Emerson Fisher 2500 Instruction Manual
Contents
1. DISPLACER SPUD 0228 1 COTTER SPRING DISPLACER ROD ALL OTHER TYPES W9357 249VS SENSOR Supply Pressure A WARNING Do not overpressurize any system component Personal injury or property damage may occur due to sudden pressure release or explosion To avoid damage provide suitable pressure relieving or pressure limiting devices if supply pressure can exceed the maximum supply pressure listed in table 1 Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean dry oil free or non corrosive gas While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications check with an Emerson Process Management field office and industry instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or method of air filtration or filter maintenance Standard 2502 controllers come complete with supply and output pressure gauges and an integrally mounted 67CFR filter regulator to reduce supply pressure from a maximum of 17 3 bar 250 psig to the 1 4 or 2 4 bar 20 or 35 psig required This regulator has built in relief and a standard 5 micrometer filter to remove particles from the supply source The output pressure connection is on the back of the controller case figure 3 Pipe the supply pressure to the in connection of the regulator mounte2. 18 Principle of Operation 19 2502 CONTIONEN eae ease ere etre 21 2502F Controller with Reset 21 42 2022 22 23 Removing Controller from Sensor 24 www Fisher com 2502 Controllers February 2015 Figure 1 Fisher 2502 Controller Mounted 249B Sensor 2502 CONTROLLER ke 249B SENSOR Changing Mounting Method 25 Installing Controller on Sensor 26 Changing Proportional Reset or Differential Relief Valve 27 Testing Relay Dead Band 27 Changing Relay 27 Replacing Bellows 27 Reversing Action 28 PS Oder 2 29 Parts 29 29 lt ey EMERSON Process Management 2502 Controllers Instruction Manual February 2015 D200126X012 Introduction Scope of Manual This instruction manual provides installation operating calibration and maintenance procedures for Fisher 2502 pneumatic controllers figure 1 used in combination with Fisher 249 level sensors This manual does not include regulator or sensor installation or maintenance procedures For this information refer to the instruction manual for the appr
3. 10 0 positions 10 If the controller is out of calibration adjust the calibration adjuster as follows Note Loosen the two calibration adjuster screws key 45 figure 14 and slide the calibration adjuster key 100 figure 14 in the desired direction a If output is below 1 0 bar for a 0 2 to 1 0 bar signal range 15 psig for a to 15 psig signal range or 2 0 bar fora 0 4 to 2 0 bar signal range 30 psig for a 6 to 30 psig signal range move the adjustor a small distance away from the pivot to increase span movement should be away from the torque tube Then repeat steps 4 through 9 b If output is above 1 0 bar for a 0 2 to 1 0 bar signal range 15 psig for a 3 to 15 psig signal range or 2 0 bar fora 0 4 to 2 0 bar signal range 30 psig for a 6 to 30 psig signal range move the adjustor a small distance toward the pivot to decrease span movement should be toward the torque tube Then repeat steps 4 through 9 Note If the controller cannot be calibrated look for other problems as described in the Troubleshooting section such as a nonperpendicular flapper nozzle condition leaky connections or a binding displacer rod If none of these troubles is apparent the displacer or torque tube may be sized for a different set of service conditions Ensure that the displacer is sized correctly for the application Startup Adjustment locations are shown in figure 9 1 Set the RAISE LEVEL control to the desired control point as det
4. 3 to 15 psig range or greater than 30 psig 2 0 bar and less than 3 4 bar 35 psig for the 0 4 to 2 0 bar 6 to 30 psig range If these conditions are not met recalibration may be desired On a controller with indicator assembly the pointer should be over the low point on the indicator plate slight adjustment might be necessary by loosening the hex nut key 40 figure 14 shifting the pointer and retightening the nut 4 Locate the process variable at its maximum value see table 2 Output pressure on direct acting controllers should be greater than 1 0 bar 15 psig and less than 1 4 bar 20 psig for the 0 2 to 1 0 bar 3 to 15 psig range or greater than 2 0 bar 30 psig and less than 3 4 bar 35 psig for the 0 4 to 2 0 bar 6 to 30 psig range If these conditions are not met recalibration may be desired On a controller with indicator assembly the pointer should be over the high point on the indicator plate slight adjustment might be necessary by loosening the hex nut key 40 figure 14 shifting the pointer and retightening the nut On a controller with level indicator the pointer should reflect the magnitude of the process variable for instance with liquid or interface level covering 50 percent of the displacer the pointer should be in the middle of the high low scale Slight plate adjustment might be necessary as described at the end of step 3 5 If all prestartup checks are satisfactory proceed to the Startup section Adjust
5. and 64 two seal rings key 55 and the nozzle block key 101 Check seal ring condition and replace rings as necessary 2 Install the nozzle block seal rings and screws on the opposite side of the beam as shown in figure 13 Disconnect the proportional band tubing key 76 and one of the two pieces of reset tubing key 75 from the bellows frame key 94 and reconnect them in the proper orientation as shown in figure 13 Figure 13 Nozzle Flapper and Tubing Arrangements for Various Actions and Mountings SEAL SCREWS SEAL SCREW RINGS SEAL SCREW RING FLAPPER SEAL SCREW HOOK an j 4 v SEAL FLAPPER miT SCREW HOOK RING g 1 1 SEAL SCREW RESET VALE RESET PROPORTIONAL TURING ii TUBING RESET TUBING PROPORTIONAL ORE TO PROPORTIONAL TUBING TO VALVE PROPORTIONAL VALVE TO RELAY DIRECT ACTING RIGHT HAND MOUNTING REVERSE ACTING RIGHT HAND MOUNTING REVERSE ACTING LEFT HAND MOUNTING DIRECT ACTING LEFT HAND MOUNTING 28 Instruction Manual 2502 Controllers D200126X012 February 2015 Note Beam overtravel can jam the flapper against the nozzle if the following step is not performed 3 Remove the flapper screw key 93 lockwasher key 84 and flapper key 60 Invert the flapper so that the flapper hook is on the opposite side of the beam from the nozzle key 58 and secure with the lockwasher and screw 4 Perform the calibration procedure
6. changed in the field if required refer to the appropriate sensor manual for instructions Changing this mounting position will change controller action from direct to reverse or vice versa Figure 3 Pressure Connections ADJUSTING SCREW PRESSURE REGULATOR LOCKNUT 1 4 18 SUPPLY CONNECTION 1 4 18 DRAIN VALVE OUTPUT CONNECTION VENT All caged sensors have a rotatable head That is the controller 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 Controller Sensor Action The following controller description is for right hand mounting Left hand mounting produces an output signal with the opposite action Figure 4 shows cage head mounting positions For right hand mounting Direct Action Increasing liquid or interface level or density increases the output signal Reverse Action Decreasing liquid or interface level or density increases the output signal A factory supplied reverse acting unit has the suffix letter R added to the type number Instruction Manual 2502 Controllers D200126X012 February 2015 Figure 4 Cage Head Mounting Positions e tae LEFT HAND MOUNTING RIGHT HAND MOUNTING 1 gt 67CFRFILTER REGULATOR AH9150 A A2613 2 Mounting Caged Sensor Note The cage must be installed plumb so that the
7. controllers are used in combination with 249 sensors and unless ordered separately the controller will be attached to the sensor A WARNING Wear protective eyewear gloves and clothing whenever possible when performing any installation operations to avoid personal injury Check with your process or safety engineer for any additional measures that must be taken to protect against process media If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual Instruction Manual 2502 Controllers D200126X012 February 2015 A WARNING Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 11 249 Sensors 249 249B 249BF 249C 249K and 2491 sensors side mount on the vessel with the displacer mounted inside a cage caged outside the vessel 249BP and 249 sensors top mount on the vessel with the displacer hanging down into the vessel cageless The 249VS sensor side mounts the vessel with the displacer hanging out into the vessel cageless The 2
