Emerson Rosemount 2130 User manual

Reference Manual
00809-0100-4130, Rev EA
May 2022
Rosemount™ 2130 Level Switch
Vibrating Fork

Safety messages
NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum product performance,
ensure you thoroughly understand the contents before installing, using, or maintaining this product.
For technical assistance, contacts are listed below:
Customer Central
Technical support, quoting, and order-related questions.
•United States - 1-800-999-9307 (7:00 am to 7:00 pm CST)
•Asia Pacific- 65 777 8211
North American Response Center
Equipment service needs.
•1-800-654-7768 (24 hours a day — includes Canada)
•Outside of these areas, contact your local Emerson representative.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or serious injury.
Ensure the level switch is installed by qualified personnel and in accordance with applicable code of practice.
Use the level switch only as specified in this manual. Failure to do so may impair the protection provided by the level switch.
The weight of a level switch with a heavy flange and extended fork length may exceed 37 lb. (18 kg). A risk assessment is required
before carrying, lifting, and installing the level switch.
WARNING
Explosions could result in death or serious injury.
Verify the operating atmosphere of the level switch is consistent with the appropriate hazardous locations certifications.
Before connecting a handheld communicator in an explosive atmosphere, ensure the instruments are installed in accordance with
intrinsically safe or non-incendive field wiring practices.
In explosion-proof/flameproof and non-incendive installations, do not remove the housing cover when power is applied to the
level switch.
The housing cover must be fully engaged to meet flameproof/explosion-proof requirements.
WARNING
Electrical shock could cause death or serious injury.
Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock.
Ensure the power to the level switch is off, and the lines to any other external power source are disconnected or not powered while
wiring the level switch.
Ensure the wiring is suitable for the electrical current and the insulation is suitable for the voltage, temperature, and environment.
WARNING
Process leaks could result in death or serious injury.
Ensure the level switch is handled carefully. If the process seal is damaged, gas might escape from the vessel (tank) or pipe.
2

WARNING
Any substitution of non-recognized parts may jeopardize safety. Repair (e.g. substitution of components) may also
jeopardize safety and is not allowed under any circumstances.
Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and
jeopardize safety. Unauthorized changes that interfere with the integrity of the welds or flanges, such as making additional
perforations, compromise product integrity and safety. Equipment ratings and certifications are no longer valid on any products
that have been damaged or modified without the prior written permission of Emerson. Any continued use of product that has
been damaged or modified without the written authorization is at the customer’s sole risk and expense.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
CAUTION
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate
readings.
For information on Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.
CAUTION
Hot surfaces
The flange and process seal may be hot at high process temperatures. Allow to cool before servicing.
3

4

Contents
Chapter 1 Introduction.............................................................................................................. 7
1.1 Using this manual........................................................................................................................ 7
1.2 Product certifications...................................................................................................................7
1.3 Product recycling/disposal...........................................................................................................7
Chapter 2 Level switch overview................................................................................................ 9
2.1 Measurement principles.............................................................................................................. 9
2.2 Process characteristics.................................................................................................................9
2.3 Vessel characteristics...................................................................................................................9
2.4 Application examples.................................................................................................................10
2.5 Components of the level switch.................................................................................................12
Chapter 3 Mechanical installation............................................................................................ 15
3.1 Safety messages........................................................................................................................ 15
3.2 Installation considerations.........................................................................................................16
3.3 Installation procedures.............................................................................................................. 25
Chapter 4 Electrical installation................................................................................................31
4.1 Safety messages........................................................................................................................ 31
4.2 Prepare the electrical connections............................................................................................. 32
4.3 Connect wiring and power up.................................................................................................... 47
Chapter 5 Operation................................................................................................................ 51
5.1 Output mode and time delay..................................................................................................... 51
5.2 LED indication status..................................................................................................................52
5.3 Set the operating mode............................................................................................................. 53
Chapter 6 Service and troubleshooting.................................................................................... 55
6.1 Safety messages........................................................................................................................ 55
6.2 Magnetic test point....................................................................................................................56
6.3 Visual inspection........................................................................................................................57
6.4 Maintenance..............................................................................................................................58
6.5 Troubleshooting........................................................................................................................ 58
6.6 Spare parts................................................................................................................................ 60
6.7 Replacement and calibration of cassettes.................................................................................. 60
6.8 Opening the lid (cover).............................................................................................................. 62
6.9 Service support..........................................................................................................................63
Appendix A Specifications and reference data............................................................................. 65
A.1 General......................................................................................................................................65
A.2 Physical specifications............................................................................................................... 65
A.3 Performance specifications........................................................................................................66
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Rosemount 2130 Level Switch 5

