Manual 2500

Instruction Manual
Form 1013
March 2005 Type 2500
2500 and 2503 Series Level-TrolR Controllers

and Transmitters
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Educational Services . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controller/Transmitter Orientation . . . . . . . . . . . 6
Mounting Caged Sensor . . . . . . . . . . . . . . . . . . . 6
Mounting Cageless Sensor . . . . . . . . . . . . . . . . . 7 2500 OR 2503 SERIES
Side-Mounted Sensor . . . . . . . . . . . . . . . . . . . . 8 CONTROLLER/
TRANSMITTER
Top-Mounted Sensor . . . . . . . . . . . . . . . . . . . . . 9
Supply and Output Pressure Connection . . . . . 9 249 SERIES SENSOR
Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . 10
Controller/Transmitter Output Connection . . 10
Prestartup Checks . . . . . . . . . . . . . . . . . . . . . . . . 10
Type 2500 Controller or Type 2500T
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Type 2500S Controller . . . . . . . . . . . . . . . . . . . . 13
Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . 14
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 W8334
Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 1. 2500 or 2503 Series Level-TrolR Controller/

Level Adjustment Transmitter on Caged 249 Series Sensor
(Controllers Only) . . . . . . . . . . . . . . . . . . . . 15
Zero Adjustment
(Transmitters Only) . . . . . . . . . . . . . . . . . . . 15 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Proportional Band Adjustment Type 2500 Controller . . . . . . . . . . . . . . . . . . . . . 20
(Except Transmitters and 2503 Type 2500T Transmitter . . . . . . . . . . . . . . . . . . 20
Series Controllers) . . . . . . . . . . . . . . . . . . . . 15 Type 2500S Controller . . . . . . . . . . . . . . . . . . . . 20
Specific Gravity Adjustment Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . 20
(Transmitters Only) . . . . . . . . . . . . . . . . . . . 15 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . 21
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Type 2500 Controller or Type 2500T
Precalibration Requirements . . . . . . . . . . . . . . . 15 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 15 Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . 21
Dry Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 16 Type 2500S Controller . . . . . . . . . . . . . . . . . . . . 21
Controller/Transmitter and Torque Tube Arm Type 2503 Controller . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Determining the Amount of Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 24
Suspended Weight . . . . . . . . . . . . . . . . . . . 16 Removing Controller/Transmitter from
Calibration Procedure . . . . . . . . . . . . . . . . . . . . 17 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type 2500 Controller and Changing Mounting Methods . . . . . . . . . . . . . . 24
2500T Transmitter . . . . . . . . . . . . . . . . . . . . 17 Installing Controller/Transmitter on Sensor . . . 26
Type 2500S and 2503 Controllers . . . . . . . . . 19 (continued on page 2)
D200124X012
www.Fisher.com
Instruction Manual
Form 1013
Type 2500 March 2005
Contents (Continued) Description

Replacing the Bourdon Tube . . . . . . . . . . . . . . 27 These instruments control or transmit the fluid level,
Changing Action . . . . . . . . . . . . . . . . . . . . . . . . . 27 the level of interface between two fluids, or the
Relay Deadband Testing (Type 2500 Controller density (specific gravity). Each unit consists of a 249
or 2500T Transmitter Only) . . . . . . . . . . . . . . . 27 Series displacer-type fluid level sensor and a 2500
Replacing the Proportional Valve . . . . . . . . . . . 28 or 2503 Series pneumatic controller or transmitter.
Changing Relay . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 1 shows a typical controller-sensor
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 combination.
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Specifications
Introduction Refer to table 1 for specifications.
Scope of Manual Educational Services

For information on available courses for 2500 or
This manual provides installation, operating, 2503 Series pneumatic controllers and transmitters,
calibration, maintenance, and parts ordering as well as a variety of other products, contact:
information for the 2500 and 2503 Series pneumatic
controllers and transmitters used in combination with Emerson Process Management
249 Series displacer sensors. Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158 - 2823
Note Phone: 800 - 338- 8158 or
Phone: 641 - 754- 3771
This manual does not include FAX: 641 - 754- 3431
installation or maintenance e-mail: education@emersonprocess.com
procedures for the supply pressure
regulator, sensor, or other devices. For
that information, refer to the
appropriate instruction manual for the
other device.
Installation
No person may install, operate or maintain a 2500 or
2503 Series pneumatic controller/transmitter without The 2500 and 2503 Series controller/transmitters
first D being fully trained and qualified in valve, work in combination with 249 Series displacer-type
actuator and accessory installation, operation and sensors. The factory attaches the
maintenance, and D carefully reading and controller/transmitter to the sensor, unless it is
understanding the contents of this manual. If you ordered separately.
have any questions about these instructions, contact
your Fisher sales office.
WARNING
Note
Always wear protective clothing and
Neither Emerson, Emerson Process
eyewear when performing any
Management, nor Fisher assume
installation operations to avoid
responsibility for the selection, use, or
personal injury.
maintenance of any product.
Responsibility for the selection, use, Check with your process or safety
and maintenance of any Fisher engineer for any additional measures
product remains with the purchaser that must be taken to protect against
and end-user. process media.
2
Instruction Manual
Form 1013
Table 1. Specifications
Available Configurations(1) Steady-State Air Consumption

Type 2500Proportional-Only controller 2500 Series Controllers and Transmitters
Type 2500CProportional-Only controller with (2500, 2500C, 2500R, 2500S, and 2500T): See
indicator (see figure 10) table 3.
Type 2500RReverse acting proportional-only Type 2503 Controller: Vents only when relay is
controller exhausting.
Type 2500SDifferential gap (snap acting)
controller. See changing controller action Proportional Band(2) Adjustment
procedure and figure 15. (Proportional-Only Controllers)
Type 2500TTransmitter
Type 2503Differential gap controller without Full output pressure change adjustable over 10 to
proportional valve; for applications requiring very 100% of displacer length.(5)
little adjustment.
Differential Gap(2) Adjustment (Differential Gap
Input Signal(2) Controllers)
Fluid Level or Fluid-to-Fluid Interface Level: Type 2500S Controller: Full output pressure
From 0 to 100% of displacer lengthstandard change adjustable from 20 to 100% of displacer
lengths for all sensors are 356 mm or 812 mm (14 length.(5)
inches or 32 inches). Other lengths available Type 2503 Controller: Full output pressure
depending on sensor construction. change adjustable over approximately 25 to 40%
Fluid Density: From 0 to 100% of displacement of displacer length.(5)
force change obtained with given displacer
volume. Standard volume for displacers are listed Span(2) Adjustment (Type 2500T Transmitter)
in table 2.
Full output pressure change adjustable from 20 to
100% of displacer length.(5)
Output Signal(2)
Type 2500 Controller and 2500T Transmitter: Set Point(2) (controllers only) or Zero(2)
0.2 to 1 bar (3 to 15 psig) or 0.4 to 2 bar (6 to 30 (transmitters only) Adjustment
psig)
Type 2500S and 2503 Differential Gap For proportional-only controllers or transmitters,
Controllers: 0 bar (0 psig) when switched off and level adjustment positions the set point or zero for
full supply [1.4 or 2.4 bar (20 or 35 psig) nominal the fluid level, interface level, or displacer force
depending on controller output pressure range] change (density) within the displacer length.
when switched on. For differential gap controllers, level adjustment
simultaneously positions both ends of the gap
within the displacer length.
Area Ratio of Relay Diaphragms
3:1 Performance
Independent Linearity(2) (transmitters only):
Supply Pressure Data 1% of output pressure change for 100% span.
See table 3(3) Hysteresis: 0.6% of output pressure change at
100% proportional band, differential gap, or span.
Repeatability(2): 0.2% of displacer length or
Maximum Supply Pressure(3,6)
displacement force change.
3 bar (45 psig) to the controller or transmitter. If Deadband(2) (except differential gap
controller or transmitter is equipped with an controllers(4)): 0.05% of proportional band or
integrally mounted Type 67FR filter/regulator, span.
typical supply pressure to the regulator is from 2.5 Typical Frequency Response(2): 4 Hz and 90
bar (35 psig) to 17 bar (250 psig), maximum. For degree phase shift at 100% proportional band
supply pressures to the filter/regulator, refer to the with output piped to typical instrument bellows
appropriate regulator instruction manual. using 6.1 meters (20 feet) of 1/4-inch tubing.
(continued)
3
Instruction Manual
Form 1013
Table 1. Specifications (Continued)
Ambient Operating Temperature Limits(6) Hazardous Area Classification

For ambient temperature ranges and guidelines 2500 and 2503 Series controllers/transmitters
for use of the optional heat insulator assembly, comply with the requirements of ATEX Group II
see figure 2. Relay temperature limits are: Category 2 Gas and Dust
Standard Construction: -40 to 71_C (-40 to
160_F)
High-Temperature Construction: -18 to 104_C
(0 to 220_F)
Supply and Output Connections
Typical Ambient Temperature Operating
1/4-inch NPT female
Influence
Output pressure changes 1.5% per 10_C Maximum Working Pressure (sensors only)
(50_F) change in temperature at 100%
proportional band when using a standard wall Refer to the appropriate sensor instruction
torque tube with 249 Series sensors. manual.
1. Controllers are field adjustable between direct or reverse action. The letter R in the type number indicates that the controller/transmitter shipped from the factory set for reverse action (see
changing controller action procedures). The letter C in the type number indicates that a pointer is attached to the torque tube shaft providing visual monitoring of torque tube motion.
2. This term is defined in ISA Standard S51.1.
3. Control and stability may be impaired if the maximum pressures are exceeded.
4. Adjusting the span of the differential gap controller is equivalent to adjusting the deadband.
5. These statements apply only to units sized to produce a full output change for a 100% level change at the maximum proportional band dial setting.
6. The pressure/temperature limits in this manual, and any applicable standard or code limitation should not be exceeded.
Table 2. Standard Displacer Volumes

STANDARD VOLUME, STANDARD VOLUME,
SENSOR TYPE
Liters Cubic Inches
249, 249B, 249BP, 249K, 249W 1.6 100(1)
249C, 249CP, 249W 1.0 60(2)
249L 1.9 120
249V 1.3(3) 80(3)
1. For 249W, with standard 812 mm (32-inch) displacer.
2. For 249W, with standard 356 mm (14-inch) displacer.
3. With standard 305 mm (12-inch) flange-face-to-displacer centerline dimension only.
Table 3. Supply Pressure Data

