546 Transducer Instruction Manual D200108X012 October 2011 Fisher� 546 Electro‐Pneumatic Transducer Figure 1. Fisher 546 Electro‐Pneumatic Transducer Contents Mounted on a 657 Pneumatic Diaphragm Actuator Introduction ................................. 1 Scope of Manual ............................. 1 Description ................................. 3 Specifications ............................... 4 Educational Services ......................... 4 Installation .................................. 5 Mounting .................................. 5 Pressure Connections ........................ 5 Diagnostic Connections ...................... 6 Electrical Connections ........................ 6 FILTER Operating Information ......................... 7 REGULATOR Adjustments ................................ 8 Calibration ................................. 8 546 Equipment Required ...................... 8 Calibration Procedure ..................... 9 Recalibration ........................... 10 Changing Output Pressure Range ............. 10 Reversing the Action ........................ 10 Split Range Operation ....................... 11 Principle of Operation ........................ 11 Maintenance ................................ 13 W2115 Relay Removal and Replacement .............. 14 Replacing the Feedback Bellows Assembly ...... 14 Troubleshooting ............................ 14 Electrical .............................. 14 Parts Ordering ............................... 16 Pneumatic ............................. 15 Parts List ................................... 17 Alignment ................................. 15 Repair Kits ................................. 17 Span Adjustment ....................... 15 Transducers ............................... 17 Torque Motor Frame .................... 16 Torque Motor .............................. 18 Armature Travel Stop .................... 16 Mounting Parts ............................. 20 Coil ................................... 16 Diagnostic Connections ..................... 22 Introduction Scope of Manual This instruction manual provides installation, operation, maintenance, and parts ordering information for Fisher 546 transducers and the 82 relay. Refer to separate manuals for instructions covering equipment used with the transducer. Do not install, operate or maintain a 546 transducer without being fully trained and qualified in valve, actuator and accessory installation, operation and maintenance. To avoid personal injury or property damage it is important to carefully read, understand, and follow all of the contents of this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson Process Management sales office before proceeding. www.Fisher.com 546 Transducer Instruction Manual October 2011 D200108X012 Table 1. Specifications (3) Available Configurations Performance Electro‐pneumatic signal transducer with Actuator Loading Time: See figure 7 explosion‐proof case and cover Reference Accuracy: ±0.75% of output signal span Independent Linearity: ±0.50% of output signal span The 546 can be ordered with or without a Fisher 67 Open Loop Gain: 26 filter regulator. A 51 mm (2 inch) circular supply Frequency Response: Gain is attenuated 3 dB at 20 Hz pressure gauge may be mounted on the regulator. with transducer output signal piped to a typical instrument bellows with 305 mm (12 inches) of 1/4 Input Signals inch tubing Electromagnetic Interference (EMI): Tested per IEC � 4 to 20 mA DC, � 10 to 50 mA DC, � 1 to 9 VDC, 61326‐1 (Edition 1.1). Meets emission levels for Class or � two‐way split range using any half of one of the A equipment (industrial locations) and Class B standard input signal spans equipment (domestic locations). Meets immunity requirements for industrial locations (Table A.1 in the Internal Resistance of Torque Motor IEC specification document). Immunity performance shown in table 2. 4 to 20 mA DC Input Signal: 176 ±10 ohms 10 to 50 mA DC Input Signal: 90 ±10 ohms (1) Operative Ambient Temperature Limits 1 to 9 VDC Input Signal: 1300 ±50 ohms (temperature‐compensated circuit) -40 to 66�C (-40 to +150�F) Output Signals Electrical Classification Ranges: Hazardous Area: 0.2 to 1.0 bar (3 to 15 psig), 0.4 to 2.0 bar (6 to 30 CSA—Explosion-proof, Dust Ignition‐proof, Div 2 psig), 0 to 1.2 bar (0 to 18 psig), or 0 to 2.3 bar (0 to FM—Explosion‐proof, Non‐incendive 33 psig) Action: The 546 is field‐reversible between direct and Refer to tables 3 and 4, and figure 2 for specific reverse action. approval information. NEMA 3R, CSA enclosure 3 (1) Supply Pressure NEMA 3R mounting orientation requires vent location Recommended: 0.3 bar (5 psig) higher than upper to be below horizontal. Vent is shown in figure 10, range limit of output signal key 69. Maximum: 3.5 bar (50 psig) Adjustments (2) Maximum Steady‐State Air Consumption Zero and Span Adjustments: Screwdriver adjustments At 1.4 bar (20 psig) Supply Pressure: 0.6 normal located inside case (see figure 5) 3 m /hr (21 scfh) At 2.4 bar (35 psig) Supply Pressure: 0.8 normal Connections 3 m /hr (30 scfh) Supply Pressure: 1/4 NPT internal located on side of case, (or located on the 67CFR filter‐regulator if (2) Maximum Output Air Capacity mounted) At 1.4 bar (20 psig) Supply Pressure: 12.9 normal Output Pressure: 1/4 NPT internal located on side of 3 m /hr (480 scfh) case At 2.4 bar (35 psig) Supply Pressure: 18.5 normal Vent: 1/4 NPT internal with screen located on relay 3 m /hr (690 scfh) Electrical: 1/2 NPT internal located on bottom of case -continued- 2 546 Transducer Instruction Manual D200108X012 October 2011 Table 1. Specifications (continued) Approximate Weight 3 of the Pressure Equipment Directive (PED) 97 / 23 / EC. It was designed and manufactured in accordance 4.1 kg (9 pounds) with Sound Engineering Practice (SEP) and cannot bear the CE marking related to PED compliance. Declaration of SEP However, the product may bear the CE marking to Fisher Controls International LLC declares this indicate compliance with other applicable European product to be in compliance with Article 3 paragraph Community Directives. NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology. 1. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded. 3 2. Normal m /hr—Normal cubic meters per hour (0�C and 1.01325 bar absolute). Scfh—Standard cubic feet per hour (60�F and 14.7 psia). 3. Performance values are obtained using a 546 transducer with a 4 to 20 mA DC input signal and a 0.2 to 1 bar (3 to 15 psig) or a 0.4 to 2 bar (6 to 30 psig) output signal. Ambient temperature is 24�C (73�F). A transducer with other input or output signals might exceed these values. Reference accuracies of ±3.5% can be expected with output ranges starting near zero psig. Table 2. Electromagnetic Immunity Performance (1) Port Phenomenon Basic Standard Test Level Performance Criteria 4 kV contact Electrostatic discharge (ESD) IEC 61000‐4‐2 A 8 kV air Enclosure 80 to 1000 MHz @ 10V/m with 1 Radiated EM field IEC 61000‐4‐3 A kHz AM at 80% Rated power frequency magnetic field IEC 61000‐4‐8 60 A/m at 50 Hz A Burst (fast transients) IEC 61000‐4‐4 1 kV A Surge IEC 61000‐4‐5 1 kV (line to ground only, each) B I/O signal/control 150 kHz to 80 MHz at 3 Vrms with Conducted RF IEC 61000‐4‐6 A 1kHz AM at 80% Specification limit = ±1% of span 1. A=No degradation during testing. B = Temporary degradation during testing, but is self‐recovering. Table 3. Hazardous Area Classifications—CSA (Canada) Certification Body Certification Obtained Entity Rating Temperature Code Enclosure Rating Explosion Proof - - - T5 (Tamb = 66�C) CSA ENC 3 Class I, Division 1, Group C,D CSA Class II, Division 1, Groups E,F,G Class I, Division 2, Groups A,B,C,D - - - T5 CSA ENC 3 Class II, Division 2, Groups F,G Table 4. Hazardous Area Classifications—FM (United States) Certification Body Certification Obtained Entity Rating Temperature Code Enclosure Rating Explosion Proof - - - T5 (Tamb = 60�C) NEMA 3R Class I, Division 1, Groups C,D FM Class II, Division 1, Groups E,F,G Class I, Division 2, Groups A,B,C,D - - - T5 NEMA 3R Class II, Division 2, Groups F,G Description The 546 transducer (figure 1) receives either a voltage (VDC) or a current (mA DC) input signal and transmits a proportional pneumatic output pressure to a final control element. A typical application is in electronic control loops where the final control element, generally a control valve, is pneumatically operated. The input signal and output pressure range of each transducer is indicated on the nameplate attached to the cover, as shown in figure 2. 3 546 Transducer Instruction Manual October 2011 D200108X012 Figure 2. FM and CSA Approvals Nameplate for Fisher 546 WARNING The 546 transducer does not meet third party approvals (CSA or FM) for use with natural gas as the supply medium. Use of natural gas as the supply medium can damage the instrument and result in personal injury or property damage from fire or explosion. The 546 does not meet third party approvals for use with natural gas. Should you need an instrument for use with natural gas, Fisher 846 and i2P‐100 transducers both meet third party approvals for use with natural gas as the supply medium. Contact your Emerson Process Management sales office for information on these products. Specifications Specifications are listed in table 1. Educational Services For information on available courses for 546 transducers, as well as a variety of other products, contact: Emerson Process Management Educational Services, Registration P.O. Box 190; 301 S. 1st Ave. Marshalltown, IA 50158-2823 Phone: 800-338-8158 or Phone: 641-754-3771 FAX: 641-754-3431 e‐mail: education@emerson.com 4 546 Transducer Instruction Manual D200108X012 October 2011 Installation WARNING Avoid personal injury from sudden release of process pressure. Before mounting the controller: � Always wear protective clothing, gloves, and eyewear when performing any installation operations to avoid personal injury. � Check with your process or safety engineer for any additional measures that must be taken to protect against process media. � If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual. Mounting When a 546 transducer is ordered as part of a control valve assembly, the factory mounts the transducer on the actuator and connects the necessary tubing, then adjusts the transducer as specified on the order. Transducers also can be ordered separately for mounting on a control valve assembly already in service. The transducer may be ordered with or without mounting parts. Mounting parts include the appropriate bracket and bolts for attaching the unit to an actuator boss (with tapped holes) or for attaching it to the diaphragm casing. If preferred, mounting parts are available for mounting the transducer on a 51 mm (2 inch) diameter pipestand, a flat surface, or a bulkhead. Tubing is not included if the transducer is not factory mounted. Use 9.5 mm (3/8‐inch) outside diameter tubing for all supply and output connections. Tubing length between the transducer output and the final control element should be as short as possible to minimize its effect on control loop stability. Pressure Connections WARNING Severe personal injury or property damage may occur if the instrument air supply is not clean, dry and oil‐free. While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications, check with an Emerson Process Management field office and industry instrument air quality standards for use with corrosive air or if you are unsure about the proper amount or method of air filtration or filter maintenance. Note The supply source must be clean, dry, oil‐free, non‐corrosive air at an unfailing pressure at least 0.3 bar (5 psig) higher than the upper limit of the transducer output pressure range. This means that for an output pressure range of 0.2 to 1.0 bar (3 to 15 psig) the supply pressure should be at least 1.4 bar (20 psig); for a 0.4 to 2.0 bar (6 to 30 psig) range, the supply pressure should be at least 2.4 bar (35 psig). The supply pressure to the filter regulator should not be more than 17.3 bar (250 psig) at a maximum temperature of 66�C (150�F). 