8. interface or liquid level applications install a gauge glass on the vessel CAUTION If the displacer is to be inserted into the vessel before being attached to the displacer rod provide a suitable means of supporting the displacer to prevent it from dropping into the vessel and suffering damage To help support 249BP or 249 displacer install the displacer stem and stem end piece or a threaded rod into the 1 4 inch 28 UNF threaded hole in the displacer spud or stem end piece figure 8 On the 249BP with optional travel stop the stem end piece pins will secure the displacer as long as the travel stop plate is installed and the sensor head is in position Side Mounted Sensor If a stillwell is required figure 7 the displacer must be attached 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 the displacer can be attached to the displacer rod before mounting the sensor to the vessel connection The displacer may then be swung 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 2502 Controllers Instruction Manual
9. must be completely submerged in the lower of two process liquids two process liquids Densit Displacer must be completely submerged in liquid having Displacer must be completely submerged in liquid y highest specific gravity expected having the lowest specific gravity expected 2502 Controllers Instruction Manual February 2015 D200126X012 1 Connect a supply pressure source to the controller and provide a supply pressure suitable for the sensing element range 1 4 bar 20 psig for a 0 2 to 1 0 bar 3 to 15 psig output pressure range or 2 4 bar 35 psig for a 0 4 to 2 0 bar 6 to 30 psig output pressure range Rotate the reset knob to 0 01 minutes per repeat Rotate the proportional band knob to zero Set the liquid at the minimum limit dry displacer Turn the RAISE LEVEL knob to zero Adjust the nozzle until output pressure is between 0 and 0 2 bar for a 0 2 to 1 0 bar signal range 0 and 3 psig for a 3 to 15 psig signal range or 0 and 0 4 bar for a 0 4 to 2 0 bar signal range 0 and 6 psig for a 6 to 30 psig signal range KR 9 7 Set the liquid at the maximum limit covered displacer 8 Turn the RAISE LEVEL knob until the output pressure is 1 0 bar for a 0 2 to 1 0 bar signal range 15 psig fora 3 to 15 psig signal range or 2 0 bar for a 0 4 to 2 0 bar signal range 30 psig for a 6 to 30 psig signal range 9 The controller is within its calibration accuracy if the RAISE LEVEL knob is between the 9 0 and
10. 49W sensor top mounts on the vessel or on a customer supplied cage External sensors provide more stable operation than do internal sensors for vessels with internal obstructions or considerable internal turbulence A WARNING When replacing the sensor assembly the displacer may retain process liquid or pressure Personal injury or property damage due to sudden release of pressure contact with hazardous liquid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or liquid This danger may not be readily apparent when disassembling the sensor 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 will be attached to the sensor when shipped Carefully uncrate the assembly CAUTION If the sensor has a thin walled torque tube always support the displacer if the travel stop must be removed A thin walled torque tube has a T stamped on the sensor end flange not visible unless the controller is removed from the sensor Note Caged sensors have a rod and block installed on each end of the displacer to protect the displacer in shipping Remove these parts before installing the sensor to allow the displacer to function properly Caged sensors will be shipped with the displacer installed in the cage If the sensor is ordered w
11. 6X012 February 2015 CAUTION If the hex nut has not been loosened according to step 2 attempting to remove the controller from the sensor may bend the rotary shaft or operating arm and linkage Be careful that the back of the controller 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 case and the torque tube arm Remove the four cap screws key 39 figure 12 that hold the controller 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 12 if one is installed Figure 12 Heat Insulator Shown Installed on Fisher 249 Sensor Z i Le 9 20A7423 C 4 If the controller has a heat insulator remove the button head cap screws key 40 Remove four washers key 53 and the insulator assembly key 35 Changing Mounting Method To avoid personal injury from contact with the process liquid lower the vessel level below the torque tube arm before proceeding For closed vessels release any pressure that may be above the liquid Also be careful to avoid overloading a thin wall torque tube and or oversized displacer Refer to figure 14 for key number locations 25 2502 Controllers Instruction Manual February 2015 D200126X012 1 Remove the controller
12. CE marking to 220 F indicate compliance with other applicable European See figure 2 Community Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 Control and stability may be impaired if this pressure is exceeded 2 The pressure temperature limits in this document and any applicable standard or code limitation should not be exceeded 3 Normal cubic meters per hour m3 hr at 0 and 1 01325 bar Scfh standard cubic feet per hour at 60 F and 14 7 psia Figure 2 Guidelines for Use of Optional Heat Insulator Assembly AMBIENT TEMPERATURE C 93 AMBIENT TEMPERATURE 71 18 10 0 10 20 30 40 50 60 70 80 90 18 10 0 C o 20 30 40 50 60 70 110 593 110 505 lt 0 800 21 800 HEAT INSULATOR wog 5 HEAT INSULATOR REQUIRED lt REQUIRED a 400 200 H 400 5 NO INSULATOR NECESSARY A NO INSULATOR NECESSARY 4 0 USE INSULATOR CAUTION IF AMBIENT DEWPOINT IS ABOVE PROCESS 2 0 TEMPERATURE ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION AND MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS REDUCE INSULATOR EFFECTIVENESS 0 2 40 10 10 140 160 0 20 40 60 80 100 120 140 160 180 200 AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F NOTE FOR SERVICE BELOW 29 C 20 F CONTACT FACTORY ee STANDARD CONTROLLER OR TRANSMITTER HIGH TEMPERATURE CONTROLLER OR TRANSMITTER 2502
13. Differential Relief Valve section 2 Turn the supply pressure and set it to 1 4 or 2 4 20 or 35 psig 3 By changing the process variable and adjusting the RAISE LEVEL control set the output pressure to 1 0 or 2 0 bar 15 or 30 psig While monitoring the output pressure slowly change the process until an output pressure change can just be detected and record the value of the process variable at the detection point 4 Change the process variable in the opposite direction until another output pressure change can be detected and again record the value of the process variable If the difference between the two recorded values the dead band is more than 0 2 percent of the maximum displacer length the relay will have to be replaced or repaired according to the Changing Relay and the Disassembling Relay sections 5 Turn off the supply pressure remove the pipe plug and install the proportional band adjustment assembly Changing Relay The relay may be removed for cleaning or replacement and must be taken off to remove the lower bellows 1 On a controller with indicator assembly loosen the two lower screws of the relay case and slide out the indicator base plate key 53 figure 14 2 Disconnect the tubing key 11 figure 14 from the relay 3 Remove both mounting screws the relay and the relay gasket keys 43 34 and 22 figure 14 4 Install a new gasket the replacement relay if necessary and both mounting screws