STANDARD SUPPLY AIR CONSUMPTION AT
NORMAL OPERATING
AND OUTPUT NORMAL OPERATING MAXIMUM
OUTPUT SIGNAL RANGE SUPPLY PRESSURE(2)
PRESSURE GAUGE SUPPLY PRESSURE SUPPLY PRESSURE
INDICATIONS(1) Psig Bar Minimum(3) Maximum(4)
0.2 to 1 bar (3 to 15 psig) 0 to 30 psig 20 1.4 4.2 scfh(5) 27 scfh(5) 3 bar (45 psig)
0.4 to 2 bar (6 to 30 psig) 0 to 60 psig 35 2.4 7 scfh(5) 42 scfh(5) 3 bar (45 psig)
1. Consult your Fisher sales office about gauges in other units.
2. Control and stability may be impaired if this pressure is exceeded.
3. At zero or maximum proportional band or specific gravity setting.
4. At setting in middle of proportional band or specific gravity range.
5. If air consumption is desired in normal m3/hr at 0_C and 1.01325 bar, multiply scfh by 0.0258.
4
Instruction Manual
Form 1013
AMBIENT TEMPERATURE (_C) 71 AMBIENT TEMPERATURE (_C)
- 10 0 10 20 30 40 50 60 70 - 18 - 10
- 18
593
0 10 20 30 40 50 60 70 80 90 100 105
1100 1100 593
PROCESS TEMPERATURE ( C)
PROCESS TEMPERATURE ( F)
PROCESS TEMPERATURE ( C)
500
PROCESS TEMPERATURE ( F)
_ 800 TOO _ TOO 500 _
HEAT INSULATOR HOT 400 _
800 HOT
REQUIRED HEAT INSULATOR 400
300
REQUIRED
400 200 300
100
400 200
0 - 18 100
NO INSULATOR NECESSARY NO INSULATOR NECESSARY
- 20 - 29 0
0
- 40 - 40 USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE PROCESS
USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT MALFUNCTION
PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT AND REDUCE INSULATOR EFFECTIVENESS.)
MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
- 20
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180 200 220
AMBIENT TEMPERATURE (_F) AMBIENT TEMPERATURE (_F)
STANDARD CONTROLLER OR TRANSMITTER HIGHTEMPERATURE CONTROLLER OR TRANSMITTER
NOTE:
FOR APPLICATIONS BELOW - 29_C (- 20_F), BE SURE THE SENSOR MATERIALS
OF CONSTRUCTION ARE APPROPRIATE FOR THE SERVICE TEMPERATURE.
CV6190-E
B1413-3/IL
Figure 2. Guidelines for Use of Optional Heat Insulator Assembly
Sensor Assembly Uncrating

Unless ordered separately, the controller/transmitter
Table 2 lists sensors recommended for use with is attached to the sensor when shipped. Carefully
controller/transmitters. For sensor installation and uncrate the assembly.
maintenance, refer to the appropriate sensor
instruction manual.
CAUTION
Sensors used for interface or density

control may be so large and heavy that
the torque tube cannot fully support
WARNING their weight in air. On the 249V, a
travel stop is used to prevent damage.
Do not remove this travel stop
assembly without first removing the
When replacing the sensor assembly, displacer from the displacer rod. Refer
the displacer may retain process fluid to the instruction manual for cageless
or pressure. Personal injury or 249 Series sensors.
property damage may occur due to
sudden release of the pressure. Note
Contact with hazardous fluid, fire, or Caged sensors have rods and blocks
explosion can be caused by installed at each end of the displacers
puncturing, heating, or repairing a to protect the displacers in shipping.
displacer retaining process pressure Remove these parts before you install
or fluid. This danger may not be the sensor to allow the displacer to
readily apparent when disassembling function properly.
the sensor assembly or removing the
displacer. Before disassembling the Caged sensors come with the displacer installed in
sensor or removing the displacer, the cage. If a tubular gauge glass is ordered with the
observe the more specific warning sensor, the gauge glass is crated separately and
provided in the sensor instruction must be installed at the site. A damping plate is
manual. installed in the lower screwed or flanged connection
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Instruction Manual
Form 1013
DISPLACER
CAGE
W2141-1B/IL
SCREWED
CONNECTION
W0144-1/IL
FLANGED
DAMPING PLATE CONNECTION
Figure 3. Damping Plate Location
(see figure 3) to provide more stable operation. Be

AH9150-A
certain that the cage equalizing connections and the A2613-2/IL
damping plate are not plugged by foreign material.

Figure 4. Cage Head Mounting Positions
A cageless sensor comes with its displacer

separated from the sensor assembly. Displacers
longer than 813 mm (32 inches) come in a separate
crate. Shorter displacers come in the same crate as All caged sensors have a rotatable head. That is, the
the sensor, but are not attached to their displacer controller/transmitter may be positioned at any of
rods. Inspect the displacer to ensure it is not dented. eight alternate positions around the cage as
A dent may reduce the pressure rating of the indicated by the numbers 1 through 8 in figure 4. To
displacer. If a displacer is dented, replace it. rotate the head, remove the head flange bolts and
nuts and position the head as desired.
Controller/Transmitter Orientation Mounting Caged Sensor

The controller/transmitter attaches to the sensor in
one of the mounting positions shown in figure 4.
Right-hand mounting is with the controller or
CAUTION
transmitter case to the right of the displacer when
you look at the front of the case; left-hand mounting Install the cage so that it is plumb; the
is with the case to the left of the displacer. The displacer must not touch the cage
mounting position can be changed in the field. wall. If the displacer touches the cage
Changing this mounting position changes the control wall, the unit will transmit an
action from direct to reverse, or vice versa. erroneous output signal.
6
Instruction Manual
Form 1013
EQUALIZING LINE
CENTER OF SHUTOFF
LIQUID OR VALVES
INTERFACE LEVEL
DRAIN VALVE
EQUALIZING LINE
DF5379-A
A1883-2/IL
Figure 6. Caged Sensor Mounting
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
A1271-2/IL
cage line has a fluid-trapping low point.
Figure 5. Cage Connection Styles
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
Note level or interface level range being measured. Also
consider installing a gauge glass on the vessel, or
If the controller/transmitter is not on the sensor cage (if the cage is tapped for a
mounted on the sensor, refer to the gauge).
Installing Controller/Transmitter on
Sensor procedures in the Maintenance
section. This section also provides
instructions for adding a heat insulator Mounting Cageless Sensor
to a unit.
Cage connections normally are either 1-1/2 or

CAUTION
2-inch, screwed or flanged. Figure 5 shows the
combinations. With flanged connections, use If a stillwell is used, install it plumb so
standard gaskets or other flat-sheet gaskets that the displacer does not touch the
compatible with the process fluid. Spiral-wound wall of the stillwell. If the displacer
gaskets without compression-controlling centering touches the wall, the unit will transmit
rings cannot be used for flange connections. an erroneous output signal.
Since the displacer hangs inside the vessel, provide
As shown in figure 6, mount the cage by running a stillwell around the displacer if the fluid is in a state
equalizing lines between the cage connections and of continuous agitation to avoid excessive turbulence
the vessel. A shutoff or hand valve with a 1-1/2 inch around the displacer.
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Instruction Manual
Form 1013
TOP
MOUNTED
SIDE
MOUNTED
CF5380-A
A3893/IL
W0645-1/IL
SIDE VIEW (SHOWING STILLWELL) SIDE VIEW (WITHOUT STILLWELL)
Figure 7. Cageless Sensor Mounting
Note temperature-compensated displacer or

piezometer ring, refer to the Special
Displacers used in an interface level Installations procedures in this section
application must be completely before proceeding.
submerged during operation. If
displacers arent completely Attach a cageless sensor to a flanged connection on
submerged, they will not calibrate or the vessel as shown in figure 7. For interface or fluid
perform properly. To obtain the level applications, install a gauge glass on the
desired controller or transmitter vessel.
sensitivity may require using either a
thin-wall torque tube, an oversized Side-Mounted Sensor
displacer, or both.
If a stillwell is required (see figure 7), attach the
displacer to the displacer rod from inside the vessel.
Note
Connect the displacer as shown in figure 8, locking
If the controller/transmitter is not the assembly with the cotter spring provided. If a
mounted on the sensor, refer to the stillwell is not required, attach the displacer rod
Installing Controller/Transmitter on before mounting the sensor on the vessel. Then, you
Sensor procedures in the Maintenance can swing the displacer out horizontally for insertion
section. This section also provides into the vessel. However, once the sensor is
instructions for adding a heat insulator installed and the displacer drops to a vertical
to a unit. If the sensor has a position, the displacer may not be capable of being
8
Instruction Manual
Form 1013
DISPLACER
STEM
END PIECE
DISPLACER ROD
DISPLACER
DISPLACER COTTER SPRING
STEM COTTER SPRING
EXTENSION SPUD
LOCKING NUTS
DISPLACER SPUD
W0229-1A/IL W0228-1A/IL DISPLACER ROD
TYPE 249V ALL OTHER TYPES
Figure 8. Displacer and Displacer Rod Connections
withdrawn for servicing later. Be sure there is with the cotter springs provided. If a stem extension
another access to the displacer to permit swinging it is used between the displacer spud and the stem
to a horizontal position or to permit disconnecting it end piece, make sure the nuts are tight at each end
from the displacer rod. of the stem. Install and tighten suitable cap screws in
the flanged connection to complete the installation.
If an extension is used between the displacer spud
and the displacer stem end piece, make sure the A special travel stop may be provided on
nuts are tight at each end of the displacer stem top-mounted sensors to aid in servicing of the
extension. Install and tighten suitable bolting or cap sensor. This option prevents dropping the displacer
screws in the flanged connection to complete the and stem when the displacer rod is disconnected.
installation.
Supply and Output Pressure

Top-Mounted Sensor
Connections
CAUTION
WARNING
If inserting the displacer into the
vessel before attaching to the To avoid personal injury or property
displacer rod, provide a means of damage resulting from the sudden
supporting the displacer to prevent it release of pressure, do not install any
from dropping into the vessel and system component where service
suffering damage. conditions could exceed the limits
given in this manual. Use
Figure 7 shows an example of a top-mounted pressure-relieving devices as required
cageless sensor. You may attach the displacer to by government or accepted industry
the displacer rod before installing the sensor on the codes and good engineering practices.
vessel. If the displacer diameter is small enough,
you may install a long or sectionalized displacer Figure 9 shows dimensions, locations, and
through the sensor head access hole after the connections for controller/transmitter installation. All
sensor is installed on the vessel. Connect the pressure connections to the controller/transmitter are
displacer as shown in figure 8, locking the assembly 1/4-inch NPT female.
9
Instruction Manual
Form 1013
OPTIONAL HEAT Standard S7.3. Use a suitable supply pressure