5 546 Transducer Instruction Manual October 2011 D200108X012 If specified, the filter regulator is mounted on the transducer case. A pressure gauge on the regulator shows the supply pressure to the transducer. 1. Connect a supply pressure source to the 1/4 NPT IN connection on the filter regulator (if furnished) or to the 1/4 NPT SUPPLY connection on the transducer case (if a regulator is not furnished). 2. Run 9.5 mm (3/8‐inch) outside diameter tubing from the 1/4 NPT OUTPUT connection on the transducer case to the input connection on the pneumatic actuator or valve positioner. This connection is made at the factory if the unit is shipped mounted on an actuator as shown in figure 1. Diagnostic Connections To support diagnostic testing of valve/actuator/positioner packages, special connectors and hardware are available. Typical connector installations are shown in figure 3. The hardware used includes a 1/4 NPT pipe nipple and pipe tee with a 1/8 NPT pipe bushing for the connector. The connector consists of 1/8 NPT body and body protector. Note If the transducer is used in a valve assembly with a positioner, no connections for diagnostic testing are required for the transducer. Install the connections for diagnostic testing at the positioner. Figure 3. Diagnostic Connections SUPPLY PIPE NIPPLE (OUTPUT CONN) GAUGE PIPE TEE PIPE BUSHING STEM PROVIDED WHEN GAUGE IS SPECIFIED BODY BODY PROTECTOR 12B8041‐B A6072‐1 / IL Install the connectors and hardware between the transducer and the actuator. 1. Before assembling the pipe nipple, pipe tee, pipe bushings, actuator piping, and connector body, apply sealant to all threads. 2. Turn the pipe tee to position the connector body and body protector for easy access when doing diagnostic testing. Electrical Connections WARNING For explosion‐proof applications, disconnect power before removing the transducer cover. Personal injury or property damage may result from fire or explosion if power is applied to the transducer with the cover removed in a hazardous area. Also refer to the Warning at the beginning of the Operating Information section. 6 546 Transducer Instruction Manual D200108X012 October 2011 For explosion‐proof applications, install rigid metal conduit and a conduit seal no more than 457 mm (18 inches) from the transducer. Personal injury or property damage may result from explosion if the seal is not installed. Select wiring and/or cable glands that are rated for the environment of use (such as hazardous area, ingress protection, and temperature). Failure to use properly rated wiring and/or cable glands can result in personal injury or property damage from fire or explosion. Wiring connections must be in accordance with local, regional, and national codes for any given hazardous are approval. Failure to follow the local, regional, and national codes could result in personal injury or property damage from fire or explosion. The electrical connections are made in the transducer case. A 1/2 NPT conduit connection is provided in the bottom of the case. Use a suitable conduit seal for hazardous locations. The wires that carry the input signal from the control device are connected to the terminal mounting bracket assembly (key 53, figure 9). For a direct‐acting unit (i.e., increasing current produces an increasing output pressure), connect the positive wire from the control device to the positive terminal of the transducer and the negative wire to the negative terminal. For a reverse‐acting unit (i.e., increasing current produces a decreasing output pressure), connect the positive wire from the control device to the negative terminal and the negative wire to the positive terminal. Typical circuits are shown in figure 4. Figure 4. Typical Circuit Drawings 450 OHMS + + + 500 1 1 1 OHMS INPUT INPUT 90 OHMS 1010 INPUT 176 OHMS OHMS - - 500 OHMS THERMISTOR - DC SIGNAL: 4 TO 20 MILLIAMPS DC SIGNAL: 10 TO 50 MILLIAMPS DC SIGNAL: 1 TO 9 VOLTS ADJUST RESISTANCE ACROSS INPUT TERMINALS TO 1300 OHMS NOTE: 1 DC RESISTANCE OF COILS CP8401‐B B1766‐2/IL CAUTION Use a lubricant (key 95, figure 8) on the case‐cover threads to prevent thread damage. Operating Information WARNING Personal injury or property damage may result from fire or explosion if power is applied to the transducer with the cover removed in a hazardous area. 7 546 Transducer Instruction Manual October 2011 D200108X012 If the transducer is installed in an application where explosion‐proof classification is required, perform the following steps (prior to removal of the transducer cover) when any procedure in this section requires removal of the cover: � Disconnect the electrical signal from the transducer. � Remove the transducer to a non‐hazardous area. � Perform procedures as described in this section. � Reinstall the transducer, and ensure the cover is secured before turning on the electrical signal. Adjustments Adjust the filter regulator to provide the proper supply pressure to the transducer, then adjust the transducer span and zero (see figures 5 and 6) to match the application requirements and be within specifications. Figure 5. Zero and Span Adjustments (Cover Removed) ZERO ADJUSTMENT SPAN ADJUSTMENT W5391/IL The zero adjustment is used to set the output pressure so that it corresponds to the proper value of the input signal. For example, if the output range is 0.2 to 1.0 bar (3 to 15 psig) and the input range is 1 to 5 mA DC and the unit is direct‐acting, use the zero adjustment to set the output pressure at 0.2 bar (3 psig) when the input signal is 1 mA DC. Use the span adjustment to set the output pressure span so that full output pressure change results for a full change in the input signal. In this example, the output pressure change would be 0.8 bar (12 psi). Thus, the output pressure should start at 3 psig and increase to 1.0 bar (15 psig) as the input signal is changed from 1 to 5 mA DC A span adjustment will affect the zero. Therefore, follow any span adjustment with a zero adjustment. Provide a suitable gauge to measure the pressure. Calibration Equipment Required Choose a current or voltage source that is capable, without switching ranges, of driving the transducer through its entire input range. Switching ranges on a current or voltage source will produce spikes or mid‐scale reverses in the input signal presented to the transducer, causing errors. 