14. F and 2502FC Standard High temperature 187 Sleeve plastic 188 O Ring 2502F and 2502FC 1 8538 0132 215 Nameplate metal Pipe Plug 2502 and 2502C 1D754828982 Heat Insulator figure 12 Note All Heat Insulator parts are included in the Heat Insulator Parts Kit 35 Heat Insulator Assembly stainless steel 36 Shaft Coupling stainless steel 37 Shaft Extension NO5500 38 Set Screw stainless steel 2 req d 39 Screw steel pl 4 req d 40 Screw steel pl 4 req d 53 Washer carbon steel pl 4 req d Recommended spare parts Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher is mark owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed
15. February 2015 D200126X012 Figure 7 Cageless Sensor Mounting SIDE MOUNTED W9517 1 SIDE VIEW SHOWING STILLWELL CF5380 A A3893 SIDE VIEW WITHOUT STILLWELL If an extension is used between the displacer spud and the displacer stem end piece make sure the nuts are tight at each end of the displacer stem extension Install and tighten suitable bolting or cap screws in the flanged connection to complete the installation Top Mounted Sensor Figure 7 shows the installation of a top mounted cageless sensor The displacer may be attached to the displacer rod before installing the sensor on the vessel Where the displacer diameter is small enough it may be desirable 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 is used between the displacer as shown in figure 8 lock the assembly with the cotter springs provided If a stem is used between the displacer spud and the stem end piece make sure the nuts are tight at each end of the stem Install and tighten suitable cap screws in the flanged connection to complete the installation Instruction Manual 2502 Controllers D200126X012 February 2015 Figure 8 Displacer and Displacer Rod Connections COTTER SPRING DISPLACER ROD DISPLACER SPUD DISPLACER STEM EXTENSION N LOCKING NUTS
16. IL OF RELIEF VALVE ASSEMBLY ON 2502F CONTROLLER FES 0 17 2 A fod 5 a RSS RE TVZ 79 41 22 63 64 DETAIL OF LEVEL INDICATOR ASSEMBLY 2502C CONTROLLER 30A8943 H 2502 Controllers February 2015 Key Description 83 Lock Washer stainless steel 2 req d 84 Lock Washer stainless steel 85 Screw stainless steel not shown 4 req d 86 Machine Screw stainless steel 2 req d 87 Link Bearing not shown stainless steel 2 req d 88 Machine Screw not shown stainless steel 4 req d 89 Machine Screw stainless steel 2 req d 91 RESET Restriction Valve Ass y 2502 and 2502C 2502F and 2502FC 93 Screw stainless steel 94 Bellows Frame aluminum 95 Bellows Frame Base not shown steel pl 96 Bellows Screw brass pl 2 req d 97 Bellows Stud not shown brass 98 Spacer zinc 99 Spring stainless steel 2 req d 100 Calibration Adjuster zinc 101 Reversing Block zinc 180 Pipe Nipple not shown 2502F 2502FC steel 181 Relief Tubing 2502F and 2502FC stainless steel 182 Machine Screw stainless steel 2 req d 2502 and 2502C not shown 2502F and 2502FC Part Number 11379546202 Instruction Manual 0200126 012 Key Description Part Number 183 O Ring 2 req d 2502F and 2502FC 1D6875X0132 184 Manifold aluminum 2502F and 2502FC 185 Manifold Nipple aluminum 2502F and 2502FC 186 Differential Relief Valve Ass y 2502
17. Instruction Manual D200126X012 Fisher 2502 Controllers Contents IPEFOGUCTION cede teed 2 Scope of 2 Mee bee ek eek 2 Specifications 2 Educational Services 2 eM NOM tase 4 249 5 5 85 5 WACKALING 5 Controller Orientation 6 Controller Sensor 6 Mounting Caged Sensors Mounting Cageless Sensors 9 Side Mounted 9 Top Mounted Sensor 10 SUDDIY PIESSUIGs 11 Prestartup Checks 12 245 13 Level Set Adjustment 13 Proportional Band Adjustment 13 Reset Adjustment 13 Differential Relief Adjustment 15 15 Precalibration Requirements 15 Wet Calibration 15 Diy CaliDration 15 Controller and Torque Tube Arm Disassembly 16 Determining Suspended Weight for 16 Calibration Procedure 17
18. Reconnect the tubing Ona controller with indicator assembly slide the base plate under the two lower screws of the relay case align the plate so that the pointer will read properly and tighten the screws Replacing Bellows Key numbers are shown in figure 14 1 To gain access to the lower bellows remove the relay according to the Changing Relay section 2 Remove the upper and lower bellows frame screws key 96 that hold both bellows assemblies to the bellows frame Unscrew each bellows from the spacer key 98 being careful not to lose the O ring key 57 not shown from the spacer end of the bellows 3 Inspect each bellows and O ring and replace if necessary using an unpainted bellows for a 0 2 to 1 0 bar 3 to 15 psig range and a red bellows for a 0 4 to 2 0 bar 6 to 30 psig range Be sure to install the O ring at the spacer end of the bellows 27 2502 Controllers Instruction Manual February 2015 0200126 012 4 Install each bellows screwing it down over the stud key 97 not shown protruding from each end of the spacer Secure with a bellows frame screw and install the relay according to the Changing Relay section 5 Perform the calibration procedure and any other necessary part of the calibration sequence Reversing Action Note The following procedure will be necessary to restore previous action if the mounting method has been changed Key numbers are shown in figure 14 1 Remove two screws keys 63
19. Specific gravity of the lighter liquid at operating temperature Vp Volume of the displacer submerged the heavier liquid in cubic inches Or V 2 4 displacer diameter x length of the displacer submerged SP GR Specific gravity of the heavier liquid at operating temperature Calibration Procedure A WARNING The following calibration procedure requires taking the controller out of service To avoid personal injury and property damage caused by an uncontrolled process provide some temporary means of control for the process before taking the controller out of service Figure 9 shows adjustment locations for the following steps except as otherwise indicated When calibrating open loop conditions must exist One way to obtain an open loop is to place the final control element into manual control or bypass it If there is no provision for manual control shut down the process It is recommended that a test pressure gauge be installed in the controller output line for subsequent calibration steps Several steps in these calibration procedures require setting the process variable at its minimum and maximum limits according to table 2 Reverse acting controllers produce the opposite response Table 2 Minimum and Maximum Limits for Setting Process Variables Liquid level Displacer must be completely out of liquid Displacer must be completely submerged in liquid Displacer must be completely submerged the upper of Displacer
20. age or vessel refer to the appropriate sensor instruction manual for assistance The method of removing the displacer or torque tube arm and attached controller will vary 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 top mounted sensors with long displacers it may also be possible to remove the sensor through the access hole in the sensor head For the 249BP sensor with the travel stop the stem end piece pins will secure the displacer as long as the travel stop plate is installed and the sensor head is in position Determining Suspended Weight for Calibration CAUTION To avoid overloading a torque tube sized for interface or density applications under dry conditions consult your Emerson Process Management sales office for the maximum allowable substitute weight W that can be used with your particular construction To det
21. and any other necessary part of the calibration sequence Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the controller type number and the serial number found on the unit nameplate figure 9 When ordering replacement parts also state the complete 11 character part number of each required part as found in the following parts list A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Parts Kits Parts List Description Part Number Key Description Controller Parts Kit Contains keys 12 15 21 24 38 55 57 58 60 62 63 64 77 79 84 86 87 93 101 and 187 Note Standard Temperature R2502X00L52 Part numbers are shown for recommended spares only For part High Temperature R2502X00H52 numbers not shown contact your Emerson Process Management sales office Relay Replacement Kit Contains keys 22 43 and the relay assembly Standard Temperature RRELAYXOL22 High Temperature RRELAYXOH22 ontroller Common Parts Heat Insulator Parts Kit Contains keys 35 36 37 38 39 40 453 2500 0012 Ti gure 1 4 2500 Controller C
