 3. Damping Plate Location

Caged sensors come with the displacer installed inthe cage. If a tubular gauge glass is ordered with thesensor, the gauge glass is crated separately andmust be installed at the site. A damping plate isinstalled in the lower screwed or flanged connection(see figure 3) to provide more stable operation. Becertain that the cage equalizing connections and thedamping plate are not plugged by foreign material.

A cageless sensor comes with its displacerseparated from the sensor assembly. Displacerslonger than 813 mm (32 inches) come in a separatecrate. Shorter displacers come in the same crate asthe sensor, but are not attached to their displacerrods. Inspect the displacer to ensure it is not dented.A dent may reduce the pressure rating of thedisplacer. If a displacer is dented, replace it.

AH9150AA26132/IL

RIGHT-HAND MOUNTING

LEFT-HAND MOUNTING

67CFR FILTER/REGULATOR.

Figure 4. Cage Head Mounting Positions

Controller/Transmitter Orientation

The controller/transmitter attaches to the sensor inone of the mounting positions shown in figure 4.Right-hand mounting is with the controller ortransmitter case to the right of the displacer whenyou look at the front of the case; left-hand mountingis with the case to the left of the displacer. Themounting position can be changed in the field.Changing this mounting position changes the controlaction from direct to reverse, or vice versa.

All caged sensors have a rotatable head. That is, thecontroller/transmitter may be positioned at any ofeight alternate positions around the cage asindicated by the numbers 1 through 8 in figure 4. Torotate the head, remove the head flange bolts andnuts and position the head as desired.


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A12712/IL

STYLE 1: TOPAND BOTTOM

STYLE 2: TOPAND LOWER SIDE

STYLE 3: UPPERAND LOWER SIDE

STYLE 3: UPPERSIDE AND BOTTOM

SCREWED: S1FLANGED: F1




Figure 5. Cage Connection Styles

Mounting Caged Sensor

Note

Install the cage so that it is plumb; thedisplacer must not touch the cagewall. If the displacer touches the cagewall, the unit will transmit anerroneous output signal.

Note

If the controller/transmitter is notmounted on the sensor, refer to theInstalling Controller/Transmitter onSensor procedures in the Maintenancesection. This section also providesinstructions for adding a heat insulatorto a unit.

EQUALIZINGLINE

DRAIN VALVE

EQUALIZING LINE

CENTER OFLIQUID ORINTERFACE LEVEL

DF5379-AA1883-2/IL

SHUTOFFVALVES

Figure 6. Caged Sensor Mounting

Cage connections normally are either NPS 1-1/2 or2, screwed or flanged. Figure 5 shows thecombinations. With flanged connections, usestandard gaskets or other flat-sheet gasketscompatible with the process fluid. Spiral-woundgaskets without compression-controlling centeringrings cannot be used for flange connections.

As shown in figure 6, mount the cage by running

equalizing lines between the cage connections andthe vessel. A shutoff or hand valve with a 1-1/2 inchdiameter or larger port should be installed in each ofthe equalizing lines. Also install a drain between thecage and shutoff or hand valve whenever the bottomcage line has a fluid-trapping low point.

On fluid or interface level applications, position thesensor so that the center line on the cage (see figure6) is as close as possible to the center of the fluidlevel or interface level range being measured. Alsoconsider installing a gauge glass on the vessel, oron the sensor cage (if the cage is tapped for agauge).

Mounting Cageless Sensor

Note

If a stillwell is used, install it plumb sothat the displacer does not touch thewall of the stillwell. If the displacertouches the wall, the unit will transmitan erroneous output signal.


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CF5380-AA3893/IL

TOPMOUNTED

SIDE VIEW (WITHOUT STILLWELL)SIDE VIEW (SHOWING STILLWELL)

SIDEMOUNTED

W9517-1

Figure 7. Cageless Sensor Mounting

Since the displacer hangs inside the vessel, providea stillwell around the displacer if the fluid is in a stateof continuous agitation to avoid excessive turbulencearound the displacer.

Note

Displacers used in an interface levelapplication must be completelysubmerged during operation. Ifdisplacers arent completelysubmerged, they will not calibrate or

perform properly. To obtain thedesired controller or transmittersensitivity may require using either athin-wall torque tube, an oversizeddisplacer, or both.

Note

If the controller/transmitter is notmounted on the sensor, refer to the

Installing Controller/Transmitter onSensor procedures in the Maintenancesection. This section also providesinstructions for adding a heat insulatorto a unit.

Attach a cageless sensor to a flanged connection onthe vessel as shown in figure 7. For interface or fluidlevel applications, install a gauge glass on thevessel.

Side-Mounted Sensor

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

Connect the displacer as shown in figure 8, lockingthe assembly with the cotter spring provided. If astillwell is not required, attach the displacer rodbefore mounting the sensor on the vessel. Then, youcan swing the displacer out horizontally for insertioninto the vessel. However, once the sensor isinstalled and the displacer drops to a vertical


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W0228-1A/IL DISPLACER ROD

DISPLACERSPUD

ALL OTHER TYPES

COTTER SPRING

LOCKING NUTS

DISPLACER SPUD

DISPLACERSTEMEXTENSION

DISPLACER ROD

COTTER SPRING

W9357

249VS

Figure 8. Displacer and Displacer Rod Connections

position, the displacer may not be capable of beingwithdrawn for servicing later. Be sure there isanother access to the displacer to permit swinging itto a horizontal position or to permit disconnecting itfrom the displacer rod.

If an extension is used between the displacer spudand the displacer stem end piece, make sure the

nuts are tight at each end of the displacer stemextension. Install and tighten suitable bolting or capscrews in the flanged connection to complete theinstallation.

Top-Mounted Sensor

CAUTION

If inserting the displacer into thevessel before attaching to thedisplacer rod, provide a means ofsupporting the displacer to prevent itfrom dropping into the vessel andsuffering damage.

Figure 7 shows an example of a top-mountedcageless sensor. You may attach the displacer tothe displacer rod before installing the sensor on thevessel. If the displacer diameter is small enough,you may install a long or sectionalized displacer

through the sensor head access hole after thesensor is installed on the vessel. Connect thedisplacer as shown in figure 8, locking the assemblywith the cotter springs provided. If a stem extensionis used between the displacer spud and the stemend piece, make sure the nuts are tight at each endof the stem. Install and tighten suitable cap screws inthe flanged connection to complete the installation.

A special travel stop may be provided ontop-mounted sensors to aid in servicing of thesensor. This option prevents dropping the displacerand stem when the displacer rod is disconnected.

Supply and Output PressureConnections

WARNING

To avoid personal injury or propertydamage resulting from the suddenrelease of pressure, do not install anysystem component where serviceconditions could exceed the limitsgiven in this manual. Usepressure-relieving devices as requiredby government or accepted industrycodes and good engineering practices.