INSULATOR regulator to reduce the supply pressure to the
EXTENSION
normal operating supply pressure shown in table 3.
223.8
176.3 8.81
As shown in figure 9, a Type 67FR filter/regulator
6.94 117.6 mounts on the back of the controller/transmitter case
4.63
and mates with the supply pressure connection on
the controller/transmitter case. Pipe the supply
123.7
4.87 pressure to the IN connection of the regulator.
239.0
9.41
Typically, the Type 67FR filter/regulator accepts
TOP VIEW supply pressures between 2.5 and 17 bar (35 and
250 psig). For specific regulator limits, refer to the
appropriate regulator instruction manual.
255.5 If operating the controller or transmitter from a high

10.06 pressure source [up to 138 bar (2000 psig)], use a
high pressure regulator system, such as the Type
1367 High Pressure Instrument Supply System. For
Type 1367 system installation, adjustment. and
FRONT VIEW 5/6-18 UNC-2B maintenance information, see the separate
4 MOUNTING HOLES instruction manual.
ONj 95.3/3.75 DBC
58.7
2.31
Controller/Transmitter Output
231.6
9.12
Connection
As shown in figure 9, the output pressure connection
is on the back of the controller/transmitter case. After
1/4-18 NPT connecting the output pressure line, turn on the
OUTPUT CONN VENT supply pressure, adjust the filter/regulator to the
1/4-18 NPT TYPE 67CFR appropriate supply pressure required for the
OUTLET CONN 1/4-18 NPT mm
PLUGGED SUPPLY CONN INCH controller/transmitter and check all connections for
AP4158-D
E0859 BACK VIEW leaks.
Figure 9. Controller/Transmitter Dimensions and Connections
Supply Pressure Prestartup Checks

Adjustments are shown in figure 10 unless otherwise
WARNING indicated. Open-loop conditions must exist when
performing the prestartup checks. To obtain
open-loop conditions:
Personal injury or property damage
may occur from an uncontrolled D make sure there is no process flow through the
process if the supply medium is not final control element, or
clean, dry, oil-free air, or non-corrosive
gas. While use and regular D disconnect the controller/transmitter output
maintenance of a filter that removes signal line and connect it to a pressure gauge.
particles larger than 40 microns in
diameter will suffice in most During prestartup, the displacer must be positioned
applications, check with a Fisher Field from its maximum to its minimum range of operation.
office and Industry Instrument air Provide a means to change the process variable (the
quality standards for use with process level or interface). If the process variable
corrosive air or if you are unsure about cannot be varied sufficiently, use the precalibration
the proper amount or method of air procedures in the Calibration section to simulate the
filtration or filter maintenance. process variable changes required for these checks.
Supply pressure must be clean, dry air or Make sure the RAISE LEVEL dial on the controller is
noncorrosive gas that meets the requirements of ISA mounted with the correct side facing out. The dial is
10
Instruction Manual
Form 1013
W0641-1B/IL
1C9283-B/DOC
BOURDON TUBE DETAIL OF

TYPE 2500S ONOFF RAISE LEVEL DIAL FOR
CONTROLLER LEFT HAND MOUNTING
LEVEL SET ARM 3 - WAY VALVE

MOUNTING SCREWS LEVEL ADJUSTMENT
FLAPPER ALIGNMENT SCREW NOZZLE
LEVEL SET PROPORTIONAL
SHAFT CLAMP NUT PLUNGER BAND ADJUSTMENT
ARM
W0671-1/IL W0656-1/IL
VENT RELAY FLAPPER
SPAN ADJUSTMENT
RIGHT HAND MOUNTED TYPE 2503R RIGHT HAND MOUNTED TYPE 2500
ON OFF CONTROLLER PROPORTIONAL CONTROLLER
SPECIFIC GRAVITY
ADJUSTMENT
ZERO
ADJUSTMENT
POINTER
ASSEMBLY
W0647-2B/IL 1E8731
W0648-1B/IL 1E8732
A1897-1/IL
DETAIL OF TRANSMITTER INDICATOR ASSEMBLY WITH TRAVEL INDICATOR PLATE

ADJUSTMENTS RIGHT HAND MOUNTING FOR LEFTHAND MOUNTING
Figure 10. Adjustment Locations
11
Instruction Manual
Form 1013
marked on both sides with an arrow. The arrow

points to the left on one side and to the right on the
other. When the sensor is mounted to the left of the
controller/transmitter, the arrow on the raise level
dial should point to the left, as shown in figure 10. If
the sensor is to the right, the arrow should point to
the right. If necessary, remove the two mounting
screws, turn the dial over so the arrow points
correctly, and reinstall the mounting screws. The
level directions shown on the dial will be correct for
both direct-acting and reverse-acting controllers. For
a transmitter, use the same side of the ZERO
ADJUSTMENT dial for both right- and left-hand
sensor mountings.
On a controller or transmitter with an optional

mechanical indicator assembly, the travel indicator
plate is also marked with an arrow on both sides. If
the sensor is to the left of the controller/transmitter,
the arrow on the plate should point to the left. If the
sensor is to the right, the arrow should point to the
right. If necessary, reinstall the plate so that the
arrow points in the correct direction. NOTE:
EACH CURVE MARKED WITH PERCENTAGE OF DISPLACER USED.
1C9259-G
A3891-1/IL
Set the PROPORTIONAL BAND control on a Type Figure 11. Proportional Band and Specific Gravity
2500 or 2500S controller, or the SPECIFIC Setting Chart (chart assumes standard wall torque tube and
GRAVITY control on a Type 2500T transmitter, as displacer volume in table 2)
follows:
Corrected
D Sensor with Both Standard Torque Tube
and Standard Volume DisplacerIf the torque 100

Dial Setting + ( L )(SP GR) Va (X)
Vr
Required
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 where:
setting. Locate the specific gravity of the process
fluid on fluid level applications, or the difference L = percentage of displacer length desired for full
between minimum and maximum specific gravity on output pressure change (e.g., if 80% of
interface level or density applications, on the vertical displacer is used, L = 80)
axis of the chart. From this location, trace
horizontally to the curve with the desired percentage SP GR = specific gravity of the process fluid (for
of displacer used, then trace vertically up or down to interface level control, use the difference
determine the proper dial setting on the horizontal between the specific gravity of the two
axis. fluids; for specific gravity control, use the
difference between the upper and lower
range limits of specific gravity).
D Sensor with Nonstandard Torque Tube
and/or Displacer with Other than Standard Va = actual displacer volume, cubic inches listed
VolumeIf the construction does not have a on the sensor nameplate.
standard wall torque tube or has a displacer volume
that deviates significantly from the volume listed in Vr = standard displacer volume, cubic inches,
table 2, or both, the PROPORTIONAL BAND or from table 2.
SPECIFIC GRAVITY dial setting does not
necessarily indicate the actual proportional band or X = torque tube factor (1.0 for standard torque
specific gravity. To determine the correct dial setting, tubes, 2.0 for thin-wall torque tubes, or 0.5
solve the following equation: for heavy-wall torque tubes).
12
Instruction Manual
Form 1013
Table 4. Recommended Settings For Pre-Startup Checks
RECOMMENDED RAISE LEVEL SETTING RECOMMENDED ZERO ADJUSTMENT SETTING FOR
FOR TYPE 2500 CONTROLLER TYPE 2500T TRANSMITTER
MOUNTING ACTION For Predetermined For Predetermined For Predetermined For Predetermined
PROPORTIONAL BAND PROPORTIONAL BAND SPECIFIC GRAVITY Dial SPECIFIC GRAVITY Dial
Dial Setting of 10(1) Dial Setting of 0(1) Setting of 1.0(1) Setting of 0(1)
Direct 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to right 0.5 to 1.0 to right
Right hand
Right-hand
Reverse 6.5 to 7.0 0.5 to 1.0 1.5 to 2.0 to left 4.0 to 4.5 to right
Direct 3.0 to 3.5 4.0 to 4.5 1.5 to 2.0 to left 0.5 to 1.0 to left
Left hand
Left-hand
Reverse 6.5 to 7.0 0.5 to 1.0 1.5 to 2.0 to right 4.0 to 4.5 to left
1. For proportional band dial settings between 10 and 0 or for specific gravity dial settings between 1.0 and 0, interpolate the value.
Type 2500 Controller or 2500T 0.4 bar (6 psig) for direct or 2 bar (30 psig) for
Transmitter reverse action.
5. On a controller or transmitter with a mechanical
Note indicator assembly, the pointer should be over the
LOW point on the indicator plate. If a slight
In the following steps the output adjustment is necessary, loosen the side hex clamp
pressure can go as high as the nut (key 40, figure 16), shift the pointer, and
controller supply pressure. retighten the nut.
1. Turn on the supply pressure and check that the 6. Increase the process variable to the level desired
supply pressure gauge reads 1.4 bar (20 psig) for a for full output change. The OUTPUT gauge on a 0.2
0.2 to 1 bar (3 to 15 psig) or 2.4 bar (35 psig) for a to 1 bar (3 to 15 psig) range should read 1 bar (15
0.4 to 2 bar (6 to 30 psig) output pressure range. If psig) for direct or 0.2 bar (3 psig) for reverse action.
the pressure is incorrect, loosen the locknut of the On a 0.4 to 2 bar (6 to 30 psig) range the OUTPUT
Type 67FR filter/regulator (figure 9); turn the gauge should read 2 bar (30 psig) for direct or 0.4
adjusting screw clockwise to increase the pressure bar (6 psig) for reverse action. On a controller or
or, counterclockwise to decrease the pressure. transmitter with an indicator assembly, the pointer
Tighten the locknut after setting the regulator should be over the HIGH point on the indicator plate;
pressure. slight plate adjustment may be necessary, as
described at the end of step 5.
2. Set the process variable to its minimum value.
7. If all prestartup checks are satisfactory, go to the
3. Make sure that the PROPORTIONAL BAND or startup procedure. If performance is unsatisfactory,
SPECIFIC GRAVITY control is at the setting proceed to the Calibration section.
determined earlier in this section. Then, set the
RAISE LEVEL or ZERO ADJUSTMENT control at an
appropriate value according to table 4. This table Type 2500S Controller
gives recommended settings based on maximum
and minimum possible PROPORTIONAL BAND and Note
SPECIFIC GRAVITY settings. If an intermediate
PROPORTIONAL BAND or SPECIFIC GRAVITY In the following steps the output
setting is necessary, extrapolation may be used to pressure can go as high as the
determine an appropriate RAISE LEVEL or ZERO controller supply pressure.
ADJUSTMENT setting. 1. Turn on the supply pressure and check that the
SUPPLY pressure gauge reads 1.4 bar (20 psig) for
Note 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)
The raise level dial does not reflect output pressure range. If the pressure is incorrect,
actual fluid level in the tank or fluid loosen the locknut of the Type 67FR filter/regulator
level position on the displacer. (figure 9); turn the adjusting screw clockwise to
4. The OUTPUT gauge on a 0.2 to 1 bar (3 to 15 increase the pressure or counterclockwise to
psig) range should read 0.2 bar (3 psig) for direct or decrease pressure. Tighten the locknut after setting
1 bar (15 psig) for reverse action. On a 0.4 to 2 bar the pressure.
(6 to 30 psig) range the OUTPUT gauge should read 2. Set the process variable to its minimum value.
13
Instruction Manual
Form 1013
3. On a controller with a mechanical indicator gap can be varied from approximately