22. as described previously 2 Acontroller is attached to the sensor in one or the other of the mounting positions shown in figure 4 Right hand mount is with the case to the right of the displacer when looking at the front of the case Left hand mount is with the case to the left of the displacer For a 249 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 3 Check the desired control action to determine if it is also necessary to reverse the controller action The nozzle block and bellows tubing should be arranged in the proper position as shown in figure 13 4 Remove the RAISE LEVEL dial turn it over and install it in the desired position The arrow on it under the word FLOAT should point toward the displacer On a controller with indicator assembly remove two screws key 41 figure 14 turn the front plate key 54 figure 14 to the side that will have the float arrow pointing toward the displacer and secure the plate with the screws 5 Install the controller according to the next section Installing Controller 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 mating the controller to the sensor Install the controller on the torque tube arm in the shop then calibrate and return the controller and
23. ble of bringing the controlled variable back to a specific control point all the time The following descriptions show how the relay works in conjunction with the standard proportional plus reset controller and how the differential relief valve construction works 2502 Controller As long as inflow and outflow of the vessel are equal the beam and flapper remain motionless and allow supply pressure to bleed through the nozzle as fast as it enters the relay through the fixed restriction A level or density change either raises or lowers the displacer and pivots the beam and flapper with respect to the nozzle Note The relay valve is double sided to control supply on one end and exhaust on the other An increase in level or density with direct action or a decrease with reverse action moves the beam and flapper closer to the nozzle and restricts the escape of supply pressure This builds up the loading differential on the side of the large diaphragm and opens the relay valve to supply pressure inflow On the other hand a decrease in level or density with direct action or an increase with reverse action moves the beam and flapper away from the nozzle and permits supply pressure to bleed through the nozzle faster than it can enter through the fixed restriction This builds up the loading differential on the side of the small diaphragm and opens the relay valve to exhaust loading pressure The three way proportional valve can be opened and adjust
24. by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com 2007 2015 Fisher Controls International LLC All rights reserved ij
25. chamber pressure exceeds that in the inner relief valve chamber by the amount of the relief pressure setting the relief diaphragm will move off the orifice in the relief valve and the pressure in the outer chamber will bleed into the reset system This action provides quick relief of excessive proportional pressure and reduces the time required by the system to return to the control point Maintenance 2502 controllers are used in combination with 249 sensors A WARNING Always wear protective eyewear gloves and clothing whenever possible when performing maintenance to avoid personal injury Personal injury or property damage due to sudden release of pressure contact with hazardous liquid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or liquid This danger may not 22 Instruction Manual 2502 Controllers D200126X012 February 2015 be readily apparent when disassembling the sensor or removing the displacer Before disassembling the sensor or removing the displacer observe the more specific warning provided in the sensor instruction manual When disconnecting any of the pneumatic connections natural gas if used as the supply medium will seep from the unit and any connected equipment into the surrounding atmosphere Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken P
26. d nitrile High temperature fluorocarbon 39 Screw not shown steel pl 2 req d 40 Hex Nut stainless steel 41 Screw steel 2502C and 2502FC 2 req d 42 Machine Screw stainless steel 8 req d 43 Machine Screw stainless steel 2 req d 30 Part Number 1 8983000 2 01019206042 07019104082 11B8577X012 11B8577X022 11B8583X012 11 8583 022 11 8577 042 11 8577 052 11 8583 032 1 919806432 1 897403012 1 873804142 1 897303012 1 873904142 1 898603012 1 874004142 1E591406992 1E5914X0062 Key 44 45 47 49 50 51 53 54 55 57 58 59 60 61 62 63 64 65 66 68 69 70 717 72 74 75 76 78 79 80 81 82 Instruction Manual Description Machine Screw steel pl 4 req d Machine Screw stainless steel 2 req d Spring not shown stainless steel Machine Screw stainless steel 13 req d Screen stainless steel Pointer Ass y 2502C and 2502FC stainless steel brass pl Base Plate aluminum 2502C and 2502FC Front Plate aluminum 2502C and 2502FC O Ring 3 req d Standard nitrile High temperature fluorocarbon O Ring not shown Standard nitrile High temperature fluorocarbon Nozzle stainless steel Beam steel pl Flapper K93600 alloy Flapper Base stainless steel Connecting Link N04400 Sealing Screw stainless steel Screw stainless steel Bellows Ass y brass 2 req d 0 2 to 1 0 bar 3 to 15 psig 0 4
27. d to the case back Provide a clean dry and noncorrosive air or gas supply to the controller After pressure connections have been made turn on the supply pressure and check all connections for leaks Vent Assembly A WARNING Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the supply pressure medium Because the instrument case and cover 2502 Controllers Instruction Manual February 2015 D200126X012 assembly do not form a gas tight seal when the assembly is enclosed a remote vent line adequate ventilation and necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas However a remote vent pipe alone cannot be relied upon to remove all flammable and hazardous gas Vent line piping should comply with local and regional codes and should be be as short as possible with adequate inside diameter and few bends to reduce case pressure buildup CAUTION When installing a remote vent pipe take care not to overtighten the pipe in the vent connection Excessive torque will damage the threads in the connection The vent assembly see figure 3 or the end of aremote vent pipe must be protected against the entrance of all foreign matter that could plug the vent Use 13 mm 1 2 inch pipe for the remote vent pipe if one is required Check the vent periodically to be certain it has not bec
28. displacer does not touch the cage wall Should the displacer touch the cage wall the unit will transmit an erroneous output signal Note the controller is not mounted on the sensor refer to the Installing Controller on Sensor section This section also provides instructions for adding a heat insulator to a unit Cage connections will normally be either NPS 1 1 2 or 2 screwed or flanged Figure 5 shows the combinations With flanged connections use standard gaskets or other flat sheet gaskets compatible with the process liquid Spiral wound gaskets without compression controlling centering rings cannot be used for flanged connections 2502 Controllers Instruction Manual February 2015 D200126X012 Figure 5 Cage Connection Styles STYLE 1 TOP STYLE 2 TOP STYLE 3 UPPER STYLE 4 UPPER AND BOTTOM AND LOWER SIDE AND LOWER SIDE SIDE AND BOTTOM fs SCREWED S1 SCREWED S2 SCREWED S3 SCREWED S4 FLANGED F1 FLANGED F2 FLANGED F3 FLANGED F4 A1271 2 Mount the cage by running equalizing lines between the cage connections and the vessel figure 6 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 liquid trapping low point On liquid or interface level applications position the sensor so that the line marked FLOAT CENTER on the cage is located as clo
