Professional Documents
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Fisher 2502 Level Trol
Fisher 2502 Level Trol
Form 1446
June 1994 2502 Series
PROCESS TEMPERATURE ( C)
PROCESS TEMPERATURE ( F)
_ TOO 500 _
800 HOT
Scope of Manual HEAT INSULATOR
REQUIRED
400
300
This instruction manual provides installation, operat- 400 200
ing, calibration, maintenance procedures for 2502 Se- 100
ries pneumatic controllers (figure 1) used in combina- NO INSULATOR NECESSARY
0
tion with 249 Series level sensors. 0
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS
ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY
CAUSE INSTRUMENT MALFUNCTION AND REDUCE
This manual does not include regulator or sensor –20 INSULATOR EFFECTIVENESS.) –29
0 20 40 60 80 100 120 140 160
installation or maintenance procedures. For this infor-
AMBIENT TEMPERATURE (_F)
mation, refer to the instruction manual for the appropri-
ate regulator and 249 Series level sensor. AMBIENT TEMPERATURE (_C) 93
–18 –10 0 10 20 30 40 50 60 70 80 90
1100 593
Only personnel qualified through training or experience
PROCESS TEMPERATURE ( F)
_ TOO 500
should install, operate, and maintain this controller. If 800 HOT
HEAT INSULATOR 400
there are any questions concerning these instructions REQUIRED
300
contact your Fisher Controls sales office or sales rep-
400 200
resentative before proceeding.
100
NO INSULATOR NECESSARY
0
0
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS
Description ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY
CAUSE INSTRUMENT MALFUNCTION AND REDUCE
–20 INSULATOR EFFECTIVENESS.) –29
The Type 2502 Level-TrolR Controller described in 0 20 40 60 80 100 120 140 160 180 200
this manual provides proportional-plus-reset and pro- AMBIENT TEMPERATURE (_F)
final control element. These controllers are designed Figure 2. Guidelines for Use of Optional
to control liquid level, the level of interface between Heat Insulator Assembly
two liquids, or density (specific gravity). Each unit con- plied reverse-acting unit has the suffix letter R added
sists of a 249 Series liquid level sensor and a 2502 to the type number.
Series pneumatic controller.
2
2502 Series
Table 1. Specifications
3
2502 Series
ADJUSTING
WARNING PRESSURE LOCKNUT SCREW
REGULATOR
1/4”-18 NPT
When replacing the sensor assembly, SUPPLY
CONNECTION
the displacer may retain process liquid
or pressure. Personal injury or property
damage due to sudden release of pres- 1/4”-18 NPT
OUTPUT
sure, contact with hazardous liquid, fire, CONNECTION
FILTER WELL
Controller Orientation
CAUTION A controller is to be mounted with the vent opening
pointing downward as shown in figure 3. This orienta-
A thin-wall torque tube has a T stamped tion is necessary to ensure draining of accumulated
on the sensor end flange (not visible un- moisture. The controller is attached to the sensor in
less the controller/transmitter is re- one or the other of the mounting positions shown in
moved from the sensor). For sensors figure 4: Right hand (with the case to the right of the
with a thin-wall torque tube, always sup- displacer when looking at the front of the case) or left
port the displacer if the travel stop must hand (with the case to the left of the displacer). The
be removed. mounting position can be changed in the field if re-
quired; refer to the appropriate sensor manual for in-
structions. Changing this mounting position will change
Note controller action from direct to reverse, or vice versa.
Caged sensors have a rod and block
All caged sensors have a rotatable head. That is, the
installed on each end of the displacer to
controller may be positioned at any of eight alternate
protect the displacer in shipping. Re-
positions around the cage as indicated by the numbers
move these parts before installing the
1 through 8 in figure 4. To rotate the head, remove the
sensor to allow the displacer to function
head flange bolts and nuts and position the head as
properly.
desired.
Caged sensors will be shipped with the displacer
installed in the cage. If the sensor is ordered with a
tubular gauge glass, the gauge glass will be crated Mounting Caged Sensor
separately and must be installed at the site. Be certain
that the cage equalizing connections are not plugged
with foreign material. CAUTION
A caged sensor has a damping plate installed in the The cage must be installed plumb so
lower screwed or flanged connection to provide more that the displacer does not touch the
stable operation. If the process liquid could clog the cage wall. Should the displacer touch
plate opening with sediment, then remove the damp- the cage wall, the unit transmits an erro-
ing plate. For screwed connections, use a 1/2-inch neous output signal.