assembly, the pointer should be over the LOW point a 89 mm (3.5 inch) level change at 1
on the indicator plate. If a slight adjustment is bar (15 psig) to a 152 mm (6.0 inch)
necessary, loosen the hex clamp nut (key 40, figure level change at 1.7 bar (25 psig) with a
16), shift the pointer and retighten the nut. standard volume displacer and a fluid
with a specific gravity of 1.0. The gap
also varies inversely according to
Note density; a fluid with 0.8 specific gravity
Adjustment of the RAISE LEVEL produces a 112 mm (4.4 inch) level
change at 1 bar (15 psig) to a 191 mm
control can set the switching points
anywhere within the length of the (7.5 inch) change at 1.7 bar (25 psig).
displacer. Be careful not to set the Set the gap at a pressure low enough
to be compatible with the limitations of
switching points so that one is off the
the diaphragm control valve or other
displacer.
final control element.
4. Make sure that the PROPORTIONAL BAND
control is at the setting determined in the previous 1. Turn on the supply pressure. If necessary, adjust
procedures. Set the RAISE LEVEL control to 0, then the Type 67FR regulator to produce the desired
set it to 1.0 for a direct-acting or 4.0 for a differential gap by loosening the locknut (figure 9)
reverse-acting controller. and turning the adjusting screw clockwise to
increase or counterclockwise to decrease pressure.
5. The OUTPUT gauge should read 0 bar (0 psig) Tighten the locknut.
for direct or supply pressure for reverse action.
2. Locate the process variable at its minimum value.
6. Increase the process variable until the OUTPUT
gauge changes to either supply pressure for direct or
0 bar (0 psig) for reverse acting. The process Note
variable should be at the desired high trip value. On
a controller with an indicator assembly, the pointer Adjustment of the RAISE LEVEL
should be over the HIGH point on the indicator plate; control can set the switching points
slight adjustment may be necessary, as described at anywhere within the length of the
the end of step 3. displacer. Be careful not to set the
switching points so that one is off the
7. Decrease the process variable until the OUTPUT displacer.
gauge changes to 0 bar (0 psig) for direct or supply
pressure for reverse action (depending on controller 3. Set the RAISE LEVEL control to 0 and then reset
range). The process variable should be at the it as follows:
desired low trip value.
a. For direct-acting controllers, set it between 1.0
8. If all prestartup checks are satisfactory, proceed and 1.5.
to the Startup section. If performance is
unsatisfactory, proceed to the Calibration section. b. For reverse-acting controllers, set it between
3.5 and 4.0.
Type 2503 Controller 4. The OUTPUT gauge should read 0 bar (0 psig)
for direct or full supply pressure for reverse action.
Note 5. Increase the process variable until the OUTPUT
gauge changes to full supply pressure for direct or 0
In the following steps the output bar (0 psig) for reverse action. The process variable
pressure can go as high as the should be at the desired high trip value.
controller supply pressure.
6. Decrease the process variable until the OUTPUT
gauge changes to 0 bar (0 psig) for direct or full
Note supply pressure for reverse action. The process
variable should be at the desired low trip value.
Since the Type 2503 controller has no
proportional valve, the differential gap 7. If all prestartup checks are satisfactory, proceed
between switching points is adjusted to the Startup section. If performance is
by varying the supply pressure. This unsatisfactory, proceed to the Calibration section.
14
Instruction Manual
Form 1013
Adjustments Proportional Band Adjustment (Except
This section explains controller/transmitter action
Transmitters and 2503 Series
and adjustments. Figure 10 shows adjustment Controllers)
locations. The proportional band adjustment varies the amount
of process variable change required to obtain a full
output pressure change. To perform this adjustment,
Control Action open the controller cover and turn the
The following is a definition of control action. PROPORTIONAL BAND adjustment (see figure 10).
Refer to the prestartup check procedures to
determine the proper setting.
D Direct ActionIncreasing fluid level, interface
level, or density, increases the output signal.
Specific Gravity Adjustment
D Reverse ActionIncreasing fluid level, (Transmitters Only)
interface level, or density, decreases the output
This adjustment also varies the amount of process
signal. Controller/transmitters factory-set for
variable change required to obtain a full output
reverse-acting have the suffix letter R added to their
pressure change. To perform this adjustment, open
type number.
the transmitter cover and turn the SPECIFIC
GRAVITY adjustment (see figure 10). Refer to the
The control action is determined by the cage head prestartup check procedures to determine the proper
mounting position and by the Bourdon tube-flapper setting.
arrangement in the controller/transmitter. Refer to
figure 4 for mounting positions and to figure 15 for
Bourdon tube-flapper arrangements. To change the
action, refer to the changing action procedure in the
Maintenance section.
Calibration
Level Adjustment (Controllers Only) Precalibration Requirements
To make a level adjustment, open the controller The controller/transmitter can be calibrated in the
cover, loosen the knurled adjustment screw, and field, mounted on the vessel containing the process
rotate the adjustment lever around the RAISE fluid. It may also be done in the shop, but other
LEVEL dial. To raise the fluid or interface level, or means of obtaining a displacement force change
increase density, rotate this knob in the direction of must be provided. There are wet and dry methods of
the arrows. To lower the level or decrease density, adapting the calibrating procedure.
rotate the knob in the opposite direction. This
procedure is the same for either direct or reverse
action. Tighten the knurled screw. Wet Calibration
Remove the entire controller/transmitter and sensor
assembly from the vessel. For caged sensors, pour
Note the fluid into the cage. For cageless sensors,
suspend the displacer to an appropriate depth in a
The RAISE LEVEL dial does not reflect fluid having a specific gravity equal to that of the
actual fluid level in the tank or fluid process fluid.
level position on the displacer.
If necessary, you may use water for wet calibration
Zero Adjustment (Transmitters Only) in the shop. You must compensate for the difference
between the specific gravities of water and the
To make a zero adjustment, open the transmitter process fluid, however. As an example, assume the
cover, loosen the adjustment screw and rotate the process fluid has a specific gravity of 0.7. The
adjustment lever around the ZERO ADJUSTMENT specific gravity of water is 1.0. To simulate a process
dial. This adjustment sets the output pressure to level of 50 percent of the input span, would require a
correspond to a specific level on the displacer. water level of 35 percent (0.7/1.0 x 50 percent = 35
Tighten the knurled screw. percent).
15
Instruction Manual
Form 1013
Dry Calibration Additionally, a threaded rod may be

installed into the 1/4-inch 28 UNF
Remove the controller/transmitter and torque tube threaded hole in the displacer spud or
arm, as a single unit, from the cage or vessel. Then, stem end piece of top-mounted
wherever the standard calibration procedures in this cageless and all caged sensors. For
manual require a specific process variable input to some top-mounted sensors with long
the sensor, simulate the process variable by displacers, the sensor may be
suspending the proper weight (such as a can of removed through the access hole in
sand) from the end of the displacer rod. Complete the sensor head.
the following procedures (Controller/Transmitter and
Torque Tube Arm Disassembly) and (Determining For Type 249BP sensors with travel
the Amount of Suspended Weight) before stop, the stem end piece pins will
proceeding to the Calibrating Procedure. secure the displacer on the travel stop
as long as the travel stop plate is
installed and the sensor head is in
Controller/Transmitter and Torque Tube position.
Arm Disassembly
Determining the Amount of Suspended
Weight
WARNING
CAUTION
To avoid personal injury from contact
with the process fluid, lower the vessel Avoid overloading a torque tube sized
level below the sensor torque tube for interface or density applications.
arm, or shut off the cage equalizing Consult your Fisher sales office for the
valves and drain the cage before maximum allowable substitute weight,
proceeding. For closed vessels, Ws, that may be used with your
release any pressure that may be in particular construction.
the vessel before removing the sensor
assembly. To determine the total weight that must be
suspended from the displacer rod to simulate a
When removing the displacer from the displacer rod certain condition of fluid level or specific gravity,
or removing the controller/transmitter and torque solve the following equation:
tube arm from the cage or vessel, refer to the
appropriate 249 Series instruction manual for W s + W d[(0.0361)(V)(SP GR)]
assistance. The method of removing the displacer or
torque tube arm and attached controller/ transmitter where:
varies with the type of sensor.
Ws = Total suspended weight in pounds (should
For a caged sensor with top equalizing connection, it never be less than 0.5 pounds). For a unit
may be appropriate to remove the entire cage from with a horizontal displacer, make sure the
the vessel before disassembling. center of gravity of the substitute weight is
where it would be on the actual displacer.
CAUTION Note
For liquid level control only, simulate
If the displacer is to be disconnected the lower range limit of the input span
from the displacer rod before the by suspending the displacer from the
sensor assembly is removed from the displacer rod. For other values of input
cage or vessel, provide a means of span, remove the displacer and
supporting the displacer to prevent it suspend the appropriate weight as
from dropping and suffering damage. determined in the equation above.
The spuds or stem end pieces on all
displacers have holes suitable for Wd = Weight of the displacer, in pounds
inserting rods or other supports. (determine by weighing displacer).
16
Instruction Manual
Form 1013
Table 5. Minimum and Maximum Limits for Setting Process Variables
APPLICATION MINIMUM LIMIT MAXIMUM LIMIT
Liquid Level Displacer must be completely out of liquid Displacer must be completely submerged in liquid
Interface Displacer must be completely submerged in lighter of two Displacer must be completely submerged in
process liquids heavier of two process liquids
Density Displacer must be completely submerged in liquid having Displacer must be completely submerged in liquid having
specific gravity of lowest range point specific gravity of highest range point
0.0361 = Weight of one cubic inch of water Calibration Procedure