29. during startup Depending on the characteristics of the process the relief valve can be positioned so that the arrow cast on the case points either to the letters RE reset or to the letter P proportional on the back of the manifold To reposition the arrow see figure 9 Remove the mounting screws Reposition the differential relief valve to RE or P and reinstall the mounting screws Calibration Precalibration Requirements Note Calibration of a unit with a displacer designed for interface or density control must be conducted with the displacer completely submerged in a liquid of the specific gravity for which the unit was designed To calibrate a controller it is necessary to place the device into operation This may be done on the vessel with the actual service liquid It may also be done in the shop but other means of obtaining a displacement force change must be provided It must be done in the shop if the process variable is not available for calibration or if the process cannot be varied for calibration There are two methods of adapting the calibration procedure to shop calibration wet and dry Wet Calibration Remove the entire controller and sensor assembly from the vessel For caged sensors pour the liquid into the cage For cageless sensors suspend the displacer to an appropriate depth a liquid having a specific gravity equal to that of the process liquid If necessary use water for wet calibration in the shop How
30. ed to allow some or all of the output pressure change to feed back to the proportional bellows in order to change the proportional band of the controller This pushes the beam and flapper opposite the way it is being pivoted by the torque tube shaft counteracting the pressure change in the nozzle and again stabilizing the relay diaphragm pressure differential The relay valve shuts off and maintains a new output pressure according to the change in sensed displacer position A wide open proportional valve permits feedback of all the output change and produces 100 percent proportional response Closing of this valve produces smaller proportional responses since part of the output change is vented through the valve exhaust and only the remainder is available to reposition the bellows The reset valve can be adjusted to channel some or all of the proportional pressure into a reset bellows that opposes proportional bellows action This automatically dampens the effect of any proportional overcorrection by a set amount per time interval as long as there is a deviation from the control point Figure 10 illustrates these principles at work in a direct acting right hand mounted construction controlling liquid inflow to a vessel by means of a direct acting diaphragm actuated control valve Nozzle positions and bellows connections would be reversed for direct action with left hand mounting or reverse action with right hand mounting 2502F Controller with Differ
31. en the case and torque tube arm to minimize the entrance of atmospheric moisture around the torque tube rotary shaft 26 Instruction Manual 2502 Controllers D200126X012 February 2015 5 Install and tighten the bearing assembly key 12 figure 14 in the case key 1 figure 14 Secure the operating arm base or pointer assembly to the rotary shaft by tightening the hex nut key 40 figure 14 Connect the supply and output pressure tubing and perform the calibration procedure Changing Proportional Reset or Differential Relief Valve 1 Remove the proportional band valve assembly key 36 figure 14 by unscrewing it from the relay base key 23 figure 14 Install the desired replacement assembly or a 1 8 NPT pipe plug into the proportional band tapping if testing relay dead band 2 To change the reset restriction valve assembly key 91 remove the two mounting screws key 182 located on the back side of case Install the replacement valve assembly and reconnect the tubing connections 3 Remove the differential relief valve assembly key 186 figure 14 by removing the two mounting screws figure 9 that anchor the valve to the manifold key 184 figure 14 Install the valve with the arrow pointing to the same letter s as before removal unless it is desired to change the relief action Relay Dead Band 1 Replace the proportional band adjustment assembly with a 1 8 NPT pipe plug according to the Changing Proportional Reset or
32. ential Relief Valve This construction figure 11 has a differential relief valve used to prevent proportional pressure from exceeding reset pressure by more than set value a feature useful for intermittent control applications Proportional valve output registers in the outer chamber of the relief valve as well as in the proportional bellows 21 2502 Controllers Instruction Manual February 2015 0200126 012 Figure 11 Fisher 2502F Controller with Differential Relief Valve MOVABLE LEVEL SET PROPORTIONAL BELLOWS ARM ADJUSTMENT RELIEF VALVE INNER CHAMBER a DIFFERENTIAL RELIEF VALVE HES lt i 1 2 RS PIVOTING Be CAM BEAM AND 0311 2 FLAPPER FA DIAPHRAGM ee fi TE ASSEMBLY T RESTRICTION RESET RESET VALVE 4 RELIEF BELLOWS DIAPHRAGM ent PROPORTIONAL __ VALVE FIXED RESTRICTION OF RELAY VALVE _ LARGE DIAPHRAGM OF ASSEMBLY 42 SUPPLY PRESSURE 4 ae on a a A OUTPUT PRESSURE NRE TY 2 4 NOZZLE PRESSURE at be 5 EXHAUST a 5 ar FEF PROPORTIONAL PRESSURE SMALL INLET END DIAPHRAGM RESET PRESSURE 073873 OF RELAY VALVE A sudden increase in the output pressure will cause rapid pressure increase in the proportional bellows the outer relief valve chamber If the outer
33. ermine the total weight that must be suspended from the displacer rod to simulate a certain condition of liquid level or specific gravity solve the following equation W W4 0 0361 V SP GR where W 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 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 Instruction Manual 2502 Controllers D200126X012 February 2015 Wa Weight of the displacer in pounds determine weighing displacer 0 0361 Weight of one cubic inch of water specific gravity 1 0 in pounds V Volume of the displacer in cubic inches that would be submerged at the level required by the calibration procedure Or V 2 4 displacer diameter 2 x length of displacer submerged SP GR Specific gravity of the process liquid at operating temperature For interface level measurement the equation becomes W Wg 0 0361 V1 SP GR 0 0361 Vp SP GRp where Volume of the displacer submerged by the lighter liquid in cubic inches Or V 2 4 displacer diameter x length of the displacer submerged SP GR
34. ermined in prestartup checks step 4 2 Set the percent proportional band control to 200 3 Set the reset control to 05 minutes per repeat Instruction Manual 2502 Controllers D200126X012 February 2015 4 Slowly open the downstream and upstream manual control valves in the pipeline and close the manual bypass valve if one is used 5 With the controller set at the desired control point narrow the proportional band until a cycling condition exists Then broaden the proportional band slightly until stable control is obtained 6 Adjust the reset control to obtain the highest reset setting without introducing cycling 7 To ensure that the optimum proportional band and reset settings have been obtained momentarily create a load upset If cycling occurs broaden the proportional band slightly and repeat the load upset until stability is attained In general the narrowest proportional band and the highest reset setting that will not produce cycling will provide the best control Principle of Operation All 2502 controllers use the same basic pressure balanced relay with a yoked double diaphragm assembly figure 10 This relay is connected so that supply pressure is fed to the inlet side of the relay valve and to the fixed restriction From this restriction the air pressure goes into the relay chamber on the side of the large diaphragm and to the nozzle As long as there is no pressure change on either diaphragm the relay valve remains in equ
