Page 1: Table Of Contents
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Fisher 2500 and 2503 Controllers and Transmitters ™ Contents Figure 1. Fisher 2500 or 2503 Controller/Transmitter on 249 Caged Sensor Introduction ....... . . Scope of Manual .
Page 2: Introduction
Refer to table 1 for specifications. Educational Services For information on available courses for 2500 or 2503 controller/transmitter as well as a variety of other products, contact: Emerson Automation Solutions Educational Services - Registration Phone: 1-641-754-3771 or 1-800-338-8158 E-mail: [email protected]...
Page 3 Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Table 1. Specifications Available Configurations Per ISO 8573-1 Maximum particle density size: Class 7 2500—Proportional‐only controller Oil content: Class 3 2500C—Proportional‐only controller with indicator Pressure Dew Point: Class 3 or at least 10_C less than (see figure 10) the lowest ambient temperature expected 2500R—Reverse acting proportional‐only controller...
Page 4 7 scfh 42 scfh 3 bar (45 psig) 1. Consult your Emerson Automation Solutions sales office about gauges in other units. 2. Control and stability may be impaired if this pressure is exceeded. 3. At zero or maximum proportional band or specific gravity setting.
Page 5: Installation
N05500 316 Stainless Steel, N06600, N10276 1. N05500 is not recommended for spring applications above 232_C (450_F). Contact your Emerson sales office or application engineer if temperatures exceeding this limit are required. Installation 2500 and 2503 controller/transmitters work in combination with 249 displacer‐type sensors. The factory attaches the controller/transmitter to the sensor, unless it is ordered separately.
Page 6: Sensor Assembly
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 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.
Page 7: Controller/Transmitter Orientation
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 3. Damping Plate Location DISPLACER CAGE W2141-1B SCREWED CONNECTION DAMPING PLATE FLANGED CONNECTION W0144-1 A cageless sensor comes with its displacer separated from the sensor assembly. Displacers longer than 813 mm (32 inches) come in a separate crate.
Page 8: Mounting Caged Sensor
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 Figure 4. Cage Head Mounting Positions RIGHT‐HAND MOUNTING LEFT‐HAND MOUNTING 67CFR FILTER/REGULATOR. AH9150-A A2613-2 Mounting Caged Sensor Note Install the cage so that it is plumb; the displacer must not touch the cage wall. If the displacer touches the cage wall, the unit will transmit an erroneous output signal.
Page 9 Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 5. Cage Connection Styles STYLE 2: TOP STYLE 1: TOP STYLE 3: UPPER STYLE 4: UPPER AND LOWER SIDE AND BOTTOM AND LOWER SIDE SIDE AND BOTTOM SCREWED: S1 SCREWED: S2 SCREWED: S3 SCREWED: S4 FLANGED: F1...
Page 10: Mounting Cageless Sensor
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 On fluid or interface level applications, position the sensor so that the center line on the cage (see figure 6) is as close as possible to the center of the fluid level or interface level range being measured. Also consider installing a gauge glass on the vessel, or on the sensor cage (if the cage is tapped for a gauge).
Page 11 Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 7. Cageless Sensor Mounting TOP MOUNTED SIDE MOUNTED W9517‐1 SIDE VIEW (SHOWING STILLWELL) CF5380‐A A3893 SIDE VIEW (WITHOUT STILLWELL) Figure 8. Displacer and Displacer Rod Connections COTTER SPRING DISPLACER ROD COTTER SPRING DISPLACER SPUD...
Page 12: Top-Mounted Sensor
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 Automation Solutions field office and industry instrument air quality standards for use with corrosive air or if you are unsure about the proper amount or method of air filtration or filter maintenance.
Page 13: Controller/Transmitter Output Connection
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 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. Figure 9. Controller/Transmitter Dimensions and Connections OPTIONAL HEAT INSULATOR EXTENSION...
Page 14: Prestartup Checks
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 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.
Page 15 Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 10. Adjustment Locations 1C9283-B W0641-1B RAISE LEVEL DIAL FOR BOURDON TUBE DETAIL OF 2500S LEFT‐HAND MOUNTING ON‐OFF CONTROLLER LEVEL SET ARM 3-WAY VALVE LEVEL ADJUSTMENT MOUNTING SCREWS FLAPPER ALIGNMENT SCREW NOZZLE PROPORTIONAL LEVEL SET...