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AP4158-DE0859

176.36.94

OPTIONAL HEATINSULATOREXTENSION

5/6-18 UNC-2B4 MOUNTING HOLESONj 95.3/3.75 DBC

1/4-18 NPTOUTPUT CONN

1/4-18 NPTOUTLET CONNPLUGGED

67CFR1/4-18 NPTSUPPLY CONN

VENT

223.88.81

117.6

4.63

123.74.87

239.09.41

255.510.06

231.69.12

58.72.31

TOP VIEW

FRONT VIEW

mmINCH

BACK VIEW

Figure 9. Controller/Transmitter Dimensions and Connections

Figure 9 shows dimensions, locations, andconnections for controller/transmitter installation. Allpressure connections to the controller/transmitter are1/4 NPT internal.

Supply Pressure

WARNING

Personal injury or property damagemay occur from an uncontrolledprocess if the supply medium is notclean, dry, oil-free air, or noncorrosivegas. While use and regularmaintenance of a filter that removesparticles larger than 40 microns indiameter will suffice in mostapplications, check with an EmersonProcess Management field office andindustry instrument air qualitystandards for use with corrosive air or

if you are unsure about the properamount or method of air filtration orfilter maintenance.

Supply pressure must be clean, dry air or

noncorrosive gas that meets the requirements of ISAStandard 7.0.01. A maximum 40 micrometer particlesize in the air system is acceptable. Further filtrationdown to 5 micrometer particle size is recommended.Lubricant content is not to exceed 1 ppm weight(w/w) or volume (v/v) basis. Condensation in the airsupply should be minimized. Alternatively, naturalgas may be used as the supply pressure medium.Gas must be clean, dry, oil-free, and noncorrosive.H2S content should not exceed 20 ppm.

Use a suitable supply pressure regulator to reducethe supply pressure to the normal operating supplypressure shown in table 3. As shown in figure 9, a

67CFR filter/regulator mounts on the back of thecontroller/transmitter case and mates with the supplypressure connection on the controller/transmittercase. Pipe the supply pressure to the IN connectionof the regulator. Typically, the 67CFR filter/regulatoraccepts supply pressures between 2.5 and 17 bar(35 and 250 psig). For specific regulator limits, referto the appropriate regulator instruction manual.

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

information, see the separate instruction manual.

Controller/Transmitter OutputConnection

As shown in figure 9, the output pressure connectionis on the back of the controller/transmitter case. Afterconnecting the output pressure line, turn on thesupply pressure, adjust the filter/regulator to theappropriate supply pressure required for thecontroller/transmitter and check all connections forleaks.

Vent Assembly

WARNING

Personal injury or property damagecould result from fire or explosion ofaccumulated gas, or from contact withhazardous gas, if a flammable orhazardous gas is used as the supply


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pressure medium. Because theinstrument case and cover assemblydo not form a gas-tight seal when theassembly is enclosed, a remote ventline, adequate ventilation, andnecessary safety measures should beused to prevent the accumulation offlammable or hazardous gas. However,a remote vent pipe alone cannot berelied upon to remove all flammableand hazardous gas. Vent line pipingshould comply with local and regionalcodes, and should be be as short aspossible with adequate inside diameterand few bends to reduce casepressure buildup.

CAUTION

When installing a remote vent pipe,take care not to overtighten the pipe inthe vent connection. Excessive torquewill damage the threads in theconnection.

The vent assembly (see figure 9) or the end of aremote vent pipe must be protected against theentrance of all foreign matter that could plug thevent. Use 13 mm (1/2inch) pipe for the remote ventpipe, if one is required. Check the vent periodicallyto be certain it has not become plugged.

Prestartup Checks

Adjustments are shown in figure 10 unless otherwiseindicated. Open-loop conditions must exist whenperforming the prestartup checks. To obtainopen-loop conditions:

D make sure there is no process flow through thefinal control element, or

D disconnect the controller/transmitter outputsignal line and connect it to a pressure gauge.

During prestartup, the displacer must be positionedfrom its maximum to its minimum range of operation.Provide a means to change the process variable (theprocess level or interface). If the process variablecannot be varied sufficiently, use the precalibrationprocedures in the Calibration section to simulate theprocess variable changes required for these checks.

Make sure the RAISE LEVEL dial on the controller ismounted with the correct side facing out. The dial ismarked on both sides with an arrow. The arrowpoints to the left on one side and to the right on theother. When the sensor is mounted to the left of thecontroller/transmitter, the arrow on the raise leveldial should point to the left, as shown in figure 10. Ifthe sensor is to the right, the arrow should point tothe right. If necessary, remove the two mountingscrews, turn the dial over so the arrow pointscorrectly, and reinstall the mounting screws. Thelevel directions shown on the dial will be correct forboth direct-acting and reverse-acting controllers. Fora transmitter, use the same side of the ZEROADJUSTMENT dial for both right- and left-handsensor mountings.

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

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

D Sensor with Both Standard Torque Tubeand Standard Volume DisplacerIf the torquetube is standard and the displacer volume is close tothat listed in table 2, use figure 11 to find thePROPORTIONAL BAND or SPECIFIC GRAVITYsetting. Locate the specific gravity of the processfluid on fluid level applications, or the differencebetween minimum and maximum specific gravity oninterface level or density applications, on the verticalaxis of the chart. From this location, tracehorizontally to the curve with the desired percentageof displacer used, then trace vertically up or down todetermine the proper dial setting on the horizontal

axis.

D Sensor with Nonstandard Torque Tubeand/or Displacer with Other than StandardVolumeIf the construction does not have astandard wall torque tube or has a displacer volumethat deviates significantly from the volume listed intable 2, or both, the PROPORTIONAL BAND orSPECIFIC GRAVITY dial setting does not


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W06411B/IL

1C9283B/DOC

W06711/ILW06561/IL

W06472B/IL W06481B/IL1E87311E8732A18971/IL

LEVEL SET ARMMOUNTING SCREWS

LEVEL SETARM

LEVEL ADJUSTMENT

PROPORTIONALBAND ADJUSTMENT

FLAPPER ALIGNMENT SCREW

SHAFT CLAMP NUT

3WAY VALVE

NOZZLE

PLUNGER

SPECIFIC GRAVITYADJUSTMENT

ZEROADJUSTMENT

POINTERASSEMBLY

FLAPPERRELAY

SPAN ADJUSTMENT

BOURDON TUBE DETAIL OF2500S ON-OFFCONTROLLER

RAISE LEVEL DIAL FORLEFT-HAND MOUNTING

RIGHT-HAND MOUNTED 2500PROPORTIONAL CONTROLLER

RIGHT-HAND MOUNTED 2503RON-OFF CONTROLLER

DETAIL OF TRANSMITTERADJUSTMENTS

INDICATOR ASSEMBLY WITHRIGHT-HAND MOUNTING

TRAVEL INDICATOR PLATEFOR LEFT-HAND MOUNTING

VENT

Figure 10. Adjustment Locations


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necessarily indicate the actual proportional band orspecific gravity. To determine the correct dial setting,solve the following equation:

CorrectedDial Setting

Required+ ( L

100)(SP GR)Va

Vr(X)

where:

L = percentage of displacer length desired for fulloutput pressure change (e.g., if 80% ofdisplacer is used, L = 80)

SP GR = specific gravity of the process fluid (forinterface level control, use the differencebetween the specific gravity of the two

fluids; for specific gravity control, use thedifference between the upper and lowerrange limits of specific gravity).