(specific gravity = 1.0), in pounds.
WARNING
V = Volume, in cubic inches, of the portion of the
displacer submerged. Or, The following calibration procedures
require taking the
controller/transmitter out of service.
V = (/4) (displacer diameter)2 (length of To avoid personal injury and property
displacer submerged) damage caused by an uncontrolled
process, provide some temporary
means of control for the process
SP GR = Specific gravity of the process fluid at
before taking the controller/transmitter
operating temperature.
out of service.
Figure 10 shows adjustment locations, except as
For interface level measurement, the equation otherwise indicated. In order to calibrate, open-loop
becomes: 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
W s +W d[(0.0361)(V t)(SP GR l) loop is to disconnect the controller/transmitter output
signal line and plug the output connection with a test
) (0.0361)(Vh)(SP GR h * SP GR l)]
pressure gauge.
Several steps in these calibrating procedures require
where: setting the process variable at its minimum and
maximum limits, according to table 5.
Vt = Total volume, in cubic inches, of the
displacer. Note
If the process cannot be varied readily
SP GRl = Specific gravity of the lighter of the or the Wet Calibration method cannot
be used in the following steps, be sure
fluids at operating temperature.
to use the proper sequence of correct
weights as found in the Determining
Vh = Volume, in cubic inches, of the portion of the Amount of Suspended Weight
displacer submerged in the heavier of the procedure. Whenever the following
fluids. steps require particular prestartup
checks, refer to the appropriate
procedures for: Type 2500 Controller
Or, or 2500T Transmitter, Type 2500S
Controller, or Type 2503 Controller.
V = (/4) (displacer diameter)2 (length of the Type 2500 Controller and 2500T
displacer submerged)
Transmitter
1. Turn on the supply pressure and check that it is
SP GRh = Specific gravity of the heavier of the set according to the appropriate prestartup checks
fluids at operating temperature. procedure.
17
Instruction Manual
Form 1013
2. Make sure that the PROPORTIONAL BAND or D For Direct Acting Type 2500, 2500T, 1.0 bar
SPECIFIC GRAVITY adjustment is at the setting (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or
determined according to the appropriate prestartup 2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig)
check procedure. output.
3. Adjust the RAISE LEVEL (Type 2500) or ZERO D For Reverse Acting Type 2500, 2500T, 0.2
ADJUSTMENT (Type 2500T) to the appropriate bar (3 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output
value per table 4. This table gives recommended or 0.4 bar (6 psig) for a 0.4 to 2.0 bar (6 to 30 psig)
settings based on maximum and minimum possible output.
PROPORTIONAL BAND (Type 2500) or SPECIFIC
GRAVITY (Type 2500T) settings. If an intermediate 9. If the output pressure agrees with that shown in
PROPORTIONAL BAND or SPECIFIC GRAVITY step 8, proceed to step 10. If the output pressure
setting is necessary, extrapolation may be used to does not agree, go to step 11.
determine a new RAISE LEVEL or SPECIFIC 10. If the unit does not contain an indicator
GRAVITY setting. assembly, go to the Startup section. If the unit
4. Set the process variable to the minimum value of contains an indicator assembly, change the pointer
the input range as shown in table 5. For span by loosening the indicator plate screws (key
constructions with an indicator assembly, make sure 41, figure 16, detail of indicator assembly), slide the
that the pointer is over the LOW mark. plate until the HIGH mark is under the pointer.
Tighten the plate screws and go to the Startup
section.
Note
In the following step, the alignment Note
screw (key 33, figure 16) must always Any sliding of the level set arm (key
remain screwed in far enough to 28, figure 16) in the following step
provide spring tension on the changes the zero as well as the output
underside of the alignment screw pressure span.
head.
11. To adjust the output pressure span, loosen the
5. Adjust the flapper (key 32, figure 16) to obtain the two level set mounting screws (see figure 16) and
appropriate pressure listed below. For coarse flapper slide the flexure strip base (key 27) right or left along
adjustment, loosen the hex nut (key 40, figure 16) the elongated slotted hole as follows:
and rotate the flapper assembly about the torque
tube shaft. For fine flapper adjustment, turn the D To increase the output pressure span, slide
flapper alignment screw (key 33, figure 16). the flexure strip base away from the torque tube
shaft.
D For Direct Acting Type 2500, 2500T, 0.2 bar
(3 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output or D To decrease the output pressure span, slide
0.4 bar (6 psig) for a 0.4 to 2.0 bar (6 to 30 psig) the flexure strip base toward the torque tube shaft.
output.
Retighten the screws. If the flexure strip base has
D For Reverse Acting Type 2500, 2500T, 1.0 been moved as far as possible and the output
bar (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output pressure span is still too large or too small, proceed
or 2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig) to step 13.
output. 12. Repeat the procedure from step 4 until the
6. Visually examine the nozzle and flapper to required calibration points are obtained.
ensure the nozzle is as square as possible with the
flapper. The nozzle can be realigned by loosening Note
the Bourdon tube mounting screws (key 45, figure
16) and rotating the Bourdon tube slightly. If the Any change of the PROPORTIONAL
nozzle is realigned, tighten the mounting screws and BAND or SPECIFIC GRAVITY
repeat step 5. adjustment in the following step
changes the zero as well as the output
7. Set the process variable to the maximum value of pressure span.
the input range as shown in table 5.
13. If the flexure strip base has been moved as far
8. The output pressure should be: as possible and the output pressure span is still too
18
Instruction Manual
Form 1013
large or too small, slightly adjust the 5. Be sure the flapper is centered over the nozzle. If
PROPORTIONAL BAND or SPECIFIC GRAVITY not, loosen the hex nut (key 40, figure 16) and
adjustment as follows: reposition the flapper, tighten the hex nut.
D If the output pressure span is too large, slightly 6. Adjust the flapper (key 32, figure 16) as
increase the PROPORTIONAL BAND or SPECIFIC described below. For coarse flapper adjustment,
GRAVITY setting. loosen the hex nut (key 40, figure 16) and rotate the
flapper assembly about the torque tube shaft. For
D If the output pressure span is too small, slightly fine flapper adjustment, turn the flapper alignment
decrease the PROPORTIONAL BAND or SPECIFIC screw (key 33, figure 16).
GRAVITY setting. D For Direct Acting Controllers, move the
14. Repeat the procedure from step 4 until the flapper toward the nozzle until the output pressure
required calibration points are obtained. switches to full supply pressure, then carefully adjust
the flapper away from the nozzle until the output
pressure switches to 0 bar (0 psig).
Note
D For Reverse Acting Controllers, move the
If you cannot calibrate the controller or flapper away from the nozzle until the output
transmitter, look for other problems as pressure switches to 0 bar (0 psig), then carefully
described in the Troubleshooting adjust the flapper toward the nozzle until the output
procedures, such as leaking pressure switches to full supply pressure.
connections, or a binding displacer
rod. If none of these troubles are 7. Slowly increase the process variable until the
apparent, ensure that the displacer is output pressure switches:
sized correctly for the application.
D For Direct Acting Controllers, slowly increase
the process variable until the output pressure
Type 2500S and 2503 Controllers switches to full supply pressure. The process
1. Turn on the supply pressure and check that it is variable should be at the maximum value of input
set according to the appropriate prestartup checks range as shown in table 5. If the process variable
procedure. agrees with table 5, proceed with step 8. If the
process variable does not agree with table 5,
2. Make sure that the PROPORTIONAL BAND proceed to step 9.
adjustment (Type 2500S only) is at the setting
determined according to the appropriate prestartup
D For Reverse Acting Controllers, slowly
check procedure.
increase the process variable until the output
3. Perform one or the other of the following: pressure switches to 0 bar (0 psig). The process
variable should be at the maximum value of input
D For direct acting controllers, set the RAISE range as shown in table 5. If the process variable
LEVEL adjustment between 1.0 and 1.5. agrees with table 5, proceed with step 8. If the
process variable does not agree with table 5,
D For reverse acting controllers, set the RAISE proceed to step 9.
LEVEL adjustment between 3.5 and 4.0.
8. If the unit does not contain an indicator assembly,
4. Set the process variable at the minimum value of go to the startup section. If the unit contains an
the input range as shown in table 5. For indicator assembly, change the pointer span by
constructions with an indicator assembly, make sure loosening the indicator plate screws (key 41, figure
that the pointer is over the LOW mark. 16, indicator assembly detail), slide the plate until
the HIGH mark is under the pointer. Tighten the
plate screws and go to the startup section.
Note
In the following step, the alignment Note
screw (key 33, figure 16) must always
remain screwed in far enough to Any sliding of the level set arm (key
provide spring tension on the 28, figure 16) in the following step
underside of the alignment screw changes the zero as well as the
head. differential gap.
19
Instruction Manual
Form 1013
9. To adjust the differential gap, loosen the two level Startup