35. ever this procedure requires compensation for the difference between the specific gravity of the water and that of the process liquids For example assume that the process liquid has a specific gravity of 0 7 and that wet calibration with water specific gravity of 1 0 is desired To simulate a process level of 50 percent of the input span a water level of 35 percent is required 0 7 1 0 x 50 percent 35 percent Dry Calibration Remove the controller and torque tube arm as a single unit from the cage or vessel Then wherever the standard calibration instructions in this manual require a specific process variable for input to the sensor simulate that variable by suspending the proper weight such as a can of sand from the end of the displacer rod Complete the following Controller and Torque Tube Arm Disassembly and the Determining Suspended Weight for Calibration sections before proceeding to the calibration procedure 2502 Controllers Instruction Manual February 2015 D200126X012 Controller and Torque Tube Arm Disassembly A WARNING To avoid personal injury from contact with the process liquid 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 and torque tube arm from the c
36. her filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Natural Gas Natural gas must be clean dry oil free and noncorrosive 25 content should not exceed 20 2502 Controllers February 2015 Supply Pressure Requirement 1 4 bar 20 psig for 0 2 to 1 0 bar 3 to 15 psig output signal or 2 4 1 35 psig for 0 4 to 2 0 bar 6 to 30 psig output signal Maximum Supply 2 3 4 bar 50 psig Supply Pressure 3 At 1 4 bar 20 Psig Minimum 0 11 normal m3 h 4 2 scfh at proportional band setting of 0 or 200 percent Maximum 0 72 normal m3 h 27 scfh at proportional band setting of 100 percent At 2 4 bar 35 psig Minimum 0 2 normal m3 h 7 scfh at proportional band setting of 0 or 200 Maximum 1 1 normal m h 42 scfh at proportional band setting of 100 percent Performance Hysteresis 0 6 percent of output pressure change at 100 percent of proportional band Repeatability 0 2 percent of displacer length or displacement force change Dead Band 0 05 percent of proportional band or span Typical Frequency Response 4 Hz and 90 degree phase shift at 100 percent of proportional band with output piped to typical instrument bellows using 6 1 meters 20 feet of 6 4 mm 1 4 inch tubing Ambient Temperature Error 1 5 percent of out
37. ilibrium with both the inlet and exhaust ends closed 2502 Controllers Instruction Manual February 2015 D200126X012 Figure 10 Direct Acting Right Hand Mounted Fisher 2502 249 Controller TORQUE TUBE SHAFT PROPORTIONAL BELLOWS FIXED MOVABLE PIVOT ARM LEVEL SET CROSS SPRINGS ADJUSTMENT CAM RESET VALVE PROPORTIONAL VALVE RESTRICTION EXHAUST END OF RELAY 5 LARGE DIAPHRAGM SUPPLY PRESSURE OUTPUT PRESSURE SMALL 2 NOZZLE PRESSURE mueren SMALL y OF RELAY _ EXHAUST VAINE OF ASSEMBLY 2 RTIONAL PRESSURE SUPPLY SE RESET PRESSURE REGULATOR DIRECT ACTING a VESSEL DIAPHRAGM INFLOW CONTROL VALVE 20 Instruction Manual 2502 Controllers D200126X012 February 2015 The area ratio of the large diaphragm to the small diaphragm is 3 to 1 A 0 8 bar 12 psig pressure change on the small diaphragm need only be balanced by a 0 3 bar 4 psig change on the large diaphragm A change in liquid level interface level or density changes the buoyant force exerted on the sensor displacer which in turn imparts a rotary motion through the torque tube shaft The rotary motion is applied to the controller which uses nozzle bellows and pneumatic relay to convert the rotary motion to a standard pneumatic output signal The output signal is sent to a final control element In conjunction with this control element 2502 249 controller sensors are capa
38. in minutes per repeat By definition this is the time in minutes required for the reset action to produce a correction which is equal to the correction produced by proportional control action This is in effect the time in minutes required for the controller to increase or decrease its output pressure by an amount equal to a proportional increase or decrease caused by a change in control conditions Figure 9 Controller Adjustments POINTER ASSEMBLY 30A8943 H 1 9283 RAISE LEVEL DIAL FOR 2502C LEVEL INDICATOR WITH LEFT HAND MOUNTING RIGHT HAND MOUNTING RESET ADJUSTMENT s MOUNTING SCREWS 2 li all vib gt M 2 SPECIFIC GRAVITY 5637 ADJUSTING eee TYPICAL RIGHT HAND DIFFERENTIAL RELIEF VALVE nes TRAVEL INDICATOR PLATE FOR LEFT HAND MOUNTING MOUNTED 2502 CONTROLLER ON BACK OF 2502 CASE Instruction Manual 2502 Controllers D200126X012 February 2015 Differential Relief Adjustment The differential relief valve protrudes from the back of the controller case on a construction with an F in the type number Although normally factory set to relieve when the differential between the proportional and reset bellows reaches 5 psi the differential may be reduced down to 2 psi by turning the adjustment screw clockwise or increased up to 7 psi by turning the screw counterclockwise The minimum differential setting will yield the minimum set point overshoot
39. ith a tubular gauge glass the gauge glass will be crated separately and must be installed at the site Be certain that the cage equalizing connections are not plugged with foreign material ul 2502 Controllers Instruction Manual February 2015 D200126X012 A caged sensor has a damping plate installed in the lower screwed or flanged connection to provide more stable operation If the process liquid could clog the plate opening with sediment then remove the damping plate For screwed connections use 1 2 inch hexagon wrench to unscrew the damping plate For flanged connections use screwdriver to pry the damping plate out of the flange A cageless sensor is shipped with the displacer separated from the sensor assembly A displacer longer than 813 mm 32 inches is crated separately A shorter displacer is crated with the sensor but is not attached to the displacer rod Inspect the displacer and replace if it is dented A dent may reduce the pressure rating of the displacer Controller Orientation A controller is to be mounted with the vent opening pointing downward as shown in figure 3 This orientation is necessary to ensure draining of accumulated moisture The controller is attached to the sensor in one or the other of the mounting positions shown in figure 4 Right hand with the case to the right of the displacer when looking at the front of the case or left hand with the case to the left of the displacer The mounting position can be
40. lean out the using the testing relay deadband fixed restriction Replace relay using procedure the procedure in the Maintenance section 3 5 Leaking controller loop 3 5 Use soap and water to check for 3 5 Replace or repair leaking parts as internal and external leaks necessary 4 Controller remains at full or zero 4 1 Supply or output pressure gauge 4 1 Insure the pressure gauges are 4 1 Replace pressure gauges Use output pressure malfunction registering correctly corrective action given in section 3 of this table 4 2 Flapper adjustment 4 2 Insure the flapper is not loose 4 2 Replace or tighten flapper the torque tube shaft Insure the assembly as necessary and or center flapper is centered on the nozzle flapper on nozzle Removing Controller from Sensor A WARNING To avoid personal injury in the following steps turn off the supply pressure and carefully release any pressure trapped in the controller before breaking any pressure connection Provide a bypass for the control device if continuous operation is required during maintenance Refer to figure 14 for key number locations unless otherwise indicated 1 Disconnect the supply and output pressure tubing from the controller 2 Loosen the hex nut key 40 that secures the operating arm base or pointer assembly key 68 or 51 to the torque tube rotary shaft Do not lose the two link bearings key 87 not shown 24 Instruction Manual 2502 Controllers D20012