4
2502 Series
AH9150–A
A2613–2/IL A1271–2/IL
5
2502 Series
VENT
CENTER OF
LIQUID OR EQUALIZING
INTERFACE LINE
LEVEL SHUTOFF
VALVES
W0645-1
DRAIN
DF5379-A
A6771/IL
TOP
MOUNTED
CAUTION
Note
Attach a cageless sensor to a flanged connection on If the displacer is to be inserted into the
the vessel as shown in figure 7. For interface or liquid vessel before being attached to the dis-
level applications, install a gauge glass on the vessel. placer rod, provide a suitable means of
6
2502 Series
supporting the displacer to prevent it
from dropping into the vessel and suf-
fering damage. DISPLACER
STEM
END PIECE
To help support a Type 249BP or 249CP displacer,
install the displacer stem and stem end piece, or a
threaded rod, into the 1/4 inch-28 UNF threaded hole
DISPLACER ROD
in the displacer spud or stem end piece (figure 8). On
the Type 249BP with optional travel stop, the stem DISPLACER
STEM
end piece pins will secure the displacer as long as the EXTENSION
COTTER SPRING
travel stop plate is installed and the sensor head is in LOCKING NUTS
position.
DISPLACER SPUD
Side-Mounted Sensor
If a stillwell is required (figure 7), the displacer must be
attached to the displacer rod from inside the vessel. W0229-1A/IL
Connect the displacer as shown in figure 8, locking the
assembly with the cotter spring provided. If a stillwell DISPLACER COTTER SPRING
SPUD
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 hor-
izontally for insertion into the vessel. 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 DISPLACER ROD
suitable bolting or cap screws in the flanged connec- W0228-1A/IL
tion to complete the installation.
Figure 8. Displacer/Displacer Rod Connections
Top-Mounted Sensor
Figure 7 shows the installation of a top-mounted cage-
less sensor. The displacer may be attached to the dis-
placer 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 dis-
placer 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 tight-
en suitable cap screws in the flanged connection to
complete the installation.
Special Constructions
Temperature-Compensated Displacer
Some sensors use a temperature-compensated dis-
placer (figure 9). This displacer is appropriate for den- A0746–1/IL
7
2502 Series
expands and contracts the same amount as the mea-
sured liquid to nullify signal changes that would be
caused by temperature changes.
Piezometer Ring
A piezometer ring (figure 10) is used when it is desir-
able to measure the specific gravity of a liquid in a
flowing line, and when the liquid velocity exceeds two
feet/minute (10 mm/second) past the displacer in the
cage. The piezometer ring reduces the velocity effects
caused by liquid passing through the displacer cage.
8
2502 Series
29A2834-C
30A8943-H
A1933/IL
RESET ADJUSTMENT
W5637/IL/A 21A6447-A
A1903/IL
1E8731-C
1E8732-C
A1897-1/IL
9
2502 Series
structions in the Calibration section to simulate the gravity of one (water service), and a 90-cubic-inch (1.5
process variable changes required for these checks. L) displacer, move the slide so that 1.0 on scale B is
over 90 on scale A. If it is desired to have water level
Make sure that the raise level dial on the controller is cover 50 per cent of the displacer length at the control
mounted with the correct side facing out. The dial is point, read up from 50 on scale D to find a 4.5 dial set-
printed on both sides with the arrow on one side point- ting on scale C.
ing to the left and the arrow on the other side pointing 5. Relocate the process variable to the control point
to the right. Figure 11 shows the dial arrow positioned determined in step 4. If not, see if another setting on
for a sensor that is mounted to the left of the control- the raise level dial brings the output pressure into
ler; the arrow points to the left. If the sensor is to the agreement with the process. For example, with water
right of the controller, remove the two mounting level at 50 percent of the height of the displacer, the
screws, turn the dial over so the arrow points to the output of a 3-15 psig (0.2 to 1.0 bar) unit should be
right, then reinstall the mounting screws. aproximately 50 percent of the way between 3 and 15
psig (0.2 and 1.0 bar) or 9 psig (0.6 bar). If the new
On a controller with optical mechanical indicator as- setting is more than one graduation away from the
sembly, the travel indicator plate is printed on both setting determined in step 4, the unit would appear to
sides. If the sensor is to the left of the controller (right- be out of calibration and recalibration may be desir-
hand mounting), use the side of the plate that has the able. See Calibribration Procedure on page 12 steps 1
arrow pointing to the left. If displacer is to right of con- thru 10.