Va = actual displacer volume, cubic inches listedon the sensor nameplate.

Vr = standard displacer volume, cubic inches,from table 2.

X = torque tube factor (1.0 for standard torquetubes, 2.0 for thin-wall torque tubes, or 0.5for heavy-wall torque tubes).

2500 Controller or 2500T Transmitter

Note

In the following steps the outputpressure can go as high as thecontroller supply pressure.

1. Turn on the supply pressure and check that thesupply pressure gauge reads 1.4 bar (20 psig) fora 0.2 to 1 bar (3 to 15 psig) or 2.4 bar (35 psig) fora 0.4 to 2 bar (6 to 30 psig) output pressure range. Ifthe pressure is incorrect, loosen the locknut of the67CFR filter/regulator (figure 9); turn the adjustingscrew clockwise to increase the pressure or,counterclockwise to decrease the pressure. Tightenthe locknut after setting the regulator pressure.

2. Set the process variable to its minimum value.

3. Make sure that the PROPORTIONAL BAND orSPECIFIC GRAVITY control is at the settingdetermined earlier in this section. Then, set theRAISE LEVEL or ZERO ADJUSTMENT control at an

NOTE:EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.1C9259GA38911/IL

TRANSMITTER SPECIFIC GRAVITY SETTING

CONTROLLER PROPORTIONAL BAND SETTING

SP

ECIFIC

GRAVITYOR

SPECIFIC

GRAVITYDIFFERENTIAL

Figure 11. Proportional Band and Specific Gravity SettingChart (chart assumes standard wall torque tube and displacer

volume in table2)

appropriate value according to table 5. This tablegives recommended settings based on maximum

and minimum possible PROPORTIONAL BAND andSPECIFIC GRAVITY settings. If an intermediatePROPORTIONAL BAND or SPECIFIC GRAVITYsetting is necessary, extrapolation may be used todetermine an appropriate RAISE LEVEL or ZEROADJUSTMENT setting.

Note

The raise level dial does not reflectactual fluid level in the tank or fluidlevel position on the displacer.

4. The OUTPUT gauge on a 0.2 to 1 bar (3 to 15psig) range should read 0.2 bar (3 psig) for direct

or 1 bar (15 psig) for reverse action. On a 0.4 to 2bar (6 to 30 psig) range the OUTPUT gauge shouldread 0.4 bar (6 psig) for direct or 2 bar (30 psig) forreverse action.

5. On a controller or transmitter with a mechanicalindicator assembly, the pointer should be over theLOW point on the indicator plate. If a slightadjustment is necessary, loosen the side hex clampnut (key 40, figure 16), shift the pointer, andretighten the nut.


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

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

2500S Controller

Note


1. Turn on the supply pressure and check that theSUPPLY pressure gauge reads 1.4 bar (20 psig) fora 0 to 1.4 bar (0 to 20 psig) output pressure rangeor 2.4 bar (35 psig) for a 0 to 2.4 bar (0 to 35 psig)output pressure range. If the pressure is incorrect,loosen the locknut of the 67CFR filter/regulator(figure 9); turn the adjusting screw clockwise toincrease the pressure or counterclockwise to

decrease pressure. Tighten the locknut after settingthe pressure.

2. Set the process variable to its minimum value.

3. On a controller with a mechanical indicatorassembly, the pointer should be over the LOW pointon the indicator plate. If a slight adjustment isnecessary, loosen the hex clamp nut (key 40,figure 16), shift the pointer and retighten the nut.

Note

Adjustment of the RAISE LEVEL

control can set the switching pointsanywhere within the length of thedisplacer. Be careful not to set theswitching points so that one is off thedisplacer.

4. Make sure that the PROPORTIONAL BANDcontrol is at the setting determined in the previousprocedures. Set the RAISE LEVEL control to 0, thenset it to 1.0 for a direct-acting or 4.0 for areverse-acting controller.

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

6. Increase the process variable until the OUTPUTgauge changes to either supply pressure for direct

or 0 bar (0 psig) for reverse acting. The processvariable should be at the desired high trip value. Ona controller with an indicator assembly, the pointershould be over the HIGH point on the indicator plate;slight adjustment may be necessary, as described atthe end of step 3.

7. Decrease the process variable until the OUTPUTgauge changes to 0 bar (0 psig) for direct or supplypressure for reverse action (depending on controllerrange). The process variable should be at thedesired low trip value.

8. If all prestartup checks are satisfactory, proceedto the Startup section. If performance is

unsatisfactory, proceed to the Calibration section.

2503 Controller

Note


Note

Since the 2503 controller has no

proportional valve, the differential gapbetween switching points is adjustedby varying the supply pressure. Thisgap can be varied from approximatelya 89 mm (3.5 inch) level change at 1bar (15 psig) to a 152 mm (6.0 inch)level change at 1.7 bar (25 psig) with astandard volume displacer and a fluidwith a specific gravity of 1.0. The gapalso varies inversely according todensity; a fluid with 0.8 specific gravityproduces a 112 mm (4.4 inch) levelchange at 1 bar (15 psig) to a 191 mm(7.5 inch) change at 1.7 bar (25 psig).

Set the gap at a pressure low enoughto be compatible with the limitations ofthe diaphragm control valve or otherfinal control element.

1. Turn on the supply pressure. If necessary, adjustthe 67CFR regulator to produce the desireddifferential gap by loosening the locknut (figure 9)and turning the adjusting screw clockwise toincrease or counterclockwise to decrease pressure.Tighten the locknut.


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2. Locate the process variable at its minimum value.

Note

Adjustment of the RAISE LEVELcontrol can set the switching pointsanywhere within the length of thedisplacer. Be careful not to set theswitching points so that one is off thedisplacer.

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

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

b. For reverse-acting controllers, set it between3.5 and 4.0.

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

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

6. Decrease the process variable until the OUTPUTgauge changes to 0 bar (0 psig) for direct or fullsupply pressure for reverse action. The processvariable should be at the desired low trip value.

7. If all prestartup checks are satisfactory, proceed

to the Startup section. If performance isunsatisfactory, proceed to the Calibration section.

Adjustments

This section explains controller/transmitter actionand adjustments. Figure 10 shows adjustmentlocations.

Control Action

The following is a definition of control action.

DDirect ActionIncreasing fluid level, interfacelevel, or density, increases the output signal.

D Reverse ActionIncreasing fluid level,interface level, or density, decreases the outputsignal. Controller/transmitters factory-set forreverse-acting have the suffix letter R added to theirtype number.

The control action is determined by the cage headmounting position and by the Bourdon tube-flapper

arrangement in the controller/transmitter. Refer tofigure 4 for mounting positions and to figure 15 forBourdon tube-flapper arrangements. To change theaction, refer to the changing action procedure in theMaintenance section.