41. ment 2 4 Insure the flapper is not loose 2 4 Replace or tighten flapper the torque tube shaft and is assembly as necessary and or center centered on the nozzle flapper on nozzle 2 5 Process variable changed 2 5 Insure the process variable has 2 5 Change process variable back to not changed from original original specification or recalibrate calibration settings displacer not If necessary provide replacement design specific gravity of process displacer of correct size and recalibrate 3 Controller cannot attain full 3 1 Supply pressure not set 3 1 Make sure supply pressure isset 3 1 Reset the regulator pressure If output range correctly correctly Make sure regulator IN problem reoccurs replace or rebuild supply pressure is within limits the regulator Insure regulator IN supply pressure is within limits at all operating levels 3 2 Flapper adjustment 3 2 Insure the flapper is not loose 3 2 Replace or tighten flapper the torque tube shaft and is assembly as necessary and or center centered on the nozzle flapper on nozzle 3 3 Process variable changed 3 3 Insure the process variable has 3 3 Change process variable back to not changed from original original specification or recalibrate calibration settings or from If necessary provide replacement displacer design specific gravity displacer of correct size and recalibrate 3 4 Relay malfunction 3 4 Check for relay malfunction by 3 4 Depress plunger to c
42. ments Controller adjustments are provided in this section Refer to figure 9 for adjustment locations Level Set Adjustment To perform the level adjustment open the controller cover loosen the knurled adjustment screw see figure 9 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 both direct and reverse action controllers Tighten the knurled screw Note The RAISE LEVEL dial does not reflect actual fluid level in the tank or fluid level position on the displacer Proportional Band Adjustment Proportional band adjustment is made to change the amount of displacement force change required to obtain full output pressure change by determining the percentage of pressure fed back to the proportional bellows The adjustment is performed by opening the controller cover and turning the percent proportional band knob just below the RAISE LEVEL dial Reset Adjustment To adjust reset action figure 9 turn the knob clockwise to decrease reset time the minutes per repeat Turn the knob counterclockwise to increase the minutes per repeat Increasing the minutes per repeat provides a slower reset action 2502 Controllers Instruction Manual D200126X012 February 2015 The reset rate adjustment dial is calibrated
43. ome plugged Prestartup Checks The following procedure requires taking the controller out of service To avoid personal injury and property damage caused by an uncontrolled process provide some temporary means of control for the process before taking the controller out of service Adjustment locations are shown in figure 9 unless otherwise indicated When performing the checks open loop conditions must exist To obtain open loop conditions make sure there is no process flow through the final control element or disconnect the controller output signal line and plug the output connection During startup it is necessary to change process levels to position the displacer from its maximum to its minimum range of operations Provide a means to change the process level or interface If the process variable cannot be varied sufficiently follow the instructions in the Calibration section to simulate the process variable changes required for these checks Make sure that the RAISE LEVEL dial on the controller is mounted with the correct side facing out The dial is printed on both sides with the arrow on one side pointing to the left and the arrow on the other side pointing to the right Figure 9 shows the dial arrow positioned for a sensor that is mounted to the left of the controller the arrow points to the left If the sensor is to the right of the controller remove the two mounting screws turn the dial over so the arrow points to the right
44. opriate regulator and 249 level sensor Do not install operate or maintain a 2502 controller without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all contents of this quick start guide including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Description The 2502 controller described in this manual provides proportional plus reset and proportional plus reset with differential relief valve control The controller output is a pneumatic signal that operates a final control element These controllers are designed to control liquid level the level of interface between two liquids or density specific gravity Each unit consists of a 249 liquid level sensor and a 2502 pneumatic controller Refer to the Principle of Operation section for a more comprehensive discussion of how the 2502 pneumatic controller operates Specifications Table 1 gives general specifications for 2502 controllers Educational Services For information on available courses for the 2502 controller as well as a variety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 e mail education emerson com http www emer
45. over Gasket Kit 1 Pilot Case Back zinc Contains qty 5 cover gaskets key 21 R2500CVRO12 2502 and 2502C 2502F 2 Pilot Case Cover aluminum Door Handle steel pl Door Handle Shaft not shown Stainless steel Machine Screw stainless steel Washer Spring stainless steel Door Hook steel pl Elastic Stop Nut steel pl oO UI 29 2502 Controllers February 2015 Key Description 9 Pin 2 req d 11 Relay Tubing stainless steel 12 Bearing 5 brass 13 Retaining Ring steel pl 2 req d 14 Gauge Glass glass 2 req d 15 Gauge Glass Gasket chloroprene 2 req d 19 Pressure Gauge 2 req d Triple Scale Brass 0 30 psig 0 0 2MPa 0 2 0 bar 0 60 psig 0 0 4MPa 0 4 0 bar Stainless steel 0 30 psig 0 0 2MPa 0 2 0 bar 0 60 psig 0 0 4MPa 0 4 0 bar Dual Scale Brass 0 30 psig 0 to 2 kg cm 0 60 psig 0 to 4 kg cm Stainless steel 0 30 psig 2 kg cm 21 Cover Gasket chloroprene 22 Relay Gasket Standard chloroprene High temperature silicone 23 Relay Base aluminum 24 Relay Base Gasket not shown Standard chloroprene High temperature silicone 29 Drive lok Pin stainless steel 31 Shaft Clamp Screw stainless steel 34 Pilot Relay Standard High temperature 35 Level Adjustment 36 Proportional Valve 37 Pressure Regulator 67CFR 38A Filter Gasket not shown Standard chloroprene High temperature silicone 38B Spacer not shown 38C O Ring Standar
46. put pressure change per 50 F 28 C of temperature change at 100 percent of proportional band when using sensor with standard wall NO5500 torque tube with 249 sensors Reset Adjustable from 0 01 to 74 minutes per repeat 100 to 0 01 repeats per minute Differential Relief 2502F and 2502FR Controllers Only Adjustable from 0 1 to 0 48 bar differential 2 to 7 psi to relieve excessive difference between proportional and reset pressures Differential relief can be switched between rising output pressure and falling output pressure Standard Tubing Connections 1 4 NPT internal Maximum Working Pressures Sensors Only Consistent with applicable ASME pressure temperature ratings continued 2502 Controllers Instruction Manual February 2015 D200126X012 Table 1 Specifications continued Hazardous Area Classification Declaration of SEP 2502 controllers comply with the requirements of Fisher Controls International LLC declares this ATEX Group II Category 2 Gas and Dust i product to be in compliance with Article 3 paragraph Ex 2 GD 3 of the Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot Operative Ambient Temperatures 2 bear the CE marking related to PED compliance Standard Construction 40 to 71 C 40 to 160 F High Temperature Construction 18 to 104 C 0 to However the product may bear the
47. r IN supply pressure is within regulator per instrument limits 1 3 Sensor not plumb and is in 1 3 Check cage vessel and stillwell 1 3 Make sure the displacer and contact with sidewall or leak in installation or for leaking displacer displacer rod hangs freely Make sure displacer linkage is tight Replace displacer if leaking 1 4 Relay malfunction 1 4 Check for relay malfunction by 1 4 Depress plunger to clean out the using the testing relay deadband fixed restriction Replace or repair procedure relay using the procedure in the Maintenance section continued 23 2502 Controllers Instruction Manual February 2015 D200126X012 Table 4 Troubleshooting Chart for Fisher 2502 Controllers continued Possible Cause 2 Controller controlling off setpoint 2 1 Supply pressure not set 2 1 Make sure regulator supply 2 1 Reset the supply regulator or switching point correctly pressure is set correctly Make sure pressure If the condition occurs regulator IN supply pressure is within again rebuild or replace regulator limits Provide a regulator input pressure within regulator limits 2 2 Leak in the controller loop 2 2 Use soap and water to checkfor 2 2 Replace or repair leaking parts internal and external leaks as necessary 2 3 Leaking displacer 2 3 Insure the displacer is not filling 2 3 Refer to sensor maintenance with process fluid procedures in the appropriate sensor instruction manual 2 4 Flapper adjust