troller (left-hand mounting), use the side of the plate
that has the arrow pointing to the right. On a controller with level indicator, the pointer should
reflect the magnitude of the process variable; for
1. Turn on the supply pressure and check that the instance, with liquid or interface level covering 50 per-
controller supply gauge reads 20 psig (1.4 bar) for a 3 cent of the displacer, the pointer should be in the
to 15 psig (0.2 to 1.0 bar) output pressure range or 35 middle of the high-low scale. Slight plate adjustment
psig (2.4 bar) for a 6 to 30 psig (0.4 to 2.0 bar) output might be necessary as described at the end of step 3.
pressure range. If the pressure is incorrect, loosen the
locknut of the filter/regulator (figure 3); turn the adjust- 6. If all prestartup checks are satisfactory proceed to
ing screw clockwise to increase or counterclockwise to the Startup section.
decrease pressure. Tighten the locknut after setting
the pressure.
2. Turn the reset control to .05 minutes per repeat. Adjustments
3. Locate the process variable at its minimum value Controller adjustments are provided in this section.
(on level applications, for instance, lower the liquid Refer to figure 11 for adjustment locations.
below the displacer). Zero the proportional band and
raise level controls. Output pressure on direct-acting Level Set Adjustment
controllers should be greater than zero but less than 3
psig (0.2 bar) for the 3 to 15 psig (0.2 to 1.0 bar) range To perform the level adjustment, open the controller
or 6 psig (0.4 bar) for the 6 to 30 psig (0.4 to 2.0 bar) cover, loosen the knurled adjustment screw (see figure
range. For reverse-acting controllers, the output pres- 11), and rotate the adjustment lever around the RAISE
sure should be greater than 15 psig (1.0 bar) and less LEVEL dial. To raise the fluid or interface level, or in-
than 20 psig (1.4 bar) for the 3 to 15 psig (0.2 to 1.0 crease density, rotate this knob in the direction of the
bar) range or greater than 30 psig (2.0 bar) and less arrows. To lower the level or decrease density, rotate
than 35 psig (3.4 bar) for the 6 to 30 psig (0.4 to 2.0 the knob in the opposite direction. This procedure is
bar) range. On a controller with indicator assembly, the same for both direct and reverse action controllers.
the pointer should be over the low point on the indica- Tighten the knurled screw.
tor plate; slight adjustment might be necessary by
loosening the bottom shaft nut (key 40, figure 16),
shifting the pointer, and retightening the nut. Note
4. Set the raise level control as desired. Determine The raise level dial does not reflect actu-
the dial setting by moving the nameplate slide until the al fluid level in the tank or fluid level
specific gravity on scale B is opposite the displacer position on the displacer.
volume on scale A. Choose the percentage of displac-
er length, as measured from the displacer bottom, that
you desire the liquid or interface level to cover. Locate
Proportional Band Adjustment
this percentage on scale D, and read up from this per- Proportional band adjustment is made to change the
centage to find the raise level dial setting on scale C. amount of displacement force change required to ob-
For example, with a liquid level application, a specific tain full output pressure change, by determining the
10
2502 Series
percentage of pressure fed back to the proportional To calibrate a controller, it is necessary to place the
bellows. The adjustment is performed by opening the device into operation. This may be done on the vessel
controller cover and turning the percent proportional with the actual service liquid. It may also be done in
band knob (just below the raise level dial). 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 calibra-
Reset Adjustment tion or if the process cannot be varied for calibration.
To adjust reset action (figure 11) turn the knob clock- There are two methods of adapting the calibration pro-
wise to decrease the minutes per repeat. Turn the cedure to shop calibration: wet and dry.
knob counterclockwise to increase the minutes per
repeat. Increasing the minutes per repeat provides a Wet Calibration
slower reset action.
Remove the entire controller and sensor assembly
The reset rate adjustment dial is calibrated in minutes from the vessel. For caged sensors, pour the liquid
per repeat. By definition, this is the time in minutes into the cage. For cageless sensors, suspend the dis-
required for the reset action to produce a correction placer to an appropriate depth in a liquid having a spe-
which is equal to the correction produced by propor- cific gravity equal to that of the process liquid.
tional control action. This is, in effect, the time in min-
utes required for the controller to increase (or de- If necessary, use water for wet calibration in the shop.
crease) its output pressure by an amount equal to a However, this procedure requires compensation for
proportional increase (or decrease) caused by a the difference between the specific gravity of the water
change in control conditions. 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)
Differential Relief Adjustment is desired. To simulate a process level of 50 percent of
the input span, a water level of 35 percent is required
The differential relief valve protrudes from the back of (0.7/1.0 x 50 percent = 35 percent).