Page 16 Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 Set the PROPORTIONAL BAND control on a 2500 or 2500S controller, or the SPECIFIC GRAVITY control on a 2500T transmitter, as follows: D Sensor with Both Standard Torque Tube and Standard Volume Displacer—If the torque tube is standard and the displacer volume is close to that listed in table 2, use figure 11 to find the PROPORTIONAL BAND or SPECIFIC GRAVITY setting.
Page 17: 2500 Controller Or 2500T Transmitter
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 SP GR = specific gravity of the process fluid (for interface level control, use the difference between the specific gravity of the two fluids; for specific gravity control, use the difference between the upper and lower range limits of specific gravity).
Page 18: 2500S Controller
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 2500S Controller Note In the following steps the output pressure can go as high as the controller supply pressure. 1. Turn on the supply pressure and check that the SUPPLY pressure gauge reads 1.4 bar (20 psig) for a 0 to 1.4 bar (0 to 20 psig) output pressure range or 2.4 bar (35 psig) for a 0 to 2.4 bar (0 to 35 psig) output pressure range.
Page 19: Adjustments
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 191 mm (7.5 inch) change at 1.7 bar (25 psig). Set the gap at a pressure low enough to be compatible with the limitations of the diaphragm control valve or other final control element. 1.
Page 20: Zero Adjustment (Transmitters Only)
There are wet and dry methods of adapting the calibrating procedure. Note Contact your Emerson sales office for information on obtaining Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters—Supplement to 249 Sensor Instruction Manuals (D103066X012). Wet Calibration Remove the entire controller/transmitter and sensor assembly from the vessel.
Page 21: Dry Calibration
Determining the Amount of Suspended Weight CAUTION Avoid overloading a torque tube sized for interface or density applications. Consult your Emerson sales office or Local Business Partner for the maximum allowable substitute weight, Ws, that may be used with your particular construction.
Page 22: Calibration Procedure
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 To determine the total weight that must be suspended from the displacer rod to simulate a certain condition of fluid level or specific gravity, solve the following equation: – (0.0361)(V)(SP GR) where: = Total suspended weight in pounds (should never be less than 0.5 pounds).
Page 23: 2500 Controller And 2500T Transmitter
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 10 shows adjustment locations, except as otherwise indicated. In order to calibrate, open‐loop conditions must exist. One way to obtain an open loop is to ensure that there is no flow through the final control element. Another way to obtain an open loop is to disconnect the controller/transmitter output signal line and plug the output connection with a test pressure gauge.
Page 24 Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 D For Direct Acting 2500, 2500T, 0.2 bar (3 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or 0.4 bar (6 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output. D For Reverse Acting 2500, 2500T, 1.0 bar (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or 2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output.
Page 25: 2500S And 2503 Controllers
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 13. If the flexure strip base has been moved as far as possible and the output pressure span is still too large or too small, slightly adjust the PROPORTIONAL BAND or SPECIFIC GRAVITY adjustment as follows: D If the output pressure span is too large, slightly increase the PROPORTIONAL BAND or SPECIFIC GRAVITY setting.
Page 26 Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 7. Slowly increase the process variable until the output pressure switches: D For Direct Acting Controllers, slowly increase the process variable until the output pressure switches to full supply pressure. The process variable should be at the maximum value of input range as shown in table 6. If the process variable agrees with table 6, proceed with step 8.
Page 27: Startup
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Startup Adjustment locations are shown in figure 10. The pre‐startup or calibration procedures must be completed prior to startup. 2500 Controller 1. Slowly open the upstream and downstream manual control valves in the pipeline. If the pipeline has a bypass valve, close the valve.
Page 28: 2500 Controller Or 2500T Transmitter
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 All 2500 and 2503 controller/transmitters use the same basic pressure‐balanced relay assembly. The following descriptions explain how the relay action produces the output signal with the various controller/transmitter constructions. 2500 Controller or 2500T Transmitter Full supply pressure comes to the relay from the regulator, as shown in figure 12.