set mounting screws (see figure 16) and slide the
flexure strip base (key 27) right or left along the Adjustment locations are shown in figure 10. The
elongated slotted hole as follows: pre-startup or calibration procedures must be
completed prior to startup.
D To decrease the differential gap, slide the
flexure strip base away from the torque tube shaft.
Type 2500 Controller
1. Slowly open the upstream and downstream
D To increase the differential gap, slide the manual control valves in the pipeline. If the pipeline
flexure strip base toward the torque tube shaft. has a bypass valve, close the valve.
2. If desired, adjust the proportional band to the
Retighten the screws. For the Type 2500S only, if narrowest (lowest) setting that maintains stable
the flexure strip base has been moved as far as control. Proportional band adjustments will affect the
possible and the differential gap is still too low, process level and may require a level adjustment. If
proceed to step 11. adjusting proportional band, make the adjustments
in small increments.
10. Repeat the procedure from step 4 until the
3. To confirm the optimum proportional band
required calibration points are obtained.
setting, momentarily create a load upset. If cycling
occurs, broaden (increase) the proportional band
until process oscillations diminish rapidly. In general,
Note the narrowest proportional band that does not
produce cycling provides the best control.
Any change in the PROPORTIONAL
BAND adjustment in the following step
changes the zero as well as the Type 2500T Transmitter
differential gap. 1. Make sure that the SPECIFIC GRAVITY and
ZERO ADJUSTMENT controls are set according to
11. If the flexure strip base has been moved as far the Type 2500 Controller or 2500T Transmitter
as possible and the differential gap is still too large portion of the pre-startup checks procedures.
or too small, adjust the PROPORTIONAL BAND as
follows: 2. Slowly open the upstream and downstream
manual control valves in the pipeline. If the pipeline
has a manual bypass valve, close the valve.
D If the differential gap is too large, slightly
decrease the PROPORTIONAL BAND setting.
Type 2500S Controller
D If the differential gap is too small, slightly 1. Set the switching points according to the Type
increase the PROPORTIONAL BAND setting. 2500S Controller portion of the prestartup checks
procedures.
12. Repeat the procedure from step 4 until the 2. Slowly open the upstream and downstream
required calibration points are obtained. manual control valves in the pipeline. If the pipeline
has a manual bypass valve, close the valve.
3. If necessary, the proportional band may be
Note adjusted to increase or decrease the differential gap.
Adjust the RAISE LEVEL adjustment to reposition
If you cannot calibrate the controller, the differential gap. After readjustment, confirm the
look for other problems as described controller is still switching correctly at both switching
in the Troubleshooting procedures, points.
such as a nozzle that is not
perpendicular to the flapper, leaky
connections, or a binding displacer Type 2503 Controller
rod. If none of these troubles are 1. Set the switching points according to the Type
apparent, ensure the displacer is sized 2503 Controller portion of the prestartup checks
correctly for the application. procedures.
20
Instruction Manual
Form 1013
2. Slowly open the upstream and downstream nozzle. If the process level change increases nozzle
manual control valves in the pipeline. If the pipeline pressure, the large diaphragm moves down; this
has a manual bypass valve, close the valve. closes the exhaust end and opens the inlet end of
the relay valve (see figure 12). This action of the
3. If necessary, reposition the switching points by
relay valve increases the output pressure to the final
adjusting the RAISE LEVEL control. For example, if
control element. Since the area ratio of the large
the differential gap is set for 102 mm (4-inches) of
diaphragm to the small diaphragm is three-to-one,
level change, this 102 mm (4-inches) can be set
the small diaphragm action amplifies the output
anywhere within the length of the displacer. After
pressure change. The three-way proportional valve
readjustment, confirm the controller is still switching
lets the increase in output pressure apply to the
correctly at both switching points.
Bourdon tube outer channel. The expansion of the
Bourdon tube moves the nozzle away from the
flapper slowing the response of the pneumatic
circuit.
Principle of Operation If the process level change decreases the nozzle
pressure, the large diaphragm moves up. This action
The controller/transmitter receives the change in
closes the inlet end and opens the exhaust end of
fluid level, fluid-to-fluid interface level, or density
the relay valve which allows output pressure to
from the change in the buoyant force the fluid exerts
exhaust. This relay valve action reduces the output
on the sensor displacer. The displacer, through a
pressure to the final control element and is the
mechanical linkage, imparts a rotary motion to the
reverse of the previous explanation.
torque tube shaft. This rotary motion positions the
flapper according to the level position of the The proportional valve varies the reaction of the
displacer; the nozzle/Bourdon tube arrangement Bourdon tube to changes in the output pressure. For
sends a pneumatic signal to the relay valve. additional information on the proportional valve
action, refer to the following proportional valve
All 2500 and 2503 Series controller/transmitters use subsection.
the same basic pressure-balanced relay assembly.
The following descriptions explain how the relay
action produces the output signal with the various Proportional Valve
controller/transmitter constructions.
The three-way proportional valve is adjustable to
allow some or all of the output pressure change to
feed back to the Bourdon tube outer channel,
Type 2500 Controller or 2500T providing proportional band control (see figure 12).
Transmitter The Bourdon tube moves to counteract the pressure
Full supply pressure comes to the relay from the changes in the nozzle, equaling the relay diaphragm
regulator, as shown in figure 12. The relay has a pressure differential. The relay valve maintains a
fixed restriction through which supply pressure new output pressure according to the change in the
bleeds before entering the large diaphragm area and process variable.
the inner Bourdon tube channel. In a steady-state
A wide-open proportional valve (fully
condition, the process level holds the torque tube
counterclockwise) permits feedback of the output
and attached flapper steady in relation to the nozzle.
pressure signal change and produces 100 percent
This allows pressure to escape between the nozzle
proportional response. A closed (fully clockwise)
and flapper at the same rate it bleeds into the large
proportional valve produces smaller proportional
diaphragm area. The large diaphragm holds the inlet
responses, because part of the output pressure
end of the relay valve slightly open to compensate
change vents through the proportional valve
for the venting of output pressure through the
exhaust.
proportional valve as it maintains a steady-state
position of the final control element. The output
pressure, through the three-way proportional valve,
affects the Bourdon tube outer channel, holding the Type 2500S Controller
Bourdon tube in a steady-state position. This construction has the same flapper, relay, and
proportional valve as the Type 2500 controller.
A process level change raises or lowers the However, the nozzle is connected (figure 12) in such
displacer, moving the flapper with respect to the a way that output pressure feedback (from the
21
Instruction Manual
Form 1013
CD2114-E
BO998-1/IL
Figure 12. Direct-Acting, Right-Hand-Mounted 2500-249 Series Controller/Transmitter
movement of the Bourdon tube) moves the nozzle in Type 2503 Controller
the opposite direction of the flapper. This action
This construction has the same flapper and sensor
completely opens the relay valve for full output
arrangement as the Type 2500 controller, but its
pressure or completely closes the relay valve for full
Bourdon tube has a three way valve operated by a
exhaust of the output pressure, allowing no
plunger (see figure 13). Note that the switch point
in-between throttling.
adjustment changes the position of the moveable
22
Instruction Manual
Form 1013
BD4466-A
CD2114-E
A1890-1/IL
Figure 13. Direct-Acting Left-Hand-Mounted Type 2503 Controller
arm and attached Bourdon tube assembly; this in seal the inner Bourdon tube channel (see figure 13).
turn changes the switch point in relationship to the This decrease in the loading pressure moves the
process level. The differential gap of the 2503 either Bourdon tube toward the flapper, producing the snap
completely opens the relay valve for full output action. Also, this decrease in loading pressure
pressure or completely closes the relay valve for full allows relay spring pressure to move the large
exhaust of the output pressure, allowing no diaphragm up, closing the inlet end and opening the
in-between throttling. exhaust end of the relay valve, allowing full exhaust
of the output pressure. This control action continues
For a direct-acting controller, as long as the process until a sensor level change moves the flapper away
variable remains above the switch point, the flapper from the plunger, permitting the Bourdon tube valve
does not depress the plunger of the Bourdon tube to close, restoring loading pressure to the pneumatic
valve. In this condition, the Bourdon tube valve circuit. Reverse-acting controllers produce the
remains closed, providing full loading pressure to the opposite effect.
Bourdon tube. This loading pressure moves the
Bourdon tube away from the flapper. Also, in this
condition, full loading pressure is on the upper
diaphragm of the relay. The loading pressure moves
the diaphragm down, closing the exhaust end and
opening the inlet end of the relay valve, allowing full Maintenance
output pressure.
The 2500 and 2503 Series controllers/transmitters
When the process level sufficiently decreases, the work in combination with 249 Series displacers.
flapper pushes in the plunger of the Bourdon tube Refer to figure 16 for key number locations, unless
valve enough to release the loading pressure and otherwise indicated.
23
Instruction Manual
Form 1013
device if continuous operation is