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 re- Dry Calibration
set bellows reaches 5 psi, the differential may be re-
duced down to 2 psi by turning the adjustment screw Remove the controller and torque tube arm, as a
clockwise or increased up to 7 psi by turning the screw single unit, from the cage or vessel. Then, wherever
counterclockwise. The minimum differential setting will the standard calibration instructions in this manual re-
yield the minimum set point overshoot during startup. quire a specific process variable for input to the sen-
sor, simulate that variable by suspending the proper
weight (such as a can of sand) from the end of the
Depending on the characteristics of the process, the
displacer rod. Complete the following Controller and
relief valve can be positioned so that the arrow cast on
Torque Tube Arm Disassembly and the Determining
the case points either to the letters RE (reset) or to the
Suspended Weight for Calibration sections before pro-
letter P (proportional) on the back of the manifold. To
ceeding to the calibration procedure.
reposition the arrow, see figure 11. Remove the
mounting screws. Reposition the differential relief
valve to RE or P and reinstall the mounting screws. Controller and Torque Tube Arm
Disassembly
Calibration WARNING
11
2502 Series
cage or vessel, refer to the appropriate sensor instruc- where:
tion manual for assistance. The method of removing
the displacer or torque tube arm and attached control- Ws = Total suspended weight in pounds (should
ler will vary with the type of sensor. never be less than 0.5 pounds). For a unit with
a horizontal displacer, make sure the center of
For a caged sensor with top equalizing connection, it gravity of the substitute weight is where it
may be appropriate to remove the entire cage from the would be on the actual displacer.
vessel before disassembling.
Note
Or,
To avoid overloading a torque tube
sized for interface or density applica- V = π/4 (displacer diameter)2 x (length of the dis-
tions under dry conditions, consult your placer submerged)
Fisher Controls sales office or sales rep-
resentative for the maximum allowable SP GR1 = Specific gravity of the lighter liquid at op-
substitute weight Ws that can be used erating temperature.
with your particular construction.
Vh = Volume of the displacer submerged by the
To determine the total weight that must be suspended heavier liquid, in cubic inches.
from the displacer rod to simulate a certain condition
of liquid level or specific gravity, solve the following Or,
equation:
V = π/4 (displacer diameter)2 x (length of the dis-
Ws = Wd - [(0.0361) (V) (SP GR)] placer submerged)
12
2502 Series
Table 2. 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
Displacer must be completely submerged in the upper Displacer must be completely submerged in the lower
Interface
of two process liquids of two process liquids
Displacer must be completely submerged in liquid having Displacer must be completely submerged in liquid
Density
highest specific gravity expected having the lowest specific gravity expected
SP GRh = Specific gravity of the heavier liquid at 8. Turn the raise level knob until the output pressure is
operating temperature. 15 psig for a 3 to 15 psig signal range (1.0 bar for a 0.2
to 1.0 bar signal range) or 30 psig for a 6 to 30 psig sig-
nal range (2.0 bar for a 0.4 to 2.0 bar signal range).
Calibration Procedure 9. The controller is within its calibration accuracy if the
raise level knob is between the 9.0 and 10.0 positions.
10. If the controller is out of calibration, adjust the cal-
WARNING ibration adjuster as follows:
13
2502 Series
2. Set the percent proportional band control to 200. Type 2502 Controller
3. Set the reset control to .05 minutes per repeat. As long as inflow and outflow of the vessel are equal,
the beam and flapper remain motionless and allow sup-
4. Slowly open the downstream and upstream manual
ply pressure to bleed through the nozzle as fast as it
control valves in the pipeline and close the manual
enters the relay through the fixed restriction. A level or
bypass valve if one is used.
density change either raises or lowers the displacer and
5. With the controller set at the desired control point, pivots the beam and flapper with respect to the nozzle.
narrow the proportional band until a cycling condition
exists. Then broaden the proportional band slightly An increase in level or density with direct action, or a
until stable control is obtained. decrease with reverse action, moves the beam and
flapper closer to the nozzle and restricts the escape of
6. Adjust the reset control to obtain the highest reset supply pressure. This builds up the loading differential
setting without introducing cycling. on the side of the large diaphragm and opens the relay
7. To ensure that the optimum proportional band and valve to supply pressure inflow.
reset settings have been obtained, momentarily create
a load upset. If cycling occurs, broaden the proportion- On the other hand, a decrease in level or density with
al band slightly and repeat the load upset until stability direct action, or an increase with reverse action,
is attained. In general, the narrowest proportional band moves the beam and flapper away from the nozzle
and the highest reset setting that will not produce cycl- and permits supply pressure to bleed through the
ing will provide the best control. nozzle faster than it can enter through the fixed restric-
tion. This builds up the loading differential on the side
of the small diaphragm, and opens the relay valve to
exhaust loading pressure.