Level Adjustment (Controllers Only)

To make a level adjustment, open the controllercover, loosen the knurled adjustment screw, androtate the adjustment lever around the RAISELEVEL dial. To raise the fluid or interface level, orincrease density, rotate this knob in the direction ofthe arrows. To lower the level or decrease density,rotate the knob in the opposite direction. Thisprocedure is the same for either direct or reverseaction. Tighten the knurled screw.

Note

The RAISE LEVEL dial does not reflectactual fluid level in the tank or fluidlevel position on the displacer.

Zero Adjustment (Transmitters Only)

To make a zero adjustment, open the transmittercover, loosen the adjustment screw and rotate theadjustment lever around the ZERO ADJUSTMENTdial. This adjustment sets the output pressure tocorrespond to a specific level on the displacer.Tighten the knurled screw.

Proportional Band Adjustment (ExceptTransmitters and 2503 SeriesControllers)

The proportional band adjustment varies the amountof process variable change required to obtain a fulloutput pressure change. To perform this adjustment,open the controller cover and turn thePROPORTIONAL BAND adjustment (see figure 10).Refer to the prestartup check procedures todetermine the proper setting.

Specific Gravity Adjustment(Transmitters Only)

This adjustment also varies the amount of processvariable change required to obtain a full outputpressure change. To perform this adjustment, openthe transmitter cover and turn the SPECIFICGRAVITY adjustment (see figure 10). Refer to theprestartup check procedures to determine the propersetting.


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Calibration

Precalibration Requirements

The controller/transmitter can be calibrated in thefield, mounted on the vessel containing the processfluid. It may also be done in the shop, but othermeans of obtaining a displacement force changemust be provided. There are wet and dry methods ofadapting the calibrating procedure.

Note

Contact your Emerson ProcessManagement sales office forinformation on obtaining the

Supplement to 249 Series SensorsInstruction Manual: Simulation ofProcess Conditions for Calibration ofFisher Level Controllers andTransmitters (part numberD103066X012).

Wet Calibration

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

If necessary, you may use water for wet calibrationin the shop. You must compensate for the differencebetween the specific gravities of water and theprocess fluid, however. As an example, assume theprocess fluid has a specific gravity of 0.7. Thespecific gravity of water is 1.0. To simulate a processlevel of 50 percent of the input span, would require awater level of 35 percent (0.7/1.0 x 50 percent = 35percent).

Dry CalibrationRemove the controller/transmitter and torque tubearm, as a single unit, from the cage or vessel. Then,wherever the standard calibration procedures in thismanual require a specific process variable input tothe sensor, simulate the process variable bysuspending the proper weight (such as a can ofsand) from the end of the displacer rod. Completethe following procedures (Controller/Transmitter andTorque Tube Arm Disassembly) and (Determining

the Amount of Suspended Weight) beforeproceeding to the Calibrating Procedure.

Controller/Transmitter and Torque TubeArm Disassembly

WARNING

To avoid personal injury from contactwith the process fluid, lower the vessellevel below the sensor torque tubearm, or shut off the cage equalizingvalves and drain the cage beforeproceeding. For closed vessels,release any pressure that may be inthe vessel before removing the sensor

assembly.

When removing the displacer from the displacer rodor removing the controller/transmitter and torquetube arm from the cage or vessel, refer to theappropriate 249 Series instruction manual forassistance. The method of removing the displacer ortorque tube arm and attached controller/ transmittervaries with the type of sensor.

For a caged sensor with top equalizing connection, itmay be appropriate to remove the entire cage fromthe vessel before disassembling.

CAUTION

If the displacer is to be disconnectedfrom the displacer rod before thesensor assembly is removed from thecage or vessel, provide a means ofsupporting the displacer to prevent itfrom dropping and suffering damage.The spuds or stem end pieces on alldisplacers have holes suitable forinserting rods or other supports.

Additionally, a threaded rod may be

installed into the 1/4-inch 28 UNFthreaded hole in the displacer spud orstem end piece of top-mountedcageless and all caged sensors. Forsome top-mounted sensors with longdisplacers, the sensor may beremoved through the access hole inthe sensor head.

For 249BP sensors with travel stop,the stem end piece pins will secure the


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displacer on the travel stop as long asthe travel stop plate is installed andthe sensor head is in position.

Determining the Amount of SuspendedWeight

CAUTION

Avoid overloading a torque tube sizedfor interface or density applications.Consult your Emerson ProcessManagement sales office for themaximum allowable substitute weight,Ws, that may be used with yourparticular construction.

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

Ws + Wd[(0.0361)(V)(SP GR)]

where:

Ws = Total suspended weight in pounds (shouldnever be less than 0.5 pounds). For a unitwith a horizontal displacer, make sure thecenter of gravity of the substitute weight is

where it would be on the actual displacer.

Note

For liquid level control only, simulatethe lower range limit of the input spanby suspending the displacer from thedisplacer rod. For other values of inputspan, remove the displacer andsuspend the appropriate weight asdetermined in the equation above.

Wd = Weight of the displacer, in pounds

(determine by weighing displacer).

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

V = Volume, in cubic inches, of the portion of thedisplacer submerged. Or,

V = (/4) (displacer diameter)2 (length ofdisplacer submerged)

SP GR = Specific gravity of the process fluid atoperating temperature.

For interface level measurement, the equationbecomes:

Ws+Wd[(0.0361)(Vt)(SP GRl)

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

where:

Vt = Total volume, in cubic inches, of thedisplacer.

SP GRl = Specific gravity of the lighter of thefluids at operating temperature.

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

displacer submerged in the heavier of thefluids.

Or,

V = (/4) (displacer diameter)2 (length of thedisplacer submerged)

SP GRh = Specific gravity of the heavier of thefluids at operating temperature.

Calibration Procedure

WARNING

The following calibration proceduresrequire taking the controller/transmitter out of service. To avoidpersonal injury and property damagecaused by an uncontrolled process,provide some temporary means ofcontrol for the process before takingthe controller/transmitter out ofservice.

Figure 10 shows adjustment locations, except as

otherwise indicated. In order to calibrate, open-loopconditions must exist. One way to obtain an openloop is to ensure that there is no flow through thefinal control element. Another way to obtain an openloop is to disconnect the controller/transmitter outputsignal line and plug the output connection with a testpressure gauge.

Several steps in these calibrating procedures requiresetting the process variable at its minimum andmaximum limits, according to table 6.


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Note

If the process cannot be varied readilyor the Wet Calibration method cannotbe used in the following steps, be sureto use the proper sequence of correctweights as found in the DeterminingAmount of Suspended Weightprocedure. Whenever the followingsteps require particular prestartupchecks, refer to the appropriateprocedures for: 2500 Controller or2500T Transmitter, 2500S Controller,or 2503 Controller.

2500 Controller and 2500T Transmitter

1. Turn on the supply pressure and check that it is

set according to the appropriate prestartup checksprocedure.