8 546 Transducer Instruction Manual D200108X012 October 2011 Calibration Procedure Note The following calibration procedure is for a 546 transducer with a 4 to 20 mA DC input signal range and a 0.2 to 1.0 bar (3 to 15 psig) output range. Calibrate transducers with other inputs and outputs in a similar manner. 1. Check the supply pressure to ensure it agrees with the minimum pressure on the transducer nameplate. 2. Adjust the input current to 4.00 mA DC. 3. Turn the zero screw until the output pressure is 0.2 ±0.006 bar (3.00 ±0.09 psig). 4. Adjust the input to 20.00 mA DC. 5. If the output pressure is less than 1.028 bar (14.91 psig), turn the span screw clockwise to increase the span. If the output pressure is greater than 1.040 bar (15.09 psig), turn the span screw counterclockwise to decrease the span. Note Do not watch the output gauge while turning the span screw because the change in output is not a good indication of the change in span. While turning the span adjustment screw, the output pressure may move in the opposite direction than expected. For example, while turning the span screw in the INCREASING SPAN direction, the output pressure might decrease. This should be disregarded since even though the output pressure decreases, the output span is increasing. 6. Repeat steps 2 through 5 until the output pressure is within one‐third of the accuracy limits at 4 and 20 mA DC. One‐third of the accuracy limits for a 0.2 to 1.0 bar (3 to 15 psig) output range is 1/3 � (±0.0075) � (15.00 - 3.00) = ±2 mbar (±0.03 psig). Calibrate for maximum accuracy at the target end points [0.20 and 1.00 bar (3.00 and 15.00 psig)]. This allows for error at other calibration points in between. 7. Run the transducer through three calibration cycles before recording data. The cycles should be run from exactly 4.00 to 20.00 mA DC in a slow ramping fashion (no large step inputs). 8. After returning from 20.00 mA DC during the last exercise cycle, move back upscale to the midpoint (12.00 mA DC) and record the first data point. Table 5 is an example of recorded data. 9. Record at the other calibration points desired by moving upscale to 20.00 mA DC then down scale to 4.00 mA DC, then back upscale to 12.00 mA DC. Refer to table 5 for common calibration points. Note During the calibration cycle, use care to avoid overshoot. In other words, if data is to be recorded at an 8.00 mA DC input while moving upscale and you accidently pass 8.00 to some higher value, run the test again starting at step 7 with the three exercise cycles. Do not reverse direction and move down scale to 8.00 mA DC. CAUTION Reversing the DC input during the calibration cycle may result in product damage. 9 546 Transducer Instruction Manual October 2011 D200108X012 10. After completing the calibration cycle and recording data, verify that all data is within ±0.75% accuracy limits. If not, the transducer may need to be recalibrated to move the end points slightly to bring the entire calibration curve within the accuracy limits. Recalibration Table 5 shows typical recorded data where recalibration is necessary. Table 5. Typical Calibration Data TRANSDUCER INPUT ACTUAL OUTPUT PRESSURE TARGET OUTPUT PRESSURE mA DC Bar Psig Bar Psig 12.00 0.612 8.89 0.620 9.00 16.00 0.823 11.95 0.826 12.00 20.00 1.035 15.02 1.033 15.00 16.00 0.828 12.02 0.826 12.00 12.00 0.617 8.96 0.620 9.00 8.00 0.413 6.00 0.413 6.00 4.00 0.207 3.01 0.206 3.00 8.00 0.409 5.95 0.413 6.00 12.00 0.618 8.97 0.620 9.00 The 0.612 bar (8.89 psig) value at 12.00 mA DC is outside the accuracy limit of ±0.09 from the target value. This data point can be raised by recalibrating the transducer and raising the end points enough to bring this low value within -0.6 mbar (-0.09 psig) of 0.62 bar (9.00 psig). A reasonable recalibration would be 0.21 and 1.04 bar (3.05 and 15.05 psig) at 4.00 mA DC and 20.00 mA DC, respectively. Recalibrate the instrument and recheck the calibration data as described in steps 7 through 10. If the transducer remains outside of accuracy specifications after altering the calibration end points as much as possible consult your Emerson Process Management sales office. For transducers inaccurate to less than 5 percent of output span, relay repair or replacement may correct the problem. Refer to the alignment procedures in the Troubleshooting section to correct the operation of a faulty transducer. Also check for air leaks at the tubing, nozzle, relay, and bellows. If the accuracy error is greater than 5 percent of output span, check the clearance between the armature and the coils. These parts are referenced as key 40 and key 42, respectively, in the Parts List section. The armature and the white plastic coil bobbin should be approximately 0.4 mm (1/64 inch) apart. If the parts are in contact, loosen the machine screws that hold the bobbin and reposition the bobbin. Changing Output Pressure Range Changing the output pressure range from 0.2 to 1.0 bar (3 to 15 psig) to 0.4 to 2.0 bar (6 to 30 psig) or vice versa requires changing the feedback bellows (key 57, figure 9). To do this, refer to the replacing the feedback bellows assembly procedures in the Maintenance section. Note Re‐magnetization of the torque motor is required when changing the output pressure range. Reversing the Action Reversing the action of a 546 transducer requires no special parts. The direction of armature rotation is dependent upon the direction of the current flow. Therefore, simply reverse the input current leads to the transducer to obtain 10 546 Transducer Instruction Manual D200108X012 