Emerson Fisher 546NS User manual

www.Fisher.com
Fisher™546NS Electro-Pneumatic Transducer
Contents
Introduction 1.................................
Scope of Manual 1.............................
Description 2.................................
Specifications 3...............................
564NS Qualification 3......................
Educational Services 3.........................
Installation 5..................................
Hazardous Area Classifications 6.................
Mounting 7..................................
Pressure Connections 7........................
Diagnostic Connections 7......................
Electrical Connections 8........................
Operating Information 9.........................
Adjustments 9................................
Calibration 10................................
Equipment Required 10.....................
Calibration Procedure 10....................
Recalibration 12...........................
Changing Output Pressure Range 12.............
Reversing the Action 12........................
Split Range Operation 13.......................
Principle of Operation 14........................
Maintenance 15................................
Relay Removal and Replacement 16..............
Replacing the Feedback Bellows Assembly 17......
Troubleshooting 17............................
Electrical 17..............................
Pneumatic 17.............................
Alignment 18.................................
Span Adjustment 18.......................
Torque Motor Frame 19....................
Armature Travel Stop 19....................
Coil 19...................................
Figure 1. Fisher 546NS Electro‐Pneumatic Transducer
Mounted on a 657 Pneumatic Diaphragm Actuator
W2115
546NS
FILTER
REGULATOR
Parts Ordering 20...............................
Repair Kits 20..................................
Parts List 20...................................
Transducer 20................................
Torque Motor 21..............................
Relay 23.....................................
Mounting Parts 24.............................
Diagnostic Connections 24.....................
Introduction
Scope of Manual
This instruction manual provides installation, operation, maintenance, and parts ordering information for the Fisher
546NS transducer and the 82 relay. Refer to separate manuals for instructions covering equipment used with the
transducer.
Instruction Manual
D103425X012
546NS Transducer
June 2021

Instruction Manual
D103425X012
546NS Transducer
June 2021
2
Do not install, operate or maintain a 546NS 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 sales office before proceeding.
Description
The 546NS 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, output pressure
range, and electrical classification, if approved, of each transducer is indicated on the nameplate attached to the
cover.
The 546NS transducer is designed for nuclear power applications. The 546NS construction includes materials that
provide superior performance in elevated temperature and radiation environments.
The O‐rings are EPDM (ethylene propylene) and the diaphragms are EPDM/NOMEXt. EPDM demonstrates superior
temperature capability and shelf life over nitrile. The NOMEX diaphragm fabric demonstrates improved strength
retention at elevated temperature and radiation conditions.
CAUTION
Use a clean, dry, oil‐free air supply with instruments containing EPDM components. EPDM is subject to degradation when
exposed to petroleum‐based lubricants.
Under the 10CFR50, Appendix B, quality assurance program, the 546NS transducer is qualified “commercial grade
dedicated”. These can be supplied as 10CFR, Part 21 items.

Instruction Manual
D103425X012
546NS Transducer
June 2021
3
Specifications
Specifications are listed in table 1.
546NS Qualification
The 546NS is qualified to meet stringent environmental conditions encountered in nuclear power plant containment
areas. Samples were subjected to the tests summarized below:
D Thermal Aging: accelerated service temperature of 54_C (130_F) over 10 years.
D Radiation Aging: 6 MRads Total Integrated Dose (TID)
D Seismic Event Simulation (DBE): no natural frequencies found between 5‐100 Hz and seismic dwells of 8g uniaxial
from 3‐40 Hz when mounted using Fisher specified seismic mounting brackets.
D LOCA/MSLB Event Simulation: saturated steam for 14 hours at 160_C ( 320_F) followed by a gradual reduction to
83_C (182_F) over a 10 hour period.
Upon conclusion of the above tests, no loss of function or visible degradation was found.
Educational Services
For information on available courses for the 546NS transducer, as well as a variety of other products, contact:
Emerson Automation Solutions
Educational Services - Registration
Phone: [phone] or 1-800-338-8158
E-mail: [email protected]
emerson.com/fishervalvetraining