Principle of Operation
All 2502 Series controllers use the same basic pres- The three-way proportional valve can be opened and
sure-balanced relay with a yoked double-diaphragm adjusted to allow some or all of the output pressure
assembly (figure 12). This relay is connected so that change to feed back to the proportional bellows in or-
supply pressure is fed to the inlet side of the relay der to change the proportional band of the controller.
valve and to the fixed restriction. From this restriction, This pushes the beam and flapper opposite the way it
the air pressure goes into the relay chamber on the is being pivoted by the torque tube shaft, counteract-
side of the large diaphragm, and to the nozzle. As long ing the pressure change in the nozzle and again stabi-
as there is no pressure change on either diaphragm, lizing the relay diaphragm pressure differential. The
the relay valve remains in equilibrium with both the relay valve shuts off and maintains a new output pres-
inlet and exhaust ends closed. sure according to the change in sensed displacer posi-
tion.
The area ratio of the large diaphragm to the small dia-
A wide-open proportional valve permits feedback of all
phragm is 3 to 1. A 12 psig (0.8 bar) pressure change
the output change and produces 100 percent propor-
on the small diaphragm need only be balanced by a 4
tional response. Closing of this valve produces smaller
psig (0.3 bar) change on the large diaphragm.
proportional responses, since part of the output
change is vented through the valve exhaust and only
A change in liquid level, interface level, or density the remainder is available to reposition the bellows.
changes the buoyant force exerted on the sensor dis-
placer, which in turn imparts a rotary motion through The reset valve can be adjusted to channel some or all
the torque tube shaft. The rotary motion is applied to of the proportional pressure into a reset bellows that
the controller, which uses a nozzle, bellows, and pneu- opposes proportional bellows action. This automatical-
matic relay to convert the rotary motion to a standard ly dampens the effect of any proportional overcorrec-
pneumatic output signal. The output signal is sent to a tion by a set amount per time interval, as long as there
final control element. In conjunction with this control is a deviation from the control point.
element, 2502-249 Series controller-sensors are capa-
ble of bringing the controlled variable back to a specif-
Figure 12 illustrates these principles at work in a di-
ic control point all the time.
rect-acting right-hand-mounted construction controlling
liquid inflow to a vessel, by means of a direct-acting
The following descriptions show how the relay works diaphragm-actuated control valve. Nozzle positions
in conjunction with the standard proportional-plus-reset and bellows connections would be reversed for direct
controller, and how the reset relief valve construction action with left-hand mounting or reverse action with
works. right-hand mounting.
14
2502 Series
CD2114-A
CJ4081-A
C0313-1
Figure 12. Direct-Acting Right-Hand-Mounted 2502-249 Series Controller
Type 2502F Controller with Reset Relief ceeding reset pressure by more than a set value, a
Valve feature useful for intermittent control applications. Pro-
portional valve output registers in the outer chamber of
This construction (figure 13) has a differential relief the relief valve as well as in the proportional bellows.
valve used to prevent proportional pressure from ex-
15
2502 Series
CJ4081-A
CU7387-B
C0311-2
16
2502 Series
Table 3 lists some common operating faults, their Changing Mounting Method
probable causes, and corrective action.
WARNING
Removing Controller from Sensor To avoid injury from contact with the
process liquid, lower the vessel level
below the torque-tube arm before pro-
ceeding. For closed vessels, release any
WARNING pressure that may be above the liquid.
Also, be careful to avoid overloading a
thin-wall torque tube and/or overweight
displacer.
To avoid injury in the following steps,
turn off the supply pressure and careful- Refer to figure 16 for key number locations.
ly release any pressure trapped in the
controller before breaking any pressure 1. Remove the controller as described previously.
connection. Provide a bypass for the
control device if continuous operation 2. A controller is attached to the sensor in one or the
is required during maintenance. other of the mounting positions shown in figure 4.
Right hand mount is with the case to the right of the
Refer to figure 16 for key number locations, unless displacer when looking at the front of the case. Left
otherwise indicated. hand mount is with the case to the left of the displacer.
For a 249 Series sensor, remove the torque tube arm
from the sensor or vessel and reinstall the torque tube
1. Disconnect the supply and output pressure tubing arm in the opposite position according to the appropri-
from the controller. ate instruction manual.