A.4 Electrical specifications..............................................................................................................67
A.5 Functional specifications........................................................................................................... 68
A.6 Environmental specifications.....................................................................................................68
A.7 Dimensional drawings............................................................................................................... 70
Contents Reference Manual
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1 Introduction
1.1 Using this manual
The sections in this manual provide detailed information on installing, operating, and
maintaining the Rosemount 2130 Level Switch - Vibrating Fork.
The sections are organized as follows:
Level switch overview provides a description of the level switch and its basic principles.
Mechanical installation contains mechanical installation instructions.
Electrical installation contains electrical installation instructions.
Operation contains how to adjust the operation and what the LED indications mean.
Service and troubleshooting provides troubleshooting techniques for the most common
operating problems.
Specifications and reference data supplies reference and specification data.
1.2 Product certifications
See the Rosemount 2130 Product Certifications document for detailed information on the
existing approvals and certifications.
1.3 Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of
in accordance with local and national legislation or regulations.
Related information
Service support
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Introduction Reference Manual
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2 Level switch overview
2.1 Measurement principles
Using the principle of a tuning fork, a piezo-electric crystal oscillates the forks at their
natural frequency. Changes to the oscillation frequency are continuously monitored by
electronics as it varies depending on the liquid medium in which the forks are immersed.
The denser the liquid, the lower the oscillation frequency.
When used as a low-level point alarm, the liquid medium in the vessel (tank) or pipe drains
down past the fork, causing a change of oscillation frequency that is detected by the
electronics and switches the output state i.e. wet-to-dry.
When the level switch is used as a high-level point alarm, the liquid rises in the vessel
(tank) or pipe making contact with the fork and causing the output state to switch i.e. dry-
to-wet.
2.2 Process characteristics
Emerson's vibrating fork technology is virtually unaffected by turbulence, foam, solids
content, coating products, and liquid properties. The natural frequency (1400 Hz) of the
fork avoids interference from plant vibration that may cause false switching to a wet state.
This allows for minimum intrusion into the tank or pipe using a short fork.
2.3 Vessel characteristics
The level switch should be mounted using its process connection, and in a horizontal or
vertical orientation so that the liquid medium can flow freely in the gap between the forks.
A vessel (tank) or pipe can be almost any shape or type, but check that the process
conditions are within the operating limits of the level switch.
Avoid installing near agitators and inlet pipes where the forks are likely to be splashed and
cause a false switch to a wet state. False switching events can be minimized by an
adjustable time delay on the electronics cassette and allows time for the fork to dry.
Never force the level switch into a vessel (tank) or pipe space. Any contact with the
opposite wall, or in-tank objects, could damage the forks and other wetted-process parts.
Extended length versions require supports at regular spaced intervals.
Related information
Required supports for extended fork
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Rosemount 2130 Level Switch 9

2.4 Application examples
Overfill prevention
Spillage caused by overfilling can be hazardous to people and the environment, resulting
in lost product and potentially high clean-up costs. The Rosemount 2130 is an overfill
prevention product from Emerson that can be used as one of multiple layers of protection.
It has been third party assessed and certified to IEC 61508.
High and low level point alarm
Maximum and minimum level detection in tanks containing different types of liquids are
ideal applications. It is common practice to have an independent high level alarm switch as
a backup to an installed level device in case of primary failure.
Pump control or limit detection
Batch processing tanks often contain stirrers and agitators to ensure mixing and product
‘fluidity’. The Rosemount 2130 has a user-selectable time delay, from 0.3 to 30 seconds,
that virtually eliminates the risk of false switching from splashing.
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Pump protection or empty pipe detection
With the fork projecting only 2 in. (50 mm) (dependent on connection type), the
Rosemount 2130 can be installed in small diameter pipes. Short forks mean minimum
intrusion on the wetside and allow for simple, low cost installation at any angle into pipes
or tanks. By selecting the option of direct load switching or relay electronics, the
Rosemount 2130 is ideal for reliable pump control and can be used to protect against
pumps running dry.
High-temperature applications
The 2130****E version is designed for high temperatures and is suitable for continuous
operation within the process temperature range of –94 to 500 °F (–70 to 260 °C).
Wireless applications
The advent of wireless communications allows process plant managers to save up to 90%
on installation cost compared with wired technologies. More data can be collected at
central locations than has ever been possible before. The Rosemount 2130 can be used
with a Rosemount 702 Wireless Discrete Transmitter to enable these benefits for your
applications.
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Rosemount 2130 Level Switch 11