WARNING required during maintenance.
1. Disconnect the supply and output pressure tubing
Always wear protective clothing and from the controller or transmitter. For a
eyewear when performing any controller/transmitter with an indicator, remove the
maintenance operations to avoid pointer assembly by referring to the Replacing the
personal injury. Bourdon Tube section.
When replacing the sensor assembly, 2. Loosen the top hex clamp nut (key 40, figure 16)
the displacer may retain process fluid and remove the flapper base (key 30, figure 16) from
or pressure. Personal injury or the torque tube rotary shaft.
property damage may occur due to
sudden release of the pressure.
Contact with hazardous fluid, fire, or CAUTION
explosion can be caused by
puncturing, heating, or repairing a If the hex clamp nut has not been
displacer that is retaining process loosened or the pointer removed
pressure or fluid. This danger may not according to step 2, attempting to
be readily apparent when remove the controller/transmitter from
disassembling the sensor assembly or the sensor may bend the flapper or
removing the displacer. Before rotary shaft. Be careful that the back of
disassembling the sensor or removing the controller/transmitter case or the
the displacer, observe the more heat insulator does not drop down and
specific warning provided in the bend the rotary shaft or shaft
sensor instruction manual. extension.
Check with your process or safety 3. Remove any insulating tape from the joint
engineer for any additional measures between the controller/transmitter case and the
that must be taken to protect against torque tube arm. Remove the four cap screws (key
process media. 39, figure 14) that hold the controller/transmitter or
heat insulator to the torque tube arm. Pull the case
straight out from the torque tube arm, easing it over
Troubleshooting the shaft coupling (key 36, figure 14) if one is
installed.
When troubleshooting, open loop conditions must
exist unless otherwise stated. When monitoring the 4. If the controller/transmitter has a heat insulator,
process variable, use the most accurate level remove the four button head cap screws and
indicating device available. The output signal washers (keys 40 and 53, figure 14) and remove the
measuring device should have corresponding insulator assembly.
accuracy.
Changing Mounting Methods
Table 6 lists some common operating faults, their
probable causes, and corrective action.
WARNING
Removing Controller/Transmitter from To avoid personal injury from contact
Sensor with the process fluid, lower the vessel
fluid level below the torque-tube arm
before proceeding. For closed vessels,
WARNING release any pressure that may be
above the fluid. Also, be careful to
To avoid injury in the following steps, avoid overloading a thin-wall torque
turn off the supply pressure and tube with an overweight displacer.
carefully release any pressure trapped Refer to figure 16 for key number locations.
in the controller/transmitter before
breaking any pressure connection. 1. Remove the controller/transmitter as described
Provide a bypass for the control previously.
24
Instruction Manual
Form 1013
Table 6. Troubleshooting Chart for 2500 Series Controller/Transmitters
FAULT POSSIBLE CAUSE CHECK CORRECTION
1. Process wanders or cycles 1.1 Proportional band or specific Ensure the prestartup procedures If stable control cannot be attained
around set point. gravity adjustment incorrect or are completed correctly. Tune 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 Use input pressure gauge to Apply correct supply pressure.
incorrect supply pressure setting. monitor stability. Make sure Use one regulator per instrument.
regulator IN supply pressure is
within limits.
1.3 Sensor not plumb and is in Check cage vessel and stillwell Make sure the displacer and
contact with sidewall or leak in installation, or for leaking displacer rod hangs freely. Make
displacer. displacer. sure linkage is tight. Replace
displacer if leaking.
1.4 Relay malfunction. Check for relay malfunction by Depress plunger to clean out the
using the testing relay deadband fixed restriction. Replace relay
procedure. using the procedure in the
2. Controller/transmitter 2.1 Supply pressure not set Make sure regulator supply Reset the supply regulator
controlling off set point or correctly. pressure is set correctly. Make pressure. If the condition occurs
switching point. sure regulator IN supply pressure again, rebuild or replace regulator.
is within limits. Provide a regulator input pressure
within regulator limits.
2.2 Leak in the Use soap and water to check for Replace or repair leaking parts as
controller/transmitter loop. internal and external leaks. necessary.
2.3 Leaking displacer. Ensure the displacer is not filling Refer to sensor maintenance
with process fluid. procedures in the appropriate
sensor instruction manual.
2.4 Flapper adjustment. Ensure the flapper is not loose on Replace or tighten flapper
the torque tube shaft and is assembly as necessary and/or
centered on the nozzle. center flapper on nozzle.
2.5 Process variable changed. Ensure the process variable has Change process variable back to
not changed from original original specification or
calibration settings, or displacer recalibrate. If necessary, provide
not designed for specific gravity of replacement displacer of correct
process. size and recalibrate.
3. Controller/transmitter cannot 3.1 Supply pressure not set Make sure supply pressure is set Reset the regulator pressure. If
attain full output range. correctly. correctly. Make sure regulator IN problem reoccurs, replace or
supply pressure is within limits. rebuild the regulator. Ensure
regulator IN supply pressure is
within limits at all operating levels.
3.3 Process variable changed. Ensure the process variable has Change process variable back to
not changed from original original specification or
calibration settings, or from recalibrate. If necessary, provide
displacers designed specific replacement displacer of correct
gravity. size and recalibrate.
3.4 Relay malfunction Check for relay malfunction by Depress plunger to clean out the
using the testing relay deadband fixed restriction. Replace relay
procedure. using the procedure in the
3.5 Leak in the Use soap and water to check for Replace or repair leaking parts as
controller/transmitter loop. internal and external leaks. necessary.
4. Controller/transmitter remains 4.1 Supply or output pressure Ensure the pressure gauges are Replace pressure gauges. Use
at full or zero output pressure. gauge malfunction. registering correctly. corrective action given in section 3
of this table.
25
Instruction Manual
Form 1013
indicator plate should point toward the displacer. If it

does not, remove the two screws (key 41, see detail
of indicator assembly in figure 16), turn the front
plate (key 54) to the side with the FLOAT arrow
pointing toward the displacer, and secure the plate
with the screws.
6. Install the controller/transmitter according to the
next section.
Installing Controller/Transmitter on
Sensor
Note
If the installation is in a location that is
not readily accessible and shop
calibration is required, remove the
torque tube arm from the cage or
vessel before installing the controller
or transmitter to the sensor. Install the
controller/transmitter on the torque
tube arm in the shop; then calibrate
and return the controller/transmitter
with the torque tube arm assembly
attached for installation.
Perform step 1 only if adding a heat
20A7423-C/DOC insulator to a unit that does not have
one. Key numbers in this step are
Figure 14. Heat Insulator for 249 Series Sensor shown in figure 14.
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
2. A controller/transmitter is attached to the sensor both set screws (key 38), with the coupling centered
in one of the mounting positions shown in figure 4. as shown in figure 14. Then mount the insulator
Right-hand mounting is with the controller/transmitter assembly (key 35) on the controller/transmitter case
case (key 1) to the right of the displacer (FLOAT), as with four button head cap screws and washers (keys
you look at the front of the case, left-hand mounting 40 and 53). Tighten the screws.
is with with the case to the left of the displacer. For a
249 Series sensor, remove the torque tube arm from
the sensor or vessel and reinstall the torque tube CAUTION
arm in the opposite position according to the
appropriate instruction manual. Note that the term In the following step, avoid bending
FLOAT is marked on the RAISE LEVEL dial and the the rotary shaft of the torque tube
indicator plate, if one is used. assembly. Bending or side loading of
this shaft could cause erroneous
3. Check the desired control action. If the control readings. Additionally, make sure the
action is not correct, refer to the changing action ball bearing assembly (key 12, figure
procedures to change it. Mount the Bourdon tube in
16) is removed from the case (key 1,
one of the positions shown in figure 15. figure 16) to provide clearance when
4. The arrow on the RAISE LEVEL dial under the installing the case on the sensor.
word FLOAT should point toward the displacer. If 2. Remove the bearing assembly (key 12, figure 16)
not, remove the dial from the controller, turn it over, from the case (key 1, figure 16).
and install it in the correct position.
3. Carefully slide the controller/transmitter case
5. For a controller/transmitter with an indicator straight in. Secure the case on the torque arm or
assembly, the arrow near the word FLOAT on the insulator with the four cap screws (key 39).
26
Instruction Manual
Form 1013
Note Changing Action
If a heat insulator is used, do not Note
insulate its exterior.
The following procedure is necessary
4. Slide the bearing assembly (key 12, figure 16) to restore previous action if the
onto the shaft or shaft extension of the insulator, and mounting method has been changed.
install the bearing assembly (key 12, figure 16) into Figure 16 shows key numbers.
the case (key 1, figure 16).
1. Reposition the Bourdon tube (and indicator
5. Install the flapper base (key 30, figure 16) on the assembly, if used) according to steps 1 through 4 of
torque tube rotary shaft, making sure the flapper is the Replacing the Bourdon Tube section.
centered over the nozzle or Bourdon tube valve.
Secure the base with the hex nut (key 40, figure 16). 2. Loosen the hex nut (key 40) and remove the
For a controller/transmitter with an indicator flapper base (key 30) from the torque tube rotary
assembly, install the pointer assembly according to shaft. Turn the flapper base over and install it on the
the Replacing the Bourdon Tube section. rotary shaft, using the proper orientation as shown in
figure 15 and making sure the flapper is centered
6. Connect the supply and output pressure tubing over the nozzle or Bourdon tube valve.
and perform the calibration procedure.
3. Perform the calibration procedure.
Replacing the Bourdon Tube

Refer to figure 16 for key number locations. Relay Deadband Testing (Type 2500
Controller or 2500T Transmitter Only)
1. Disconnect the tubing (key 10 for Type 2503 and
key 11 for Type 2500) from the Bourdon tube base. 1. Replace the appropriate (proportional or specific
For a controller/transmitter with indicator assembly, gravity) adjustment assembly with the 1/8-inch NPT
loosen the side hex clamp nut (key 40) and remove pipe plug according to the Replacing the
the pointer assembly (key 51) from the torque tube Proportional Valve section.
rotary shaft. 2. Turn on the supply pressure and set it to 1.4 to
2. Remove the mounting screws (key 45) and 2.4 bar (20 or 35 psig), depending on the
Bourdon tube assembly (key 16). controller/transmitter operating range.
3. Inspect the Bourdon tube. Replace it if 3. By changing the process variable and adjusting
necessary, using a tube with a black color code for a the RAISE LEVEL or ZERO ADJUSTMENT control,
0.2 to 1 bar or 0 to 1.4 bar (3 to 15 psig or 0 to 20 set the output pressure to 1.0 or 2.0 bar (15 or 30
psig) range. Use a tube with a red color code for a psig). While monitoring the output pressure, slowly
0.4 to 2 bar or 0 to 2.4 bar (6 to 30 psig or 0 to 35 change the process variable until the output
psig) range. The range is stamped at the Bourdon pressure just changes, and record the value of the
tube base. process variable at the detection point.
4. Mount the Bourdon tube on the level set arm (key 4. Change the process variable in the opposite
28). Secure it with the mounting screws, using the direction until the output pressure just changes and
proper orientation as shown in figure 15. Connect again record the value of the process variable. If the
the tubing to the tube base, with tubing from the R difference between the two recorded values (the
connection on the relay (key 34) going to the marked deadband) is more than 0.2% of the maximum
base connection. The other tubing goes to the displacer length, the relay must be replaced or
unmarked base connection. With an indicator repaired according to the Changing Relay section.
assembly, install the pointer assembly on the rotary 5. Turn off the supply pressure, remove the pipe
shaft and tighten the hex nut. plug, and install the appropriate adjustment
5. Perform the calibration procedure. assembly.
27
Instruction Manual
Form 1013
AC9554
AR8148
BO996-1/IL
Figure 15. Bourdon Tube-Flapper Arrangements for Various Actions and Mountings
Replacing the Proportional Valve 4. Replace the tubing (key 10) to the proportional
band valve assembly.
Note Changing Relay

The following procedure, to convert to The relay may be removed for cleaning or
or from the pipe plug or the desired replacement.
adjustment assembly, can be used for
any type number covered in this Removal
manual. 1. For a controller or transmitter with indicator
assembly, loosen the two lower relay screws (key
1. Remove the tubing (key 10) from the proportional
96) and slide out the indicator base plate (key 53).
band valve assembly.
2. Disconnect the tubing (key 10 or 11) from the
2. Unscrew the base of the PROPORTIONAL relay.
BAND or SPECIFIC GRAVITY adjustment assembly
3. Remove both mounting screws, relay, and relay
(key 36 or 90, figure 16), or the 1/8-inch NPT pipe
gasket (keys 43, 34, and 22).
plug (key 73, not shown), from the relay base (key
23, figure 16). Replacement
3. Install the pipe plug or the desired adjustment 1. Install a new gasket (key 22), the replacement
assembly into the relay base. relay (key 34), and secure with two mounting screws
28
Instruction Manual
Form 1013
(key 43). On a controller or transmitter with an Parts List
indicator assembly, slide the base plate under the
two lower screws of the relay case, align the plate so Description Part Number
the pointer will read properly, and tighten the screws.
Controller Parts Kits
2. Connect the tubing (key 10 or 11) to the relay. Type 2500 Controller Repair Kits
Contains keys 12, 15, 21, 24, 38, and
3. Test the relay deadband, according to the Relay the flapper assembly
Deadband Testing procedure in this section. Standard temperature R2500X00L32
High temperature R2500X00H32
4. If the deadband is within tolerance, go to the
Type 2503 Controller Repair Kit
Calibration section.
Standard temperature only
The kit contains
keys 12, 21, 22, 24, 38, and the
flapper assembly. R2503X00022
Relay Replacement Kit