Page 29: 2503 Controller
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 12. Direct‐Acting, Right‐Hand‐Mounted Fisher 2500‐249 Controller/Transmitter OUTER BOURDON INNER BOURDON TUBE TUBE CHANNEL CHANNEL LEVEL SET FIXED PIVOT ADJUSTMENT MOVABLE ARM NOZZLE EXHAUST EXHAUST END FLAPPER OF RELAY VALVE FIXED LARGE DIAPHRAGM RESTRICTION OF ASSEMBLY...
Page 30: Maintenance
This control action continues until a sensor level change moves the flapper away from the plunger, permitting the Bourdon tube valve to close, restoring loading pressure to the pneumatic circuit. Reverse‐acting controllers produce the opposite effect. Figure 13. Direct‐Acting Left‐Hand‐Mounted Fisher 2503 Controller INNER BOURDON TUBE CHANNEL...
Page 31: Troubleshooting
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 When replacing the sensor assembly, the displacer may retain process fluid or pressure. Personal injury or property damage may occur due to sudden release of the pressure. Contact with hazardous fluid, fire, or explosion can be caused by puncturing, heating, or repairing a displacer that is retaining process pressure or fluid.
Page 32: Removing Controller/Transmitter From Sensor
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 Table 7. Troubleshooting Chart for Fisher 2500 Controller/Transmitters (continued) Fault Possible Cause Check Correction 2. Controller/transmitter 2.1 Supply pressure not set Make sure regulator supply pressure Reset the supply regulator pressure. controlling off set point or switching correctly.
Page 33: Changing Mounting Methods
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 CAUTION If the hex clamp nut has not been loosened or the pointer removed according to step 2, attempting to remove the controller/transmitter from the sensor may bend the flapper or rotary shaft. Be careful that the back of the controller/transmitter case or the heat insulator does not drop down and bend the rotary shaft or shaft extension.
Page 34: Installing Controller/Transmitter On Sensor
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 1. Remove the controller/transmitter as described previously. 2. A controller/transmitter is attached to the sensor in one of the mounting positions shown in figure 4. Right‐hand mounting is with the controller/transmitter case (key 1) to the right of the displacer (FLOAT), as you look at the front of the case, left‐hand mounting is with with the case to the left of the displacer.
Page 35: Replacing The Bourdon Tube
Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 4. Slide the bearing assembly (key 12, figure 16) onto the shaft or shaft extension of the insulator, and install the bearing assembly (key 12, figure 16) into the case (key 1, figure 16). 5.
Page 36: Relay Deadband Testing (2500 Controller Or 2500T Transmitter Only)
Instruction Manual 2500 and 2503 Controllers/Transmitters June 2017 D200124X012 Figure 15. Bourdon Tube‐Flapper Arrangements for Various Actions and Mountings DIRECT ACTING—RIGHT HAND MOUNTING REVERSE ACTING—RIGHT HAND MOUNTING CONSTRUCTION REVERSE ACTING—LEFT HAND MOUNTING DIRECT ACTING—LEFT HAND MOUNTING 2500 OR 2500T (INCLUDING C VERSIONS) 2500S (INCLUDING...
Page 37: Replacing The Proportional Valve
4. If the deadband is within tolerance, go to the Calibration section. Parts Ordering Whenever corresponding with your Emerson sales office or Local Business Partner about this equipment, use the controller/transmitter type number and the serial number. The serial number is found on the nameplate (key 215,...
Page 38: Parts List
Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions should not, under any circumstances, be used in any Fisher instrument. Use of components not supplied by Emerson Automation Solutions may void your warranty, might adversely affect the performance of the instrument, and could cause personal injury and property damage.
Page 39 Instruction Manual 2500 and 2503 Controllers/Transmitters D200124X012 June 2017 Figure 16. Fisher 2500 Controller / Transmitter Constructions LEVEL SET MOUNTING SCREWS SEE VIEW A 30A8865-D TYPICAL CONTROLLER SEE 2503 CONNECTION DETAIL 30A8866-C VIEW A 2503R CONTROLLER 30A8869-D CONSTRUCTION NOTE: PARTS NOT SHOWN 4, 24, 38, 39, 47, AND 48. DETAIL OF INDICATOR ASSEMBLY ON C VERSIONS...
Page 40 Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user. Fisher is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co.

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