Instruction Manual
D103425X012
546NS Transducer
June 2021
4
Table 1. Specifications
Available Configuration
Electro‐pneumatic signal transducer with
explosion‐proof case and cover, with EPDM
elastomers for use in elevated temperature and
radiation environments
The 546NS can be ordered with or without a Fisher 67
series filter regulator. A 51 mm (2 inch) circular
supply pressure gauge may be mounted on the
regulator.
Input Signals
J4 to 20 mA DC, J10 to 50 mA DC, J1 to 9 VDC,
or Jtwo‐way split range using any half of one of the
standard input signal spans
Internal Resistance of Torque Motor
4 to 20 mA DC Input Signal: 176 ±10 ohms
10 to 50 mA DC Input Signal: 90 ±10 ohms
1 to 9 VDC Input Signal: 1300 ±50 ohms
(temperature-compensated circuit)
Output Signals
Ranges:
0.2 to 1.0 bar (3 to 15 psig), 0.4 to 2.0 bar
(6 to 30 psig)
Action: 546NS is field‐reversible between direct and
reverse action.
Supply Pressure(1)
Recommended: 0.3 bar (5 psig) higher than upper
range limit of output signal
Maximum: 3.5 bar (50 psig)
Maximum Steady‐State Air Consumption(2)
At 1.4 bar (20 psig) Supply Pressure:
0.6 normal m3/hr (21 scfh)
At 2.4 bar (35 psig) Supply Pressure:
0.8 normal m3/hr (30 scfh)
Maximum Output Air Capacity(2)
At 1.4 bar (20 psig) Supply Pressure:
12.9 normal m3/hr (480 scfh)
At 2.4 bar (35 psig) Supply Pressure:
18.5 normal m3/hr (690 scfh)
Performance(3)
Actuator Loading Time: See figure 6
Reference Accuracy(4):±0.75% of the output span
Independent Linearity: ±0.50% of the output span
Open Loop Gain: 26
Frequency Response: Gain is attenuated 3 dB at 20 Hz
with transducer output signal piped to a typical
instrument bellows with 305 mm (12 inches) of
1/4 inch tubing
Electromagnetic Interference (EMI): Tested per IEC
61326‐1 (Edition 1.1). Meets emission levels for Class
A equipment (industrial locations) and Class B
equipment (domestic locations). Meets immunity
requirements for industrial locations (Table A.1 in the
IEC specification document). Immunity performance
shown in table 2.
Operative Ambient Temperature Limits(1)
-40 to 66_C (-40 to +150_F)
Humidity Rating
80% for temperatures up to 31_C (88_F), decreasing
linearly to 50% RH at 40_C (104_F)
Altitude Rating
Up to 2000 meters (6562 feet)
Application for Use
This product is intended for indoor use only
Electrical Classification
Hazardous Area:
CSA— Explosion-proof, Dust Ignition‐proof, Div 2
FM— Explosion-proof, Dust Ignition‐proof,
Non‐incendive
Refer to table 3 and 4 for specific approval
information.
NEMA 3R, CSA enclosure 3
NEMA 3R mounting orientation requires vent location
to be below horizontal. Vent is shown in figure 9, key
69.
Pollution Degree: 2
Overvoltage Category: II
-continued-

Instruction Manual
D103425X012
546NS Transducer
June 2021
5
Table 1. Specifications (continued)
Adjustments
Zero and Span Adjustments: Screwdriver adjustments
located inside case (see figure 4)
Connections
Supply Pressure: 1/4 NPT internal located on side of
case, (or located on the 67CFR filter‐regulator if
mounted)
Output Pressure: 1/4 NPT internal located on side of
case
Vent: 1/4 NPT internal with screen located on relay
Electrical: 1/2 NPT internal located on bottom of case
Approximate Weight
4.1 kg (9 pounds)
Declaration of SEP
Fisher Controls International LLC declares this
product to be in compliance with Article 4 paragraph
3 of the Pressure Equipment Directive (PED)
2014/68/EU. It was designed and manufactured in
accordance with Sound Engineering Practice (SEP)
and cannot bear the CE marking related to PED
compliance.
However, the product may bear the CE marking to
indicate compliance with other applicable European
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.
2. Normal m3/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.
4. Reference accuracy includes the effects of non-linearity, hysteresis, and deadband per SAMA Standard PMC 20.1-1973.
Table 2. Electromagnetic Immunity Performance
Port Phenomenon Basic Standard Test Level Performance Criteria(1)
Enclosure
Electrostatic discharge (ESD) IEC 61000‐4‐2 4 kV contact
8 kV air A
Radiated EM field IEC 61000‐4‐3 80 to 1000 MHz @ 10V/m with 1
kHz AM at 80% A
Rated power frequency magnetic field IEC 61000‐4‐8 60 A/m at 50 Hz A
I/O signal/control
Burst (fast transients) IEC 61000‐4‐4 1 kV A
Surge IEC 61000‐4‐5 1 kV (line to ground only, each) A
Conducted RF IEC 61000‐4‐6 150 kHz to 80 MHz at 3 Vrms with
1kHz AM at 80% A
Specification limit = ±1% of span
1. A=No degradation during testing. B = Temporary degradation during testing, but is self‐recovering.
For Declaration of Conformity available in multiple languages:
Installation
WARNING
Warning - Explosion Hazard
Do not connect or disconnect this equipment unless power has been removed or the area is known to be nonhazardous.
AVERTISSEMENT
Avertissement- Risque d'explosion
Ne pas debrancher tant que le circuit est sous tension, a moins qu'il ne s'agisse d'un emplacement non dangereux.