Hygienic applications
With the highly polished forks option providing a surface finish (Ra) better than 0.4 μm,
the Rosemount 2130 meets the most stringent hygienic requirements used in food and
beverage, and pharmaceutical applications. The Rosemount 2130 is robust enough to
easily withstand CIP (Clean-In- Place) and SIP (Steam-In-Place) cleaning routines.
2.5 Components of the level switch
Figure 2-1 shows the components of a Rosemount 2130.
Figure 2-1: Rosemount 2130 Features
C, D
E
A, B
G, H, I
F
J
K
A. Direct Load, DPCO Relay, Fault + Alarm (2 x SPCO) Relays, PLC/PNP, NAMUR, or 8/16 mA
electronics
B. Mode switch, adjustable time delay, and 'heartbeat' LED
C. Housings in aluminum or 316 stainless steel
D. Magnetic test point
E. Thermal tube in 316/316L stainless steel (2130****E version only)
F. Threaded, flanged, or Tri Clamp process connections
G. ‘Fast drip’ fork design
H. Wetted material in 316/316L stainless steel, Alloy C and Alloy C-276, or ECTFE-coated
316/316L stainless steel
I. Short fork length or extensions up to 157.5-in. (4 m)
J. Two cable/ conduit entries
K. External ground screw
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2.5.1 Short fork technology
Using short-fork technology, the device can be used in almost all liquid applications.
Extensive research has maximized the operational effectiveness of the fork design, making
it suitable for most liquid mediums including coating liquids, aerated liquids, and slurries.
2.5.2 Fork design
The “fast drip” design allows the liquid to be quickly drawn away from the fork tip, making
the Rosemount 2130 quicker and more responsive in high density or viscous liquid
applications.
Figure 2-2: “Fast drip” forks
2.5.3 Instrument health monitor and continuous self-check
The Rosemount 2130 continuously performs instrument health diagnostics to self-check
the condition of the fork and sensor. These diagnostics can detect damage to the forks
including corrosion, internal or external damage to the forks, and breakages to the
internal wiring.
Detected damage will trigger the 'heartbeat' LED to pulse intermittently, followed by safe
handling of the electrical load.
2.5.4 Heartbeat LED
Each electronics cassette of the level switch has a ‘heartbeat’ LED indicating its operation
status. The LED flashes when the level switch output is ‘off’ and is constantly lit when 'on'.
The LED gives a constant indication that the level switch is functioning correctly (different
flash rates are used to indicate a product malfunction) and gives a local indication of the
process state.
2.5.5 Mode switch and adjustable output delay
A mode switch on the electronics cassette allows the level switch output to be 'on' or 'off'
when the forks are wet or dry. Typically is set to 'dry on' (for a low-level point alarm) or 'wet
on' (for a high-level point alarm). There is also a user-selectable time delay (0.3, 1, 3, 10, or
30 seconds) on the electronics cassette to virtually eliminate the risk of false switching in
turbulent or splashing applications.
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Rosemount 2130 Level Switch 13

2.5.6 Magnetic test point
A magnetic test point is located on the side of the housing, allowing a functional test of
the Rosemount 2130 and a system connected to it. Holding a magnet to the test point
causes the output to change state.
2.5.7 Electrical connections
The terminal blocks extend above the housing and give easy terminal access. Electrical
protections make electrical hook-up safe and easy.
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3 Mechanical installation
3.1 Safety messages
Instructions and procedures in this section may require special precautions to ensure the
safety of the personnel performing the operations. Information that potentially raises
safety issues is indicated by a warning symbol ( ). Refer to the following safety messages
before performing an operation preceded by this symbol.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or
serious injury.
Ensure the level switch is installed by qualified personnel and in accordance with
applicable code of practice.
Use the level switch only as specified in this manual. Failure to do so may impair the
protection provided by the level switch.
The weight of a level switch with a heavy flange and extended fork length may exceed 37
lb. (18 kg). A risk assessment is required before carrying, lifting, and installing the level
switch.
Repair, e.g. substitution of components, etc. may jeopardize safety and is under no
circumstances allowed.
WARNING
Explosions could result in death or serious injury.
Verify the operating atmosphere of the level switch is consistent with the appropriate
hazardous locations certifications.
Before connecting a handheld communicator in an explosive atmosphere, ensure the
instruments are installed in accordance with intrinsically safe or non-incendive field wiring
practices.
In explosion-proof/flameproof and non-incendive installations, do not remove the housing
cover when power is applied to the level switch.
The housing cover must be fully engaged to meet flameproof/explosion-proof
requirements.
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Rosemount 2130 Level Switch 15