2. Loosen the hex nut (key 40) that secures the oper- 3. Check the desired control action to determine if it is
ating arm base or pointer assembly (key 68 or 51) to also necessary to reverse the controller action. The
the torque tube rotary shaft. Do not lose the two link nozzle block and bellows tubing should be arranged in
bearings (key 87, not shown). the proper position as shown in figure 15.
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
CAUTION controller with indicator assembly, remove two screws
(key 41, figure 16), turn the front plate (key 54, figure
16) to the side that will have the float arrow pointing
If the hex nut has not been loosened ac- toward the displacer, and secure the plate with the
cording to step 2, attempting to remove screws.
the controller from the sensor may bend 5. Install the controller according to the next section.
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 Installing Controller on Sensor
shaft or shaft extension.
17
2502 Series
Table 3. Troubleshooting Chart for 2502 Series Controllers
Fault Possible Cause Check Correction
1. Process wanders or cycles 1.1 Proportional band or specific 1.1 Insure the prestartup 1.1 If stable control cannot be
around setpoint. gravity adjsutment incorrect or procedures are completed attained and all other elements are
improperly tuned control loop. correctly. Tune control loop. functionally correct, examine other
ossible 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.
incorrect supply pressure setting. monitor stability. Make sure It is recommended to use one
regulator IN supply pressure is regulator per instrument.
withlin 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
displacer. sure 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
using the testing relay deadband the fixed restriction. Replace or
procedure repair relay using the procedure in
the Maintenance section.
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 again, rebuilld or replace regulator.
within limits. Provide a regulator input pressure
within regulator limits.
2.2 Leak in the controller loop. 2.2 Use soap and water to check 2.2 Replace or repair leaking parts
for 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 adjustment. 2.4 Insure the flapper is not loose 2.4 Replace or tighten flapper
on the torque tube shaft and is assembly as necessary and/or
centered on the nozzle. center flapper on nozzle.
2.5 Process variable changed. 2.5 Insure the process variable has 2.5 Change process variable back
not changed from original to original sepcification or
calibration settings or, displacer not recalibrate. If necessary, provide
design specific gravity of process. replacement displacer of correct
size and recalibrate.
3. Controller cannot attain full 3.1 Supply pressure not set 3.1 Make sure supply pressure is 3.1 Reset the regulator pressure. If
output range. correctly. set correctly. Make sure regulator problem reoccurs, replace or
IN supply pressure is within limits. rebuild 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
on the torque tube shaft and is assembly as necessary and/or
centered on the nozzle. center flapper on nozzle.
3.3 Process variable changed. 3.3 Insure the process variable has 3.3 Change process variable back
not changed from original to original specificaton or
calibration settings or, from recalibrate. If necessary, provide
displacer design specific gravity. replacement displacer of correct
size and recalibrate.
3.4 Relay malfunction. 3.4 Check for relay malfunction by 3.4 Depress plunger to clean out
using the testing relay deadband the fixed restriction. Replace or
procedure. repair relay using the procedure in
the Maintenance section.
3.5 Leaking controller loop. 3.5 Use soap and water to check 3.5 Replace or repair leaking parts
for internal and external leaks. as necessary.
4. Controller remains at full or zero 4.1 Supply or output pressure 4.1 Insure the pressure gauges are 4.1 Replace pressure gauges. Use
output pressure. gauge 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
on the torque tube shaft. Insure the assembly as necesary and/or
flapper is centered on the nozzle. center flapper on nozzle.
Perform step 1 only if adding a heat insulator to a 1. To install the heat insulator, secure the shaft exten-
unit that does not have one. Key numbers in this sion (key 37) to the torque tube assembly rotary shaft
step are shown in figure 14. with the shaft coupling (key 36). Tighten both set
screws (key 38), with the coupling centered as shown
18
2502 Series
20A7423-C/DOC
CAUTION
16) to provide clearance when installing Figure 15. Nozzle, Flapper, and Tubing Arrangements
the case on the sensor. for Various Actions and Mountings
2. Remove the bearing assembly (key 12) from the
case (key 1).
Note
3. Carefully slide the controller case straight in, guid-
ing the bearing assembly (key 12), operating arm base If a heat insulator is used, do not insu-
or pointer assembly (key 68 or 51, figure 16) over the late its exterior.
rotary shaft and easing an attached heat insulator over 4. On a unit without a heat insulator, tape the joint
the shaft coupling (key 36, figure 14) if necessary. Se- between the case and torque tube arm to minimize the
cure the case or insulator to the torque tube arm with entrance of atmospheric moisture around the torque
the four cap screws (key 39, figure 14). tube rotary shaft.