Contains keys 22, 43, and the relay assembly
Standard temperature RRELAYX0L22
High temperature RRELAYX0H22
Parts Ordering
Heat Insulator Retrofit Kit
Whenever corresponding with your Fisher sales Contains the heat insulator parts shown
office about this equipment, use the in figure 14 and listed under Heat
controller/transmitter type number and the serial Insulator in this parts list R2500XH0012
number. The serial number is found on the
nameplate (key 215, figure 16). When ordering Common Controller/Transmitter Parts
replacement parts, also state the complete
11-character part number of each part required as (figure 16)
found in the following parts list. Key Description Part Number
1 Case back 57A0953X012
2 Case cover, aluminum 50B9454X012
3 Door handle, pl steel 1C897225082
4 Door handle shaft (not shown), brass 1C898414012
Note 5 Machine screw, steel 1C8958X0022
6 Spring washer, stainless steel 1C897036032
7 Door hook, pl steel 1C897125082
Use only genuine Fisher replacement
8 Stop nut, pl steel 1C8959X0012
parts. Components that are not 9 Drive-lock pin, (2 reqd) 1C8991X0022
supplied by Fisher should not, under 10 Tubing assembly, stainless steel
any circumstances, be used in any For all 2500 Series except Type 2503 1N7983X0012
Fisher instrument. Use of components For Type 2503 only 1H3093X0012
not supplied by Fisher will void your 11 Relay tubing, stainless steel 1N7984X0012
warranty, might adversely affect the 12 Ball bearing assembly, Brass, pl 1C8983000A2
performance of the instrument, and 13 Retaining ring, pl steel (2 reqd) 1A465828992
might jeopardize worker and 14 Gauge glass (2 reqd) 0T019206042
workplace safety. 15 Gauge glass gasket, neoprene (2 reqd) 0T019104082
16* Bourdon tube assembly,
Brass
Type 2500 and 2500T
Note 3 to 15 psig 32B1231X012
6 to 30 psig 32B1231X022
Type 2500S
Neither Emerson, Emerson Process 0 to 20 psig 32B1233X012
Management, nor Fisher assume 0 to 35 psig 32B1233X022
responsibility for the selection, use, or Type 2503
maintenance of any product. 0 to 20 psig 32B1234X012
0 to 35 psig 32B1234X022
Responsibility for the selection, use,
Stainless steel
and maintenance of any Fisher Type 2500 and 2500T
product remains with the purchaser 3 to 15 psig 32B1232X032
and end-user. 6 to 30 psig 32B1232X042
*Recommended spare parts 29

Instruction Manual
Form 1013
LEVEL SET MOUNTING SCREWS SEE VIEW A
30A8865-D/DOC
TYPICAL CONTROLLER
30A8866-C/DOC
TYPE 2503R CONTROLLER

CONSTRUCTION
30A8869-D/DOC
NOTE:
PARTS NOT SHOWN 4, 24, 38, 39, 47, AND 48. DETAIL OF INDICATOR
ASSEMBLY ON C VERSIONS
Figure 16. 2500 Series Controller / Transmitter Constructions
30
Instruction Manual
Form 1013
Key Description Part Number Key Description Part Number
19* Triple scale gauge (2 reqd) 37 Type 67FR regulator
Brass 38A* Filter gasket (not shown)
0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8577X012 Standard temperature, neoprene 1C898603012
0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8577X022 High temperature, silicon 1N874004142
Stainless steel 38B Spacer, aluminum (not shown) T21043T0012
0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B8583X012 38C* O-ring (not shown)
0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B8583X022 Standard temperature, nitrile 1E591406992
19* Dual scale gauge (2 reqd) High temperature, fluoroelastomer 1E5914X0062
Brass 39 Cap screw (not shown), pl steel (2 reqd) 1C197024052
0 to 30 psig / 0 to 2 kg/cm2 11B8577X042 40 Hex nut, pl steel
0 to 60 psig / 0 to 4 kg/cm2 11B8577X052 (2 reqd for C versions, 1 reqd for all others) 1L286338992
Stainless steel 41 Screw, pl steel
0 to 30 psig / 0 to 2 kg/cm2 11B8583X032 (2 reqd for C versions only) 16A6938X022
21* Cover gasket, nitrile 1C919806342 42 Machine screw, pl steel (8 reqd) 1V7435X0022
22* Relay gasket 43 Machine screw, pl steel (2 reqd) 1A3776X0012
Standard temperature, neoprene 1C897403012 44 Machine screw, pl steel (6 reqd) 1A5733X0012
High temperature, silicon 1N873804142 45 Machine Screw, pl steel (2 reqd) 1H1581X0012
23 Relay base 47A0950X012 46 Machine Screw, pl steel (4 reqd) 1C8990X0012
24* Relay base gasket (not shown)
Standard temperature, neoprene 1C897303012 47 Spring (not shown), stainless steel 1J423437022
High temperature, silicon 1N873904142 48 Cap screw, pl steel (4 reqd) 1A3816K0012
25 Flexure strip, stainless steel, 1C897836012 49 Machine screw, pl steel (13 reqd) 1B7839X0012
50 Screen, alloy 400 0L078343062
26 Flexure strip nut, pl steel (2 reqd) 1C897525082 51 Pointer assembly (C versions only),
27 Flexure strip base, pl steel 1C897725082 Stainless steel/brass, pl 1E8735000A2
28 Level set arm, pl steel 1C897625082
29 Drivelok pin, pl steel 1C8989X0012 52 Washer (C versions only), steel (2 reqd) 1E8730X0012
30 Flapper base, brass, pl 1C926114022 53 Base plate (C versions only), aluminum 1E873111992
31 Shaft clamp screw, SST 54 Front plate (C versions only), aluminum 1E873211992
(2 reqd for C version only, 1 reqd for all others)1B451435172 73 Pipe plug (Type 2503 only), brass (not shown) 1A621914012
90 Specific gravity adjustment assembly
32 Flapper, stainless steel 1C926238992 Standard and high temperature 10A8870X0A2
33 Alignment screw, brass, pl 1B451714022 Corrosive service 10A8870X022
34 Relay assembly 215 Nameplate - - - - - - - -
For all 2500 Series except Type 2503
Standard temperature 22B0463X012
High temperature 22B0462X012
Corrosive service 22B0463X032
Type 2503 only
Standard temperature 32B0464X012 Heat Insulator (figure 14)
High temperature 32B0465X012 35 Heat Insulator Assembly, stainless steel 22A0033X012
36 Shaft Coupling, stainless steel 1A577935032
35 Level adjustment assembly (controllers only) 10A8939X0A2 37 Shaft extension, alloy K500 1B681540022
35 Zero adjustment assembly (transmitters only) 10A8939X0C2 38 Set screw, stainless steel (2 reqd) 1E6234X0022
36 Proportional band adjustment assembly
(except transmitters and Type 2503 controllers, see key 90) 39 Cap screw, pl steel (4 reqd) 1A381624052
Standard and high temperature 10A9122X032 40 Cap screw, pl steel (4 reqd) 1V239528982
Corrosive service 10A9122X122 53 Washer, carbon steel, pl (4 reqd) 1B865928982
*Recommended spare parts 31

Instruction Manual
Form 1013
Level-Trol and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of
Emerson Electric Co. The Emerson logo is a trademark and service mark 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.
We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Neither Emerson, Emerson Process Management not Fisher assume responsibility for the selection, use or maintenance of any product. Responsibility
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Fisher
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Manual 2500

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Instruction Manual

2500 and 2503 Series Level-TrolR Controllers

Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 1. 2500 or 2503 Series Level-TrolR Controller/

Contents (Continued) Description

Scope of Manual Educational Services

Available Configurations(1) Steady-State Air Consumption

Table 1. Specifications (Continued)

Ambient Operating Temperature Limits(6) Hazardous Area Classification

Table 2. Standard Displacer Volumes

Table 3. Supply Pressure Data

Figure 2. Guidelines for Use of Optional Heat Insulator Assembly

Sensor Assembly Uncrating

Sensors used for interface or density

Figure 3. Damping Plate Location

(see figure 3) to provide more stable operation. Be

damping plate are not plugged by foreign material.

A cageless sensor comes with its displacer

Controller/Transmitter Orientation Mounting Caged Sensor

Figure 6. Caged Sensor Mounting

diameter or larger port should be installed in each of

Cage connections normally are either 1-1/2 or

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

Figure 7. Cageless Sensor Mounting

Note temperature-compensated displacer or

W0229-1A/IL W0228-1A/IL DISPLACER ROD

TYPE 249V ALL OTHER TYPES

Figure 8. Displacer and Displacer Rod Connections

Supply and Output Pressure

OPTIONAL HEAT Standard S7.3. Use a suitable supply pressure

255.5 If operating the controller or transmitter from a high

Supply Pressure Prestartup Checks

BOURDON TUBE DETAIL OF

LEVEL SET ARM 3 - WAY VALVE

DETAIL OF TRANSMITTER INDICATOR ASSEMBLY WITH TRAVEL INDICATOR PLATE

Figure 10. Adjustment Locations

marked on both sides with an arrow. The arrow

On a controller or transmitter with an optional

3. On a controller with a mechanical indicator gap can be varied from approximately

Dry Calibration Additionally, a threaded rod may be

0.0361 = Weight of one cubic inch of water Calibration Procedure

9. To adjust the differential gap, loosen the two level Startup

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

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

device if continuous operation is

indicator plate should point toward the displacer. If it

Replacing the Bourdon Tube

Note Changing Relay

Relay Replacement Kit

*Recommended spare parts 29

LEVEL SET MOUNTING SCREWS SEE VIEW A

TYPE 2503R CONTROLLER

*Recommended spare parts 31

Emerson Process Management

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