WARNING
Electrical shock could cause death or serious injury.
Avoid contact with the leads and terminals. High voltage that may be present on leads can
cause electrical shock.
Ensure the power to the level switch is off, and the lines to any other external power
source are disconnected or not powered while wiring the level switch.
Ensure the wiring is suitable for the electrical current and the insulation is suitable for the
voltage, temperature, and environment.
WARNING
Process leaks could result in death or serious injury.
Ensure the level switch is handled carefully. If the process seal is damaged, gas might
escape from the vessel (tank) or pipe.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or
misconfiguration of end users’ equipment. This could be intentional or unintentional and
needs to be protected against.
Physical security is an important part of any security program and fundamental to
protecting your system. Restrict physical access by unauthorized personnel to protect end
users’ assets. This is true for all systems used within the facility.
CAUTION
Hot surfaces
The flange and process seal may be hot at high process temperatures. Allow to cool before
servicing.
3.2 Installation considerations
Before installing the level switch, review the safety, environmental, application, and pre-
installation sections.
3.2.1 Environmental considerations
The Rosemount 2130 is weatherproof and protected against the ingress of dust, but must
be protected from flooding. Avoid installing the level switch near heat sources.
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Figure 3-1: Environmental Considerations
OKOK
3.2.2 Application considerations
The Rosemount 2130 is a wired point-level device for use on open or closed vessels (tanks)
and in pipework containing liquid mediums.
For most liquids, including coating, aerated liquids and slurries, the function is virtually
unaffected by flow, turbulence, bubbles, foam, vibration, solid particles, build-up, or
properties of the liquid medium.
Avoid process medium build-up on the forks
Avoid situations where a drying and coating process medium may create an excessive
build-up or implement preventative maintenance programs to ensure the build-up is not
enough to impair performance (see Figure 3-2).
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Rosemount 2130 Level Switch 17

Always ensure:
•There is sufficient distance between build-up on the tank wall and the fork.
•There is no risk of ‘bridging’ the level switch forks.
Examples of products that can create ‘bridging’ of forks and impair performance are
dense paper slurries and bitumen.
Figure 3-2: Avoid Product Build-up
OK
Operating temperature and pressure ranges
Ensure the process is operating within the instrument operating temperature and pressure
ranges.
Liquid density requirements
Minimum standard density is 37.5 lb/ft3 (600 kg/m3).
Minimum density is 31.2 lb/ft3 (500 kg/m3 when ordered with the Low Density Range
option.
Liquid viscosity range
Up to 10000 cP (centiPoise) when operating in the Normal mode.
Up to Up to 1000 cP (centiPoise) when operating in Self-check mode.
Solids content in the liquid medium
As a guideline, the maximum solid particle diameter in the liquid process medium is 0.2 in.
(5 mm). Extra consideration is needed when solid particles are bigger than 0.2 in. (5 mm)
and advice should be sought from Emerson.
Foams
In almost all cases, the Rosemount 2130 is insensitive to foams (i.e. does not see the
foam).
However in rare occasions, some very dense foams may be seen as liquid; known examples
of this are found in ice-cream and orange juice manufacturing.
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Switching point
The switching point varies with different liquid densities. The switching point (SP) and
hysteresis (HY) for water are shown in Figure 3-3.
Figure 3-3: Switching Point in Inches (Millimeters)
SP
HYSP
0.5
(13)
0.1
(2.5)
0.5
(13)
Note
When mounted vertically, a low density medium has a switching point closer to the
process connection. A high density medium has a switching point closer to fork tip.
3.2.3 Pre-installation considerations
Measurement accuracy is dependent upon the proper installation of the device. Keep in
mind the need for easy access, personnel safety, practical field calibration, and a suitable
environment for the device.
Device identification
To identify a version of the level switch, see the labels on the housing and on the
electronics cassette inside the housing.
How to handle a level switch
Handle the level switch with great care.
The weight of the level switch with a heavy flange and extended fork length may exceed
37 lb. (18 kg). A risk assessment is required to be done before carrying, lifting, and
installing the level switch.
Use both hands to carry the extended length and high temperature versions, and do not
hold a level switch by the forks (see Figure 3-4).
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Rosemount 2130 Level Switch 19

Figure 3-4: Handling
Make no alterations to the level switch
Never make any alterations to the mechanical or electrical features of the level switch.
Figure 3-5: Make No Alterations
Allow adequate space outside tank or pipe
Mount the level switch so that it is removable and allow easy access to the wiring terminals
when the top cover is removed. Ensure there is also enough room for fitting cable glands
and cables.
A clearance of 1.2 in. (30 mm) is required for the top cover to be removed.
Note
The electronics housing cannot be rotated to assist with the cabling.
Covers installation
Ensure a proper seal by installing the electronics housing cover so that metal contacts
metal. Always use Emerson's O-rings.
Mounting orientation
Mount the Rosemount 2130 at any angle that allows the level of the process medium to
rise, fall, or flow through the fork gap.
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