2. Make sure that the PROPORTIONAL BAND orSPECIFIC GRAVITY adjustment is at the settingdetermined according to the appropriate prestartupcheck procedure.

3. Adjust the RAISE LEVEL (2500) or ZEROADJUSTMENT (2500T) to the appropriate value pertable 5. This table gives recommended settingsbased on maximum and minimum possiblePROPORTIONAL BAND (2500) or SPECIFICGRAVITY (2500T) settings. If an intermediatePROPORTIONAL BAND or SPECIFIC GRAVITY

setting is necessary, extrapolation may be used todetermine a new RAISE LEVEL or SPECIFICGRAVITY setting.

4. Set the process variable to the minimum value ofthe input range as shown in table 6. Forconstructions with an indicator assembly, make surethat the pointer is over the LOW mark.

Note

In the following step, the alignmentscrew (key 33, figure 16) must always

remain screwed in far enough toprovide spring tension on theunderside of the alignment screwhead.

5. Adjust the flapper (key 32, figure 16) to obtain theappropriate pressure listed below. For coarse flapperadjustment, loosen the hex nut (key 40, figure 16)and rotate the flapper assembly about the torquetube shaft. For fine flapper adjustment, turn theflapper alignment screw (key 33, figure 16).

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

DFor Reverse Acting 2500, 2500T, 1.0 bar (15psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or 2.0

bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig)output.

6. Visually examine the nozzle and flapper toensure the nozzle is as square as possible with theflapper. The nozzle can be realigned by looseningthe Bourdon tube mounting screws (key 45,figure 16) and rotating the Bourdon tube slightly. Ifthe nozzle is realigned, tighten the mounting screwsand repeat step 5.

7. Set the process variable to the maximum value ofthe input range as shown in table 6.

8. The output pressure should be:

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

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

9. If the output pressure agrees with that shown instep 8, proceed to step 10. If the output pressuredoes not agree, go to step 11.

10. If the unit does not contain an indicatorassembly, go to the Startup section. If the unitcontains an indicator assembly, change the pointerspan by loosening the indicator plate screws (key41, figure 16, detail of indicator assembly), slide theplate until the HIGH mark is under the pointer.Tighten the plate screws and go to the Startupsection.

Note

Any sliding of the level set arm (key28, figure 16) in the following step

changes the zero as well as the outputpressure span.

11. To adjust the output pressure span, loosen thetwo level set mounting screws (see figure 16) andslide the flexure strip base (key 27) right or left alongthe elongated slotted hole as follows:

D To increase the output pressure span, slidethe flexure strip base away from the torque tubeshaft.


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Table 5. Recommended Settings For Pre-Startup Checks

MOUNTING ACTION

RECOMMENDED RAISE LEVEL SETTINGFOR 2500 CONTROLLER

RECOMMENDED ZERO ADJUSTMENT SETTING FOR2500T TRANSMITTER

For PredeterminedPROPORTIONAL BAND

Dial Setting of 10(1)

For PredeterminedPROPORTIONAL BAND

Dial Setting of 0(1)

For PredeterminedSPECIFIC GRAVITY Dial

Setting of 1.0(1)

For PredeterminedSPECIFIC GRAVITY Dial

Setting of 0(1)

Right-handDirect 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to right 0.5 to 1.0 to right

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

Left-handDirect 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to left 0.5 to 1.0 to left

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

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

D To decrease the output pressure span, slidethe flexure strip base toward the torque tube shaft.

Retighten the screws. If the flexure strip base hasbeen moved as far as possible and the output

pressure span is still too large or too small, proceedto step 13.

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

Note

Any change of the PROPORTIONALBAND or SPECIFIC GRAVITYadjustment in the following stepchanges the zero as well as the outputpressure span.

13. If the flexure strip base has been moved as faras possible and the output pressure span is still toolarge or too small, slightly adjust thePROPORTIONAL BAND or SPECIFIC GRAVITYadjustment as follows:

D If the output pressure span is too large, slightlyincrease the PROPORTIONAL BAND or SPECIFICGRAVITY setting.

D If the output pressure span is too small, slightlydecrease the PROPORTIONAL BAND or SPECIFICGRAVITY setting.

14. Repeat the procedure from step 4 until the

required calibration points are obtained.

Note

If you cannot calibrate the controller ortransmitter, look for other problems asdescribed in the Troubleshootingprocedures, such as leakingconnections, or a binding displacerrod. If none of these troubles are

apparent, ensure that the displacer issized correctly for the application.

2500S and 2503 Controllers

1. Turn on the supply pressure and check that it isset according to the appropriate prestartup checksprocedure.

2. Make sure that the PROPORTIONAL BANDadjustment (2500S only) is at the setting determinedaccording to the appropriate prestartup checkprocedure.

3. Perform one or the other of the following:

D For direct acting controllers, set the RAISELEVEL adjustment between 1.0 and 1.5.

D For reverse acting controllers, set the RAISELEVEL adjustment between 3.5 and 4.0.

4. Set the process variable at the minimum value ofthe input range as shown in table 6. Forconstructions with an indicator assembly, make surethat the pointer is over the LOW mark.

Note

In the following step, the alignmentscrew (key 33, figure 16) must alwaysremain screwed in far enough toprovide spring tension on theunderside of the alignment screwhead.

5. Be sure the flapper is centered over the nozzle. Ifnot, loosen the hex nut (key 40, figure 16) andreposition the flapper, tighten the hex nut.


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Table 6. Minimum and Maximum Limits for Setting Process Variables

APPLICATION MINIMUM LIMIT MAXIMUM LIMIT

Liquid Level Displacer must be completely out of liquid Displacer must be completely submerged in liquid

Interface Displacer must be completely submerged in lighter of two

process liquids

Displacer must be completely submerged in

heavier of two process liquidsDensity Displacer must be completely submerged in liquid having

specific gravity of lowest range pointDisplacer must be completely submerged in liquid havingspecific gravity of highest range point

6. Adjust the flapper (key 32, figure 16) asdescribed below. For coarse flapper adjustment,loosen the hex nut (key 40, figure 16) and rotate theflapper assembly about the torque tube shaft. Forfine flapper adjustment, turn the flapper alignmentscrew (key 33, figure 16).

D For Direct Acting Controllers, move theflapper toward the nozzle until the output pressure

switches to full supply pressure, then carefully adjustthe flapper away from the nozzle until the outputpressure switches to 0 bar (0 psig).

D For Reverse Acting Controllers, move theflapper away from the nozzle until the outputpressure switches to 0 bar (0 psig), then carefullyadjust the flapper toward the nozzle until the outputpressure switches to full supply pressure.

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

D For Direct Acting Controllers, slowly increase

the process variable until the output pressureswitches to full supply pressure. The processvariable should be at the maximum value of inputrange as shown in table 6. If the process variableagrees with table 6, proceed with step 8. If theprocess variable does not agree with table 6,proceed to step 9.