October 2011 the opposite action. Whenever the action is changed, readjust the zero of the transducer as outlined in the adjustments procedures. Split Range Operation 546 transducers are suitable for two‐way split range operation. In a two‐way split the milliampere (mA) or voltage output signal of a single control device is split between two transducers electrically connected in series. Although each transducer receives the full signal, it is calibrated to provide a full output pressure range of 0.2 to 1.0 bar (3 to 15 psig) or 0.4 to 2.0 bar (6 to 30 psig) to the control valve with one‐half the input signal. Since the transducer operates on only one‐half of the normal input span, the feedback bellows must be changed to compensate for the shorter span. Change the bellows as described in the replacing feedback bellows assembly procedure in the Maintenance section. Table 6 indicates which bellows is required for your conditions. Reset the span and zero adjustments to the split range values. Note that these transducers cannot provide a three‐way split range. Table 6. Feedback Bellows Output Pressure Range BELLOWS SIZE OPERATION INPUT SIGNAL, DC Full Half Quarter Bar Psig Bar Psig Bar Psig (1) 1 to 9 V Full Range 0.2 to 1.0 3 to 15 0.4 to 2.0 6 to 30 - - - - - - 4 to 20 mA 10 to 50 mA 4 to 12 mA or 12 to 20 mA Split Range - - - - - - 0.2 to 1.0 3 to 15 0.4 to 2.0 6 to 30 10 to 30 mA or 30 to 50 mA 1 to 5 VDC or 5 to 9 VDC 1. Temperature compensated circuit. Principle of Operation Refer to the schematic drawing in figure 6. Assume that the transducer is direct‐acting. An increase in the DC signal to the coils increases the magnetic field around the coils. This field increases the magnetic strength in the armature and the magnetic attraction across the air gap between the armature and the pole pieces. The pole pieces are already polarized by the permanent magnet. The armature polarity is as shown in the schematic. The magnetic attraction will therefore be downward at the nozzle end and upward at the feedback bellows end, resulting in a torque that rotates the armature about the fixed torsion rod to cover the nozzle. The resulting restriction produces an increased pressure in the nozzle, in the upper chamber of the relay, and in the feedback bellows. The relay responds to the increase in nozzle pressure to increase the output pressure to the actuator and control valve. The increased pressure in the feedback bellows creates a force that acts on the armature to move it back to an equilibrium position. In this way, the new nozzle pressure is compared to the input current by the force‐balance principle. The relay operates in the following manner. The nozzle pressure acts on the large top diaphragm to force the center spacer assembly (mounted between the two diaphragms) downward against the valve plug, closing the exhaust port and opening the supply port. Supply air then flows through the open port to the output load. The output pressure continues to increase until the relay diaphragm assembly is pushed back to its original position by the force of the pressure acting on the small diaphragm. When this occurs, the valve plug is closed again. When a decreasing DC signal is received, the magnetic attraction across the air gap is reduced. The armature rotates to uncover the nozzle and decrease the pressure in the nozzle, relay, and feedback bellows. The relay diaphragm assembly moves upward, and the exhaust port opens to bleed the output pressure to atmosphere. The output decreases until the diaphragm assembly is forced back to its original position and the exhaust port is closed again. The reduced pressure in the feedback bellows diminishes the force to return the armature to the equilibrium position. 11 546 Transducer Instruction Manual October 2011 D200108X012 Figure 7 shows output‐time relationship curves for loading and exhausting an actuator. Exhausting times are nominally 25 percent of the loading times. Reverse‐acting transducers operate in a similar manner except that when the DC input signal increases, the output pressure from the relay decreases. Conversely, a decreasing input signal increases the output pressure. Figure 6. Transducer Schematic SPAN ADJUSTMENT FEEDBACK BELLOWS (MAGNETIC SHUNT) ZERO ADJUSTMENT PERMANENT MAGNET POLE PIECES ARMATURE COIL NOZZLE OUTPUT PRESSURE ARMATURE NOZZLE PRESSURE TORSION ROD SUPPLY PRESSURE EXHAUST EXHAUST PRESSURE OUTPUT CENTER SPACER ASSEMBLY FIXED RELAY RESTRICTION VALVE PLUG SUPPLY CP4285-A A1505-3 / IL Figure 7. Output‐Time Relationship 100 90 80 70 LOADING 60 50 40 30 EXHAUSTING 20 10 0 100 0 10 2030 40 506070 8090 19A1361‐A TIME (%) A3103 / IL 12 OUTPUT (% OF 546 OUTPUT SPAN) 546 Transducer Instruction Manual D200108X012 October 2011 Maintenance Maintenance of the transducer consists of relay repair or replacement, and replacement of the feedback bellows. WARNING The following maintenance procedures require that the transducer be taken out of service. This requires that certain precautions be taken to avoid personal injury or equipment damage caused by sudden release of pressure. Prior to maintenance: � Always wear protective clothing, gloves, and eyewear when performing any maintenance procedures to avoid personal injury. � Disconnect electrical power before removing the transducer cover. � Shut off or disconnect pressure lines to the transducer. � Disconnect any operating lines providing air pressure, electrical power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. � Use bypass valves or completely shut off the process to isolate the valve from process pressure. � Do not remove the actuator from the valve while the valve is still pressurized. � Relieve process pressure on both sides of the valve. � Vent the power actuator loading pressure and relieve any actuator spring precompression. � Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment. � Check with your process or safety engineer for any additional measures that must be taken to protect against process media. WARNING