19
2502 Series
5. Install and tighten the bearing assembly (key 12) in 1. On a controller with indicator assembly, loosen the
the case (key1). Secure the operating arm base or point- two lower screws (key 96, figure 17) of the relay case
er assembly to the rotary shaft by tightening the hex nut and slide out the indicator base plate (key 53, figure 16).
(key 40, figure 16). Connect the supply and output pres- 2. Disconnect the tubing (key 11, figure 16) from the
sure tubing and perform the calibration procedure. relay.
3. Remove both mounting screws, the relay, and the
Changing Proportional, Reset, or relay gasket (keys 43, 34, and 22, figure 16).
Differential Relief Valve 4. Install a new gasket, the replacement relay if nec-
1. Remove the proportional band valve assembly (key essary, and both mounting screws. Reconnect the tub-
36, figure 16) by unscrewing it from the relay base ing. On a controller with indicator assembly, slide the
(key 23, figure 16). Install the desired replacement base plate under the two lower screws of the relay
assembly, or a 1/8-inch (3.2 mm) NPT pipe plug into case, align the plate so that the pointer will read prop-
the proportional band tapping if testing relay dead erly, and tighten the screws.
band.
2. To change the reset restriction valve assembly (key Replacing Bellows
91), remove the two mounting screws (key 182) located
Key numbers are shown in figure 16.
on the back side of case. Install the replacement valve
assembly, and reconnect the tubing connections. 1. To gain access to the lower bellows, remove the
3. Remove the differential relief valve assembly (key relay according to the Changing Relay section.
186, figure 16) by removing the two mounting screws 2. Remove the upper and lower bellows frame screws
(figure 11) that anchor the valve to the manifold (key (key 96) that hold both bellows assemblies to the bel-
184, figure 16). Install the valve with the arrow pointing lows frame. Unscrew each bellows from the spacer
to the same letter(s) as before removal, unless it is (key 98), being careful not to lose the O-ring (key 57,
desired to change the relief action. not shown) from the spacer end of the bellows.
3. Inspect each bellows and O-ring and replace if nec-
essary, using an unpainted bellows for a 3 to 15 psig
Testing Relay Dead Band (0.2 to 1.0 bar) range and a red bellows for a 6 to 30
1. Replace the proportional band adjustment assem- psig (0.4 to 2.0 bar) range. Be sure to install the O-ring
bly with a 1/8-inch (3.2 mm) NPT pipe plug according at the spacer end of the bellows.
to the Changing Proportional, Reset, or Differential
Relief Valve section. 4. Install each bellows by screwing it down over the
stud (key 97, not shown) protruding from each end of
2. Turn on the supply pressure and set it to 20 or 35 the spacer. Secure with a bellows frame screw, and
psig (1.4 or 2.4 bar). install the relay according to the Changing Relay sec-
3. By changing the process variable and adjusting the tion if it was removed.
raise level control, set the output pressure to 15 or 30 5. Perform the calibration procedure and any other
psig (1.0 or 2.0 bar). While monitoring the output pres- necessary part of the calibration sequence.
sure, slowly change the process until an output pres-
sure change can just be detected, and record the val-
ue of the process variable at the detection point. Reversing Action
4. Change the process variable in the opposite direc-
tion until another output pressure change can be de- Note
tected, and again record the value of the process vari- The following procedure will be neces-
able. If the difference between the two recorded sary to restore previous action if the
values (the dead band) is more than 0.2 percent of the mounting method has been changed.
maximum displacer length, the relay will have to be Key numbers are shown in figure 16.
replaced or repaired according to the Changing Relay
and the Disassembling Relay sections. 1. Remove two screws (keys 63 and 64), two seal
rings (key 55), and the nozzle block (key 101). Check
5. Turn off the supply pressure, remove the pipe plug, seal ring condition and replace rings as necessary.
and install the proportional band adjustment assembly.
2. Install the nozzle block, seal rings, and screws on
the opposite side of the beam as shown in figure 15.
Changing Relay Disconnect the proportional band tubing (key 76) and
one of the two pieces of reset tubing (key 75) from the
The relay may be removed for cleaning or repair, and bellows frame (key 94) and reconnect them in the
must be taken off to remove the lower bellows. proper orientation as shown in figure 15.
20
2502 Series
Note 10. Install the casing screws and tighten them slowly
to ensure a good seal.
Beam overtravel can jam the flapper
11. Install the assembled orifice assembly, and install
against the nozzle if the following step
the relay according to the Changing Relay section.
is not performed.