D For Reverse Acting Controllers, slowlyincrease the process variable until the outputpressure switches to 0 bar (0 psig). The processvariable should be at the maximum value of inputrange as shown in table 6. If the process variableagrees with table 6, proceed with step 8. If theprocess variable does not agree with table 6,proceed to step 9.

8. If the unit does not contain an indicator assembly,go to the startup section. If the unit contains anindicator assembly, change the pointer span byloosening the indicator plate screws (key 41,figure 16, indicator assembly detail), slide the plateuntil the HIGH mark is under the pointer. Tighten theplate screws and go to the startup section.

Note

Any sliding of the level set arm (key28, figure 16) in the following stepchanges the zero as well as thedifferential gap.

9. To adjust the differential gap, loosen the two levelset mounting screws (see figure 16) and slide theflexure strip base (key 27) right or left along the

elongated slotted hole as follows:

D To decrease the differential gap, slide theflexure strip base away from the torque tube shaft.

D To increase the differential gap, slide theflexure strip base toward the torque tube shaft.

Retighten the screws. For the 2500S only, if theflexure strip base has been moved as far as possibleand the differential gap is still too low, proceed tostep 11.


Note

Any change in the PROPORTIONALBAND adjustment in the following stepchanges the zero as well as thedifferential gap.

11. If the flexure strip base has been moved as faras possible and the differential gap is still too largeor too small, adjust the PROPORTIONAL BAND asfollows:

D If the differential gap is too large, slightlydecrease the PROPORTIONAL BAND setting.

D If the differential gap is too small, slightlyincrease the PROPORTIONAL BAND setting.


Note

If you cannot calibrate the controller,look for other problems as described


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in the Troubleshooting procedures,such as a nozzle that is notperpendicular to the flapper, leakyconnections, or a binding displacerrod. If none of these troubles areapparent, ensure the displacer is sizedcorrectly for the application.

Startup

Adjustment locations are shown in figure 10. Thepre-startup or calibration procedures must becompleted prior to startup.

2500 Controller1. Slowly open the upstream and downstreammanual control valves in the pipeline. If the pipelinehas a bypass valve, close the valve.

2. If desired, adjust the proportional band to thenarrowest (lowest) setting that maintains stablecontrol. Proportional band adjustments will affect theprocess level and may require a level adjustment. Ifadjusting proportional band, make the adjustmentsin small increments.

3. To confirm the optimum proportional bandsetting, momentarily create a load upset. If cyclingoccurs, broaden (increase) the proportional banduntil process oscillations diminish rapidly. In general,the narrowest proportional band that does notproduce cycling provides the best control.

2500T Transmitter1. Make sure that the SPECIFIC GRAVITY andZERO ADJUSTMENT controls are set according tothe 2500 Controller or 2500T Transmitter portion ofthe pre-startup checks procedures.

2. Slowly open the upstream and downstreammanual control valves in the pipeline. If the pipelinehas a manual bypass valve, close the valve.

2500S Controller1. Set the switching points according to the 2500SController portion of the prestartup checksprocedures.


3. If necessary, the proportional band may beadjusted to increase or decrease the differential gap.Adjust the RAISE LEVEL adjustment to repositionthe differential gap. After readjustment, confirm thecontroller is still switching correctly at both switchingpoints.

2503 Controller1. Set the switching points according to the 2503Controller portion of the prestartup checksprocedures.


3. If necessary, reposition the switching points byadjusting the RAISE LEVEL control. For example, ifthe differential gap is set for 102 mm (4-inches) oflevel change, this 102 mm (4-inches) can be setanywhere within the length of the displacer. Afterreadjustment, confirm the controller is still switchingcorrectly at both switching points.

Principle of Operation

The controller/transmitter receives the change influid level, fluid-to-fluid interface level, or densityfrom the change in the buoyant force the fluid exertson the sensor displacer. The displacer, through a

mechanical linkage, imparts a rotary motion to thetorque tube shaft. This rotary motion positions theflapper according to the level position of thedisplacer; the nozzle/Bourdon tube arrangementsends a pneumatic signal to the relay valve.

All 2500 and 2503 Series controller/transmitters usethe same basic pressure-balanced relay assembly.The following descriptions explain how the relayaction produces the output signal with the variouscontroller/transmitter constructions.

2500 Controller or 2500T Transmitter

Full supply pressure comes to the relay from theregulator, as shown in figure 12. The relay has afixed restriction through which supply pressurebleeds before entering the large diaphragm area andthe inner Bourdon tube channel. In a steady-statecondition, the process level holds the torque tubeand attached flapper steady in relation to the nozzle.This allows pressure to escape between the nozzleand flapper at the same rate it bleeds into the largediaphragm area. The large diaphragm holds the inlet


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end of the relay valve slightly open to compensatefor the venting of output pressure through theproportional valve as it maintains a steady-stateposition of the final control element. The outputpressure, through the three-way proportional valve,affects the Bourdon tube outer channel, holding theBourdon tube in a steady-state position.

A process level change raises or lowers thedisplacer, moving the flapper with respect to thenozzle. If the process level change increases nozzlepressure, the large diaphragm moves down; thiscloses the exhaust end and opens the inlet end ofthe relay valve (see figure 12). This action of therelay valve increases the output pressure to the finalcontrol element. Since the area ratio of the largediaphragm to the small diaphragm is three-to-one,the small diaphragm action amplifies the output

pressure change. The three-way proportional valvelets the increase in output pressure apply to theBourdon tube outer channel. The expansion of theBourdon tube moves the nozzle away from theflapper slowing the response of the pneumaticcircuit.

If the process level change decreases the nozzlepressure, the large diaphragm moves up. This actioncloses the inlet end and opens the exhaust end ofthe relay valve which allows output pressure toexhaust. This relay valve action reduces the outputpressure to the final control element and is thereverse of the previous explanation.

The proportional valve varies the reaction of theBourdon tube to changes in the output pressure. Foradditional information on the proportional valveaction, refer to the following proportional valvesubsection.

Proportional Valve

The three-way proportional valve is adjustable toallow some or all of the output pressure change tofeed back to the Bourdon tube outer channel,providing proportional band control (see figure 12).

The Bourdon tube moves to counteract the pressurechanges in the nozzle, equaling the relay diaphragmpressure differential. The relay valve maintains anew output pressure according to the change in theprocess variable.

A wide-open proportional valve (fullycounterclockwise) permits feedback of the outputpressure signal change and produces 100 percentproportional response. A closed (fully clockwise)proportional valve produces smaller proportionalresponses, because part of the output pressurechange vents through the proportional valveexhaust.

2500S Controller

This construction has the same flapper, relay, andproportional valve as the 2500 controller. However,the nozzle is connected (figure 12) in such a waythat output pressure feedback (from the movementof the Bourdon tube) moves the nozzle in theopposite direction of the flapper. This action

completely opens the relay valve for full outputpressure or completely closes the relay valve for fullexhaust of the output pressure, allowing noin-between throttling.