For explosion proof applications, disconnect power before opening the transducer cover. Personal injury or property damage may result from fire or explosion if power is not disconnected. CAUTION The presence of Emerson Process Management personnel and also approval agency personnel may be required if you service (other than normal, routine maintenance, such as calibration) or replace components on a transducer that carries a third‐party approval. When you replace components, use only components specified by the factory. Substitution with other components may void the third‐party approval. Also, always use proper component replacement techniques, as presented in this manual. Improper techniques can cause poor quality repairs and impair the safety features of the device. Figure 9 shows the torque motor and associated parts. Shaded key numbers indicate parts that should not be disassembled from the torque motor because the magnetism in the torque motor magnets will decrease permanently. Certain troubleshooting and alignment procedures are described at the end of this section. These may serve as a guide to correct some problems. Improper supply pressure and mechanical defects in pneumatic and electrical connections should be apparent upon inspection and repaired as appropriate. 13 546 Transducer Instruction Manual October 2011 D200108X012 CAUTION Never disassemble the torque motor assembly because the magnetism in the torque motor magnets will decrease permanently. Shaded key numbers indicate parts that should not be disassembled from the torque motor (see figure 9). If troubleshooting or alignment attempts indicate either a faulty torque motor or the necessity of disassembling the torque motor consult your Emerson Process Management sales office. Relay Removal and Replacement Use the following procedure when removing and replacing a relay assembly. Refer to figure 10 for key number locations, unless otherwise directed. 1. Loosen the two mounting screws (key 68), and remove the relay assembly from the transducer case (key 1, figure 8). 2. To install the replacement relay assembly, install the two relay mounting screws (key 68) into the relay assembly. Apply lubricant (key 96) to the O‐rings, and make sure the O‐rings (keys 72, 73, and 74) are in place on the relay assembly. 3. Install the relay assembly on the transducer case. Tighten the mounting screws. 4. With the torque motor installed, apply supply pressure to the transducer case, and check the relay assembly for leaks with a soap solution. Replacing the Feedback Bellows Assembly Refer to figure 9 for key number locations. 1. Loosen the hex nut (key 31). 2. Remove the bellows screw (key 56) and O‐ring (key 36) under the head of the bellows screw. 3. Pull the bellows assembly (key 57) out. The armature is slotted to allow removal of the bellows assembly. 4. Inspect and, if necessary, replace the two O‐rings (key 36). Make sure the O‐rings under the bellows assembly are in place. 5. Choose the correct bellows assembly as outlined in table 6. Install the new bellows assembly. Make sure that the O‐ring (key 36) is in place. 6. Install the bellows screw and O‐ring, and tighten the screw. Be sure the bellows assembly is not distorted in any direction. Tighten the hex nut (key 31). 7. Refer to the adjusting zero and span procedures in the Adjustments section. Troubleshooting This section contains some checks for operational difficulties that may be encountered. If correcting the difficulties is not possible, contact your Emerson Process Management sales office or service center. Electrical 1. Check the output of the control device. Make sure that it is reaching the transducer. 2. Check the DC input signal. It should be the same as the range stamped on the transducer nameplate. 3. Check the resistance of the transducer circuit to see that it coincides with the value listed on the circuit identification tag located on the torque motor. 14 546 Transducer Instruction Manual D200108X012 October 2011 4. Check the terminal lugs for proper connections. If reverse action of the transducer is observed, simply reverse the input leads as indicated in the Reversing the Action procedures in the Operating Information section. Pneumatic CAUTION Do not attempt to remove the nozzle (key 19, figure 9) for any reason. Nozzle removal requires disassembling the torque motor. Disassembling the torque motor will permanently reduce the strength of the magnets, causing improper operation. Also, do not adjust the baffle (key 18, figure 9). The spacing between the baffle and nozzle is preset and locked at the factory to obtain optimum performance of the transducer. 1. Connect supply pressure and a pressure gauge to monitor the output. Check the operation of the transducer as follows: a. Force the baffle (key 18, figure 9) against the nozzle. The output pressure should build up to approximately the supply pressure. If it does not, check for a leak in the pneumatic system or a burr on the nozzle. b. Force the baffle away from the nozzle. The output pressure should drop to less than 0.07 bar (1 psig). If it does not, check the flame arrestors in the transducer case (see figure 8). If the flame arrestors require cleaning, first remove the torque motor assembly from the case by removing four machine screws (key 9, figure 8). Then, clean the flame arrestors by blowing them out with air pressure. 2. Check zero and span adjustment for proper setting. Refer to the adjustments procedure. 3. Check the supply pressure. It should be at least 0.3 bar (5 psig) above the upper limit of the output pressure range. 4. Check the filter regulator for moisture in the dripwell. Drain off any moisture, and clean the filter element if necessary. 5. If the transducer cycles, be sure there are no sharp bends in the copper capillary feedback tubing (key 56, figure 9) and that the tubing is not plugged. 6. Check the nozzle. If it is clogged, remove the entire torque motor assembly from the case by removing four machine screws (key 9, figure 8). Run a wire through the nozzle from the underside of the assembly. 