Instruction Manual
D103425X012
546NS Transducer
June 2021
6
WARNING
Avoid personal injury from sudden release of process pressure. Before mounting the controller:
D Always wear protective clothing, gloves, and eyewear when performing any installation operations to avoid personal
injury.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
D If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this
instruction manual.
Hazardous Area Classifications
Certain nameplates may carry more than one approval, and each approval may have unique installation/wiring
requirements and/or conditions of “safe use”. These special instructions for “safe use” are in addition to, and may
override, the standard installation procedures. Special instructions are listed by approval.
Note
This information supplements the nameplate markings affixed to the product.
Always refer to the nameplate itself to identify the appropriate certification. Contact your Emerson sales office for
approval/certification information not listed here.
CSA and FM
No special conditions of safe use.
Refer to table 3 and 4 for approval information.
Table 3. Hazardous Area Classifications—CSA (Canada)
Certification Body Certification Obtained Temperature Code
CSA
Explosion-proof
Class I, Division 1, Group C,D T5 (Tamb = 66_C)
Class II, Division 1, Groups E,F,G
Class I, Division 2, Groups A,B,C,D
Class II, Division 2, Groups F,G
T5
Table 4. Hazardous Area Classifications— FM (United States)
Certification Body Certification Obtained Temperature Code
FM
Explosion-proof
Class I, Division 1, Groups C,D T5 (Tamb = 60_C)
Class II, Division 1, Groups E,F,G
Class I, Division 2, Groups A,B,C,D
Class II, Division 2, Groups F,G
T5

Instruction Manual
D103425X012
546NS Transducer
June 2021
7
Mounting
When a 546NS 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. Brackets for seismic mounting capability available upon request.
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 Automation Solutions field office and industry instrument air quality standards for use
with corrosive air or if you are unsure about the proper amount or method of air filtration or filter maintenance.
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).
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 2. 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.

Instruction Manual
D103425X012
546NS Transducer
June 2021
8
Figure 2. Diagnostic Connections
PIPE NIPPLE (OUTPUT CONN)
12B8041‐B
A6072‐1
PIPE TEE
PIPE
BUSHING
BODY
BODY
PROTECTOR
SUPPLY GAUGE
STEM PROVIDED
WHEN GAUGE
IS SPECIFIED
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.
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 8).
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 3.

Instruction Manual
D103425X012
546NS Transducer
June 2021
9
Figure 3. Typical Circuit Drawings
DC SIGNAL: 1 TO 9 VOLTS
ADJUST RESISTANCE ACROSS INPUT
TERMINALS TO 1300 OHMS
1
+
-
176 OHMS
DC SIGNAL: 4 TO 20 MILLIAMPS
INPUT 1
+
-
90 OHMS
DC SIGNAL: 10 TO 50 MILLIAMPS
INPUT
NOTE:
1 DC RESISTANCE OF COILS
1
+
-
1010
OHMS
INPUT
500 OHMS
THERMISTOR
450 OHMS
500
OHMS
CP8401‐C
B1766‐2/IL
CAUTION
Use a lubricant (key 95, figure 7) 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.
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:
D Disconnect the electrical signal from the transducer.
D Remove the transducer to a non‐hazardous area.
D Perform procedures as described in this section.
D 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 4 and 5) to match the application requirements and be within specifications.

Instruction Manual
D103425X012
546NS Transducer
June 2021
10
Figure 4. Zero and Span Adjustments (Cover Removed)
W5391/IL
ZERO ADJUSTMENT
SPAN ADJUSTMENT
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 4 to 20 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 4 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 4 to 20 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.
CAUTION
If the transducer is not used as specified in this instruction manual, the protection provided by the equipment may be
impaired.
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 source will produce spikes or mid‐scale reverses in the input signal
presented to the transducer, causing errors.
Calibration Procedure
Note
The following calibration procedure is for a 546NS 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.