2503 Controller

This construction has the same flapper and sensorarrangement as the 2500 controller, but its Bourdontube has a three way valve operated by a plunger(see figure 13). Note that the switch point adjustmentchanges the position of the moveable arm andattached Bourdon tube assembly; this in turn

changes the switch point in relationship to theprocess level. The differential gap of the 2503 eithercompletely opens the relay valve for full outputpressure or completely closes the relay valve for fullexhaust of the output pressure, allowing noin-between throttling.

For a direct-acting controller, as long as the processvariable remains above the switch point, the flapperdoes not depress the plunger of the Bourdon tubevalve. In this condition, the Bourdon tube valveremains closed, providing full loading pressure to theBourdon tube. This loading pressure moves theBourdon tube away from the flapper. Also, in this

condition, full loading pressure is on the upperdiaphragm of the relay. The loading pressure movesthe diaphragm down, closing the exhaust end andopening the inlet end of the relay valve, allowing fulloutput pressure.


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CD2114EBO9981/IL

OUTERBOURDONTUBECHANNEL

INNERBOURDONTUBECHANNEL

LEVEL SETADJUSTMENT

CAM

EXHAUST

MOVABLE ARM

FIXED PIVOT

NOZZLE

FLAPPER

FIXEDRESTRICTION

PROPORTIONALVALVE

EXHAUST END OFRELAY VALVE

INLET END OFRELAY VALVE

SUPPLY SOURCE

TO OTHERPNEUMATICINSTRUMENT, ONTRANSMITTERCONSTRUCTION

SMALLDIAPHRAGMOF ASSEMBLY

LARGE DIAPHRAGMOF ASSEMBLY

DIRECT-ACTINGDIAPHRAGMCONTROL VALVE

VESSEL INFLOW

67CFRFILTER REGULATOR

SUPPLY PRESSURE

OUTPUT PRESSURE

NOZZLE PRESSURE

PROPORTIONAL PRESSURE

EXHAUST

Figure 12. Direct-Acting, Right-Hand-Mounted 2500-249 Series Controller/Transmitter

When the process level sufficiently decreases, theflapper pushes in the plunger of the Bourdon tubevalve enough to release the loading pressure andseal the inner Bourdon tube channel (see figure 13).This decrease in the loading pressure moves the

Bourdon tube toward the flapper, producing the snapaction. Also, this decrease in loading pressureallows relay spring pressure to move the largediaphragm up, closing the inlet end and opening theexhaust end of the relay valve, allowing full exhaust


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BD4466ACD2114EA18901/IL

INNER BOURDONTUBE CHANNEL

OUTER BOURDONTUBE CHANNEL

THREE-WAY BOURDON

TUBE VALVE (OPEN FORRELEASE OF LOADINGPRESSURE)

MOVABLE ARM

FLAPPER

FIXEDPIVOT

LARGE DIAPHRAGM

EXHAUST END OFRELAY VALVE

INLET END OFRELAY VALVE

CAM

SMALLDIAPHRAGM

SWITCHPOINT

ADJUSTMENT

TORQUE TUBE

SUPPLY PRESSURE

LOADING PRESSURE

OUTPUT PRESSURE

Figure 13. Direct-Acting Left-Hand-Mounted 2503 Controller

of the output pressure. This control action continuesuntil a sensor level change moves the flapper awayfrom the plunger, permitting the Bourdon tube valveto close, restoring loading pressure to the pneumaticcircuit. Reverse-acting controllers produce theopposite effect.

Maintenance

The 2500 and 2503 Series controllers/transmitterswork in combination with 249 Series displacers.Refer to figure 16 for key number locations, unlessotherwise indicated.

WARNING

Always wear protective clothing,gloves, and eyewear when performing

any maintenance operations to avoidpersonal injury.

When replacing the sensor assembly,the displacer may retain process fluidor pressure. Personal injury orproperty damage may occur due tosudden release of the pressure.Contact with hazardous fluid, fire, orexplosion can be caused bypuncturing, heating, or repairing adisplacer that is retaining processpressure or fluid. This danger may not

be readily apparent whendisassembling the sensor assembly orremoving the displacer. Beforedisassembling the sensor or removingthe displacer, observe the morespecific warning provided in thesensor instruction manual.

When disconnecting any of thepneumatic connections, natural gas, ifused as the supply medium, will seep


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from the unit and any connectedequipment into the surroundingatmosphere. Personal injury orproperty damage may result from fireor explosion if natural gas is used asthe supply medium and preventativemeasures are not taken.

Preventative measures may include:

D remote venting of the unit,

D re-evaluating the hazardous areaclassification,

D the removal of any ignitionsources, and

D ensuring adequate ventilation.

For information on remote venting ofthis controller refer to page 10.

Check with your process or safetyengineer for any additional measuresthat must be taken to protect againstprocess media.

Troubleshooting

When troubleshooting, open loop conditions mustexist unless otherwise stated. When monitoring theprocess variable, use the most accurate levelindicating device available. The output signalmeasuring device should have correspondingaccuracy.

Table 7 lists some common operating faults, theirprobable causes, and corrective action.

Removing Controller/Transmitter fromSensor

WARNING

To avoid injury in the following steps,turn off the supply pressure andcarefully release any pressure trapped

in the controller/transmitter beforebreaking any pressure connection.Provide a bypass for the controldevice if continuous operation isrequired during maintenance.

1. Disconnect the supply and output pressure tubingfrom the controller or transmitter. For acontroller/transmitter with an indicator, remove thepointer assembly by referring to the Replacing theBourdon Tube section.

20A7423C/DOC

Figure 14. Heat Insulator for 249 Series Sensor

2. Loosen the top hex clamp nut (key 40, figure 16)and remove the flapper base (key 30, figure 16) fromthe torque tube rotary shaft.

CAUTION

If the hex clamp nut has not beenloosened or the pointer removedaccording to step 2, attempting toremove the controller/transmitter fromthe sensor may bend the flapper orrotary shaft. Be careful that the back ofthe controller/transmitter case or theheat insulator does not drop down and

bend the rotary shaft or shaftextension.

3. Remove any insulating tape from the jointbetween the controller/transmitter case and thetorque tube arm. Remove the four cap screws(key 39, figure 14) that hold the controller/transmitteror heat insulator to the torque tube arm. Pull thecase straight out from the torque tube arm, easing itover the shaft coupling (key 36, figure 14) if one isinstalled.


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Table 7. Troubleshooting Chart for 2500 Series Controller/Transmitters

FAULT POSSIBLE CAUSE CHECK CORRECTION

1. Process wanders or cyclesaround set point.

1.1 Proportional band or specificgravity adjustment incorrect orimproperly tuned control loop.

Ensure the prestartup proceduresare completed correctly. Tunecontrol loop.

If stable control cannot be attainedand all other elements arefunctionally correct, examine other

possible causes related to thecontroller/transmitter.

1.2 Supply pressure varying orincorrect supply pressure setting.

Use input pressure gauge tomonitor stability. Make sureregulator IN supply pressure iswithin limits.