7. Erratic operation may be caused by metal chips in the air gap between the armature and the pole pieces. Blow any chips out of the torque motor assembly with low pressure air. 8. If a problem persists, check the relay as described in the Relay Maintenance procedures in this section. Alignment The following alignment procedures can be used in conjunction with troubleshooting procedures to correct the operation of a faulty transducer. Span Adjustment Refer to figure 9 for key number locations, unless otherwise directed. If setting the required span is not possible, additional span adjustment can be obtained by shifting the entire span adjustment assembly (key 55) at the flexure pivot end. The alignment procedure is as follows: 1. Shut off the DC input signal and supply pressure to the transducer. 2. Disconnect the external lead wires from the terminal mounting bracket assembly (key 53). 15 546 Transducer Instruction Manual October 2011 D200108X012 3. Loosen the four machine screws (key 9, figure 8) that hold the torque motor assembly to the case. Remove the entire torque motor assembly from the case. 4. Loosen the two flexure pivot screws (key 25) that hold the flexure pivot to the torque motor assembly base. 5. Slide the span adjustment assembly in or out as required. Sliding it in toward the base decreases the span; sliding it out away from the base increases the span. 6. Tighten the flexure pivot screws. Replace the torque motor assembly, and tighten the screws (key 9, figure 8). Make sure that the O‐ring (key 37) is in place. Connect the external lead wires, and turn on the air supply. 7. Make final adjustment of the span with the span adjustment screw. Torque Motor Frame The top pole piece plate (key 50, figure 9) of the torque motor can become twisted with respect to the bottom pole piece plate (key 51, figure 9). If this happens contact your Emerson Process Management sales office. Armature Travel Stop The armature travel stop (key 52, figure 9) must be in place to prevent overstressing the armature and coil support (key 41, figure 9) due to over‐travel. The clearance between the armature and travel stop should be 0.13 mm (0.005 inches). The two screws at the base of the travel stop can be loosened if an alignment is necessary. Coil The coil assembly (key 42, figure 9) consists of a nylon bobbin wound with wire. The coils are not attached to the armature itself, and therefore, they must not touch the armature, or armature movements will be restricted. If this problem exists, loosen the two screws that attach each coil assembly to the armature and coil support. Sight down the armature and realign the coil assemblies for clearance with the armature. Tighten the screws. Parts Ordering Whenever corresponding with your sales office about this equipment, mention the serial number of the unit. This serial number can be found on the nameplate. When ordering replacement parts, also state the complete 11‐character part number of each part needed as found in the following parts list. Note In the torque motor assembly drawing (figure 9), there are many shaded key numbers. The shading indicates that these parts should not be disassembled and that they are not available as individual items. Consequently, no part numbers are shown for these parts in the Parts List. WARNING Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management should not, under any circumstances, be used in any Fisher instrument. The use of components not manufactured by Emerson Process Management may void your warranty, might adversely affect the performance of the instrument, and could result in personal injury or property damage. 16 546 Transducer Instruction Manual D200108X012 October 2011 Figure 8. Transducer Assembly 82 RELAY TORQUE MOTOR FILTER REGULATOR FLAME ARRESTOR FLAME ARRESTOR APPLY LUBRICANT/SEALANT NOTE: KEY 4 NOT SHOWN 30A8595‐L B1768‐3 / IL Key Description Part Number Parts List   1 Transducer Case Ass'y, aluminum   2 Case Cover, aluminum Repair Kits   3 Protective Plug, plastic Description Part Number     4 Tagging Plate (optional)  Stainless steel (SST) Transducer Repair Kit Kit includes keys 6, 12, 36, 37, and 58 R546X000022   5 Nameplate, Standard, SST 82 Relay Replacement Assembly   Assembly includes   6* O‐Ring, nitrile 1D444806992  two mounting screws (Key 68) 10A8593X082   8* Pressure Gauge  Triple scale 546 Transducers (figure 8)   0-30 psig/0-.2 MPa/0-2 bar 11B8582X012   0-60 psig/0-.4 MPa/0-4 bar 11B8582X022  Dual scale Note 2   0-30 psig/0-2 Kg/cm 11B8582X042 Part numbers are shown for recommended spares only. For part 2   0-60 psig/0-4 Kg/cm 11B8579X072 numbers not shown, contact your Emerson Process Management sales office. *Recommended spare parts 17 546 Transducer Instruction Manual October 2011 D200108X012 Figure 9. Torque Motor Assembly APPLY LUBRICANT/SEALANT NOTES: 1. SHADED KEY NUMBERS INDICATE PARTS THAT SHOULD NOT BE DISASSEMBLED FROM TORQUE MOTOR. 2. KEY NUMBERS 22 AND 103 ARE NOT SHOWN. 30A8594‐K B1767‐3 Key Description Part Number Key Description   9 Machine Screw, brass pl (4 req'd) Torque Motor (figure 9)  10 Screw, steel pl (1)  15 Adjusting Screw  11 Cap Screw, steel pl (2 req'd) use with (1)  16 Spring Seat  integrally mounted filter regulator only (1)  17 Spring‐Zero Adjustment  12* O‐Ring, use with integrally mounted ( )  18 1 Baffle  filter regulator only, nitrile 1E591406992 ( )  19 1 Nozzle  13 Pipe Nipple, steel pl, (1)  20 Hook‐Up Wire Ass'y  For filter regulator only (not shown) (1)  21 Hook‐Up Wire Ass'y  92 Wire Retainer, steel pl (2 req'd) (1)  22 Hook‐Up Wire (not shown)  95 Lithium grease, see note immediately below (1)  25 Machine Screw  (not furnished with unit) (1)  26 Screw 107 Street Elbow, use with integrally mounted filter (1)  27 Cap Screw  regulator w/0-60 dual scale gauge (1)  28 Machine Screw 108 Pipe Plug, steel  For regulator w/o gauge *Recommended spare parts 1. Parts are not field repairable. The torque motor assembly should never be disassembled because the magnetism in the torque motor will decrease permanently. Shaded key numbers shown in figure 9 indicate parts that should 18 not be disassembled. 