48. reventive measures may include but are not limited to one or more of the following remote venting of the unit re evaluating the hazardous area classification the removal of any ignition sources and ensuring adequate ventilation For information on remote venting of this controller refer to page 11 Check with your process or safety engineer for any additional measures that must be taken to protect against process media Troubleshooting When troubleshooting open loop conditions must exist unless otherwise stated When monitoring the process variable use the most accurate level indicting device readily available The output signal measuring device should have a corresponding accuracy Table 3 lists some common operating faults their probable causes and corrective action Table 3 Troubleshooting Chart for Fisher 2502 Controllers Possible Cause 1 Process wanders or cycles around 1 1 Proportional band or specific 1 1 Insure the prestartup procedures 1 1 If stable control cannot be setpoint gravity adjustment incorrect or are completed correctly Tune attained and all other elements are improperly tuned control loop control loop functionally correct examine other possible causes related to the controller transmitter 1 2 Supply pressure varying or 1 2 Use input pressure gauge to 1 2 Apply correct supply pressure It incorrect supply pressure setting monitor stability Make sure is recommended to use one regulato
49. se as possible to the center of the liquid level or interface level range being measured Also consider installing a gauge glass either on the vessel or on the sensor cage if the cage is tapped for a gauge Figure 6 Caged Sensor Mounting CENTER OF LIQUID OR INTERFACE LEVEL Pa osa DRAIN VALVE Cicily A1883 2 EQUALIZING LINE Instruction Manual 2502 Controllers D200126X012 February 2015 Mounting Cageless Sensor Note If a stillwell is used it must be installed plumb so that the displacer does not touch the wall of the stillwell Should the displacer touch the wall while the unit is in service the unit will transmit an erroneous output signal Since the displacer hangs inside the vessel provide a stillwell around the displacer if the liquid is in a state of continuous agitation to avoid excessive turbulence around the displacer Note Displacers used in an interface level application must be completely submerged during operation If displacers aren t completely submerged they will not calibrate or perform properly To obtain the desired controller sensitivity may require using either a thin wall torque tube an oversized displacer or both Note the controller is not mounted on the sensor refer to the Installing Controller on Sensor section This section also provides instructions for adding a heat insulator to a unit Attach a cageless sensor to a flanged connection on the vessel as shown in figure 7 For
50. sonprocess com education Instruction Manual D200126X012 Table 1 Specifications Available Configurations 2502 A direct acting controller which provides proportional plus reset control 2502C A 2502 with a level indicator assembly 2502F A 2502 with a differential relief valve These products are also available with reverse action For example 2502R 2502CR and 2502FR Input Signal Liquid Level or Liquid to Liquid Interface Level From to 100 percent of displacer length standard lengths for all sensors are 356 mm 14 inches or 813 mm 32 inches Other lengths available depending on sensor construction Liquid Density From 0 to 100 percent of displacement force change obtained with given displacer volume standard volumes are 980 cm 60 inches for 249C and 249CP sensors or 1640 cm 100 inches for most other 249 sensors other volumes available depending on construction Output Signal 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Action Field reversible between direct increasing liquid or interface level or specific gravity increases output pressure and reverse increasing liquid or interface level or specific gravity decreases output pressure Area Ratio of Relay Diaphragms 3 1 Supply Medium Air or Natural Gas Air Supply pressure must be clean dry air that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Furt
51. then reinstall the mounting screws On a controller with optional level indicator assembly the travel indicator plate is printed both sides If the sensor is to the left of the controller right hand mounting use the side of the plate that has the arrow pointing to the left If displacer is to right of controller left hand mounting use the side of the plate that has the arrow pointing to the right 1 Turn on the supply pressure and check that the controller supply gauge reads 1 4 bar 20 psig for a 0 2 to 1 0 bar 3 to 15 psig output pressure range or 2 4 bar 35 psig for a 0 4 to 2 0 bar 6 to 30 psig output pressure range If 12 Instruction Manual 2502 Controllers D200126X012 February 2015 the pressure is incorrect loosen the locknut of the filter requlator figure 3 turn the adjusting screw clockwise to increase or counterclockwise to decrease pressure Tighten the locknut after setting the pressure 2 Turn the reset control to 05 minutes per repeat 3 Locate the process variable at its minimum value see table 2 Zero the proportional band and raise level controls Output pressure on direct acting controllers should be greater than zero but less than 0 2 bar 3 psig for the 0 2 to 1 0 bar 3 to 15 psig range or 0 4 bar 6 psig for the 0 4 to 2 0 bar 6 to 30 psig range For reverse acting controllers the output pressure should be greater than 1 0 bar 15 psig and less than 1 4 bar 20 psig for the 0 2 to 1 0 bar
52. to 2 0 bar 6 to 30 psig Level Set Arm steel pl Operating Arm steel pl Operating Arm Base brass pl 2502 and 2502F Level Set Pivot Pin stainless steel Pivot Base steel pl Spring Washer stainless steel Washer stainless steel 2502 2 req d 2502C and 2502FC 4 req d Washer stainless steel 6 req d Reset Tubing Ass y stainless steel 2 req d Proportional Band Tubing Ass y stainless steel Bellows Frame Gasket not shown Standard chloroprene High temperature silicone Spacer not shown brass Bellows Gasket 2 req d Standard chloroprene High temperature silicone Machine Screw stainless steel 4 req d Machine Screw not shown stainless steel 2 req d Machine Screw stainless steel 4 req d Recommended spare parts D200126X012 Part Number 1D687506992 1N430406382 1E222606992 1N838706382 10639135132 11379641012 14 5726 012 14 5726 032 1 885128982 1 265403012 1 873504142 10397003012 1 873604142 Instruction Manual D200126X012 Figure 14 Fisher 2502 Controller Constructions 2502 Controllers February 2015 4 AS 1 WAR ee Oe 8 9 094208 QMEOI E149 09 9 9 6903 63 a 69 0801 TYPICAL CONTROLLER 88 97 3 5 ery R SECTION LERN pany 183 186 184 182 88 DETA
53. torque tube arm assembly to the 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 12 unless otherwise indicated 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 the figure Then mount the insulator assembly key 35 on the controller case with four washers key 53 and button head cap screws key 40 Tighten the screws CAUTION In the following step avoid bending the torque tube 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 14 is removed from the case key 1 figure 14 to provide clearance when installing the case on the sensor 2 Remove the bearing assembly key 12 from the case key 1 3 Carefully slide the controller case straight in guiding the bearing assembly key 12 operating arm base or pointer assembly key 68 or 51 figure 14 over the rotary shaft and easing an attached heat insulator over the shaft coupling key 36 if necessary Secure the case or insulator to the torque tube arm with the four cap screws key 39 Note If a heat insulator is used do not insulate its exterior 4 On aunit without a heat insulator tape the joint betwe
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