Apply correct supply pressure. Useone regulator per instrument.

1.3 Sensor not plumb and is incontact with sidewall or leak indisplacer.

Check cage vessel and stillwellinstallation, or for leakingdisplacer.

Make sure the displacer anddisplacer rod hangs freely. Makesure linkage is tight. Replacedisplacer if leaking.

1.4 Relay malfunction. Check for relay malfunction byusing the testing relay deadbandprocedure.

Depress plunger to clean out thefixed restriction. Replace relayusing the procedure in theMaintenance section.

2. Controller/transmitter controllingoff set point or switching point.

2.1 Supply pressure not setcorrectly.

Make sure regulator supplypressure is set correctly. Makesure regulator IN supply pressureis within limits.

Reset the supply regulatorpressure. If the condition occursagain, rebuild or replace regulator.Provide a regulator input pressurewithin regulator limits.

2.2 Leak in thecontroller/transmitter loop.

Use soap and water to check forinternal and external leaks.

Replace or repair leaking parts asnecessary.

2.3 Leaking displacer. Ensure the displacer is not fillingwith process fluid.

Refer to sensor maintenanceprocedures in the appropriatesensor instruction manual.

2.4 Flapper adjustment. Ensure the flapper is not loose onthe torque tube shaft and iscentered on the nozzle.

Replace or tighten flapperassembly as necessary and/orcenter flapper on nozzle.

2.5 Process variable changed. Ensure the process variable hasnot changed from originalcalibration settings, or displacernot designed for specific gravity ofprocess.

Change process variable back tooriginal specification or recalibrate.If necessary, provide replacementdisplacer of correct size andrecalibrate.

3. Controller/transmitter cannotattain full output range.

3.1 Supply pressure not setcorrectly.

Make sure supply pressure is setcorrectly. Make sure regulator INsupply pressure is within limits.

Reset the regulator pressure. Ifproblem reoccurs, replace orrebuild the regulator. Ensureregulator IN supply pressure iswithin limits at all operating levels.



3.3 Process variable changed. Ensure the process variable hasnot changed from originalcalibration settings, or fromdisplacers designed specificgravity.

Change process variable back tooriginal specification or recalibrate.If necessary, provide replacementdisplacer of correct size andrecalibrate.

3.4 Relay malfunction Check for relay malfunction byusing the testing relay deadbandprocedure.

Depress plunger to clean out thefixed restriction. Replace relayusing the procedure in the

Maintenance section.

3.5 Leak in thecontroller/transmitter loop.

Use soap and water to check forinternal and external leaks.

Replace or repair leaking parts asnecessary.

4. Controller/transmitter remainsat full or zero output pressure.

4.1 Supply or output pressuregauge malfunction.

Ensure the pressure gauges areregistering correctly.

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




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4. If the controller/transmitter has a heat insulator,remove the four button head cap screws andwashers (keys 40 and 53, figure 14) and remove theinsulator assembly.

Changing Mounting Methods

WARNING

To avoid personal injury from contactwith the process fluid, lower the vesselfluid level below the torque-tube armbefore proceeding. For closed vessels,release any pressure that may beabove the fluid. Also, be careful toavoid overloading a thin-wall torque

tube with an overweight displacer.

Refer to figure 16 for key number locations.

1. Remove the controller/transmitter as describedpreviously.

2. A controller/transmitter is attached to the sensorin one of the mounting positions shown in figure 4.Right-hand mounting is with the controller/transmittercase (key 1) to the right of the displacer (FLOAT), asyou look at the front of the case, left-hand mountingis with with the case to the left of the displacer. For a249 Series sensor, remove the torque tube arm fromthe sensor or vessel and reinstall the torque tube

arm in the opposite position according to theappropriate instruction manual. Note that the termFLOAT is marked on the RAISE LEVEL dial and theindicator plate, if one is used.

3. Check the desired control action. If the controlaction is not correct, refer to the changing actionprocedures to change it. Mount the Bourdon tube inone of the positions shown in figure 15.

4. The arrow on the RAISE LEVEL dial under theword FLOAT should point toward the displacer. Ifnot, remove the dial from the controller, turn it over,and install it in the correct position.

5. For a controller/transmitter with an indicatorassembly, the arrow near the word FLOAT on theindicator plate should point toward the displacer. If itdoes not, remove the two screws (key 41, see detailof indicator assembly in figure 16), turn the frontplate (key 54) to the side with the FLOAT arrowpointing toward the displacer, and secure the platewith the screws.

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

Installing Controller/Transmitter onSensor

Note

If the installation is in a location that isnot readily accessible and shopcalibration is required, remove thetorque tube arm from the cage orvessel before installing the controlleror transmitter to the sensor. Install thecontroller/transmitter on the torquetube arm in the shop; then calibrateand return the controller/transmitterwith the torque tube arm assemblyattached for installation.

Perform step 1 only if adding a heat

insulator to a unit that does not haveone. Key numbers in this step areshown in figure 14.

1. To install the heat insulator, secure the shaftextension (key 37) to the torque tube assemblyrotary shaft with the shaft coupling (key 36). Tightenboth set screws (key 38), with the coupling centeredas shown in figure 14. Then mount the insulatorassembly (key 35) on the controller/transmitter casewith four button head cap screws and washers(keys 40 and 53). Tighten the screws.

CAUTION

In the following step, avoid bendingthe rotary shaft of the torque tubeassembly. Bending or side loading ofthis shaft could cause erroneousreadings. Additionally, make sure theball bearing assembly (key 12, figure16) is removed from the case (key 1,figure 16) to provide clearance wheninstalling the case on the sensor.

2. Remove the bearing assembly (key 12, figure 16)from the case (key 1, figure 16).

3. Carefully slide the controller/transmitter casestraight in. Secure the case on the torque arm orinsulator with the four cap screws (key 39).

Note

If a heat insulator is used, do notinsulate its exterior.

4. Slide the bearing assembly (key 12, figure 16)onto the shaft or shaft extension of the insulator, and


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install the bearing assembly (key 12, figure 16) intothe case (key 1, figure 16).

5. Install the flapper base (key 30, figure 16) on thetorque 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 16).For a controller/transmitter with an indicatorassembly, install the pointer assembly according tothe Replacing the Bourdon Tube section.

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

Replacing the Bourdon Tube

Refer to figure 16 for key number locations.

1. Disconnect the tubing (key 10 for 2503 andkey 11 for 2500) from the Bourdon tube base. For acontroller/transmitter with indicator assembly, loosenthe side hex clamp nut (key 40) and remove thepointer assembly (key 51) from the torque tuberotary shaft.

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

3. Inspect the Bourdon tube. Replace it ifnecessary, using a tube with a black color code fora 0.2 to 1 bar or 0 to 1.4 bar (3 to 15 psig or 0 to 20psig) range. Use a tube with a red color code for

a 0.4 to 2 bar or 0 to 2.4 bar (6 to 30 psig or 0 to 35psig) range. The range is stamped at the B

controlador 2500

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