546 Transducer Instruction Manual D200108X012 October 2011 Figure 10. Fisher 82 Relay Assembly RESTRICTION HOLES APPLY LUBRICANT/SEALANT NOTE: KEY 76 IS NOT SHOWN A1504‐1 / IL Key Description Part Number Key Description Part Number  57* Bellows Ass'y, brass (1)  29 O‐Ring, nitrile  Full Size, 21 mm (27/32 inch) O.D. 1U3958000A2  31 Hex Nut, brass pl  Half Size, 13 mm (1/2 inch) O.D. 1U3975000A2 (1)  32 Washer  Quarter Size, 9.5 mm (3/8 inch) O.D. 1R6521000A2  33 Washer, brass pl  58 Tubing Ass'y, brass/copper (1)  34 Washer (1)  35 Washer  94 Anti‐seize sealant  36* O‐Ring, nitrile (2 req'd) 1D687506992  (not furnished with unit)  37* O‐Ring, nitrile 1C782206992  96 Silicone‐based lubricant, medium grade (1)  38 E‐Ring  (not furnished with unit) (1)  40 Armature (1)  41 Coil Support 103 Set Screw, SST/nylon (not shown) (1)  42 Coil Ass'y (1) (1) 105 Spacer  48 Magnet (1)  49 Pole Piece (1)  50 Top Pole Piece Plate Relay (figure 10) (1)  51 Bottom Pole Piece Plate (1)  52 Travel Stop (1)  53 Terminal Mounting Bracket Ass'y Note (1) The 546 relay is not repairable. If the relay is defective, order the 82  55 Span Adjustment Ass'y  56 Bellows Screw, brass Relay Replacement Assembly (refer to Parts Kits). *Recommended spare parts 1. Parts are not field repairable. The torque motor assembly should never be disassembled because the magnetism in the torque motor will decrease permanently. Shaded key numbers shown in figure 9 indicate parts that should not 19 be disassembled. 546 Transducer Instruction Manual October 2011 D200108X012 Key Description Mounting Parts (figures 11 & 12)  82 Cap Screw, steel pl  Yoke mounting (4 req'd)   480 all sizes   513 all sizes   656 size 40 thru 60 Note   657 & 667 size 30 thru 80 Part numbers are shown for recommended spares only. For part   1051 size 40 & 60 all positions numbers not shown, contact your Emerson Process Management sales   1052 sizes 40 thru 70 all positions   1061 all sizes all positions office.  Yoke mounting (2 req'd)   585C, all sizes   656, size 30   1250R   1051 size 33 all positions   1052 size 33 all positions Key Description Part Number  Casing mounting (2 req'd)   All types, all sizes  Pipestand mounting (2 req'd) 79 Elbow, brass  Surface mounting (2 req'd)  Yoke mounting,  Bulkhead mounting (2 req'd)   513, 657, 1051, 1052, 1061   all sizes  83 Cap Screw  Yoke mounting (2 req'd)  Casing mounting (2 req'd)   480, 585C, 667   1051, 1052, all sizes, all positions   all sizes   513, 657, 1051, 1052, 1061  85 Washer, steel pl   all sizes  Yoke mounting (4 req'd)  Casing mounting   All types, all sizes, except 1250R   657, 667 1051, 1052  Casing mounting (2 req'd)   all sizes  Pipestand mounting (4 req'd)  Yoke mounting 1250R, none required  81 Mounting Plate, steel  86 Cap Screw, steel pl (2 req'd)  Yoke mounting  Yoke mounting   480, 513, 585C 656,   490, all sizes    657, 667, all sizes   657NS & 667NS, Sizes 70, 80   1051 size 33 all positions,   1051 & 1052, size 33, positions 1 & 3   480, all sizes    size 40 and 60 position 1,   1052 size 33 all positions,   585C, Sizes 25 & 50   656, Size 30    sizes 40 thru 70 position 1   1061 size 30 all positions,   1051 & 1052, size 33, positions 2 & 4  Casing mounting    sizes 40 thru 100 position 1   1250R   657 & 667, Sizes 30 through 60   1051 size 40 and 60 position 3   657 & 667, Size 70   1052 sizes 40 thru 70 position 3   GX   1061 sizes 40 thru 100 position 3    size 225 and 750    size 1200  Casing mounting   657 & 667, all sizes except size 80  87 Spacer, steel (2 req'd)   1051, 1052, all sizes, all positions  Yoke mounting   GX, size 225, 750, and 1200   490, all sizes   656, Sizes 30  Pipestand mounting   1051 & 1052, size 33, positions 1 & 3  81*  Surface mounting 2R1001X0012   1051 & 1052, size 33, positions 2 & 4  Surface mounting  Bulkhead mounting 20 *Recommended spare parts 546 Transducer Instruction Manual D200108X012 October 2011 Figure 11. Typical Actuator Mounting Figure 12. Typical Casing Mounting 546 TRANSDUCER 1051/52 SIZE 33 ACTUATOR 42B0737‐A A5426‐1 / IL 546 TRANSDUCER Key Description 585 SIZE 25 AND 50 ACTUATORS  97 U‐Bolt, steel pl (2 req'd) 48A9176‐B A5425‐1 / IL  1250R, all sizes  98 Hex Nut, steel pl  1250R, all sizes (4 req'd) Key Description  GX, size 225, 750, and 1200 (2 req'd)  88 Mounting Bracket, steel  99 Lock washer, SST  Yoke mounting  Yoke mounting (4 req'd)   480, all sizes   585C, size 25 & 50   1250R, all sizes  89 Hex Nut, steel pl (2 req'd)  Yoke mounting (2 req'd)  Yoke mounting   1051 & 1052, size 33, all positions   480, all sizes 101 Washer (2 req'd)  90 Pipe Clamp, steel pl  Casing mounting  Pipestand mounting   1051, 1052, all sizes, all positions 21 546 Transducer Instruction Manual October 2011 D200108X012 Diagnostic Connections FlowScanner� diagnostic system hook‐up  Includes pipe tee, pipe nipple, pipe bushings,  connector body, and body protector. See figure 3  for part identification. Note Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office. If the transducer is used in a valve assembly with a positioner, no hook‐up for diagnostic testing is required for the transducer. The hook‐up for diagnostic testing should be installed at the positioner. Description  For units with gauges   SST fittings   Brass fittings  For units without gauges   SST fittings   Brass fittings 22 546 Transducer Instruction Manual D200108X012 October 2011 23 546 Transducer Instruction Manual October 2011 D200108X012 Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user. Fisher and FlowScanner are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management Marshalltown, Iowa 50158 USA Sorocaba, 18087 Brazil Chatham, Kent ME4 4QZ UK Dubai, United Arab Emirates Singapore 128461 Singapore www.Fisher.com 24 �Fisher Controls International LLC 1977, 2011; All Rights Reserved