3. Remove the flapper screw (key 93), lockwasher
(key 84), and flapper (key 60). Invert the flapper so Parts Ordering
that the flapper hook is on the opposite side of the Whenever corresponding with the Fisher Controls
beam from the nozzle (key 58), and secure with the sales office or sales representative about this equip-
lockwasher and screw. ment, always mention the controller type number and
4. Perform the calibration procedure and any other the serial number found on the unit nameplate (figure
necessary part of the calibration sequence. 11). When ordering replacement parts, also state the
complete 11-character part number of each required
part as found in the following parts list.
Disassembling Relay
Disassembly can be accomplished in the following Parts Kits
steps. Key numbers are shown in figure 17. Key Description Part Number
Controller Parts Kit
1. Remove the relay according to the Changing Relay Contains keys 12, 15, 21, 24, 38, 55, 57, 58, 60, 62, 63, 64,
section. 77, 79, 84, 86, 87, 93, 101, and 187
Standard Temperature R2502 X0L52
2. Remove the orifice assembly (key 88) and check
High Temperature R2502 X0H52
for orifice plugging or damage. Replace the O-ring Relay Parts Kit
(key 90) before installing the orifice assembly. Contains keys 22, 85, 86, 87, 88, 90, 91, 92, 93 and 94,
(99 and 100 high temp only)
3. Remove the casing screws (key 96) and washers Standard Temperature RRELAY X0L12
(key 98), casing assembly (key 85), and top dia- High Temperature RRELAY X0H12
phragm (key 91). On a high-temperature relay also Relay Replacement Kit
remove the top gasket (key 100) that covers the top Contains keys 22, 43, and the relay assembly
diaphragm. Standard Temperature RRELAY X0L22
High Temperature RRELAY X0H22
4. Remove the spacer ring (key 84), diaphragm as- Heat Insulator Parts Kit
sembly (key 86), and relay spring (key 92) from the Contains keys 35, 36, 37, 38, 39, 40, and 53 R2500XH 0012
relay body (key 83). On a high-temperature relay also
remove the bottom gasket (key 99) from underneath Parts List
the diaphragm assembly.
5. Remove the screws (key 97), spring plate (key 95),
Heat Insulator (figure 14)
35 Heat Insulator Assembly, stainless steel 22A0033 X012
spring plate gasket (key 94), spring (key 93), and 36 Shaft Coupling, stainless steel 1A5779 35032
valve plug (key 87). 37 Shaft Extension, K-Monel 1B6815 40022
38 Set Screw, stainless steel (2 req’d) 1E6234 X0022
6. Inspect the diaphragms and gaskets and replace if 39 Cap Screw, steel, pl (4 req’d) 1A3816 24052
necessary. Also replace the spring and valve plug if 40 Cap Screw, steel, pl (4 req’d) 1V2395 28982
they show signs of corrosion. The lower diaphragm 53 Washer, carbon steel, pl (4 req’d) 1B8659 28982
comes as part of an assembly and must be installed
as such. Clean all parts thoroughly before assembling. Controller Common Parts (figure 16)
1 Pilot Case Back, zinc
7. Put the valve plug and its spring in the relay body. Types 2502 and 2502C 1J4157 44012
Replace the spring plate gasket and spring plate and Type 2502F 23A2073 X012
secure with four screws. 2 Pilot Case Cover, aluminum 50B9454 X012
3 Door Handle, steel, pl 1C8972 25082
8. Place the relay spring in the relay body and, on a 4 Door Handle Shaft (not shown),
high-temperature relay, install a bottom gasket. Install stainless steel 1C8984 14012
the diaphragm assembly, spacer ring, and top dia- 5 Machine Screw, stainless steel 1C8958 X0022
6 Washer Spring, stainless steel 1C8970 36032
phragm on the body so that all flow passage holes are 7 Door Hook, steel, pl 1C8971 25082
lined up. On a high-temperature relay also install a 8 Elastic Stop Nut, steel, pl 1C8959 X0012
gasket over the top diaphragm. 9 Drive Pin, (2 req’d) 1C8991 X0022
11 Relay Tubing
9. Put the casing assembly on the top diaphragm so Copper 17A9100 X012
that the lugs on the casing and spacer ring line up and Stainless steel (2502 and 2502C only) 17A9100 X022
are also lined up with the body lug. 12* Ball Bearing Ass’y, brass, pl 1C8983 000A2
30A8942-H/DOC
30A8943-H/DOC
43A2366-H/DOC
22
2502 Series
Key Description Part Number Key Description Part Number
22B0463-A/DOC