Emerson Rosemount 2501 User manual

Quick Start Guide
00825-0100-2501, Rev AA
October 2019
Rosemount™ 2501 Solids Level Switch
Rotating Paddle

Contents
Introduction.................................................................................................................................3
Mechanical installation...............................................................................................................11
Electrical installation.................................................................................................................. 20
Configuration.............................................................................................................................25
Operation...................................................................................................................................28
Maintenance.............................................................................................................................. 31
Product certifications................................................................................................................. 33
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1 Introduction
The level switch detects the presence and absence of a process media at its
installation point, and reports it as a switched electrical output.
Note
Other language versions of this Quick Start Guide can be found at
Emerson.com/Rosemount.
1.1 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
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.
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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.
Explosions could result in death or serious injury.
•The level switch must only be installed and operated in non-hazardous
(ordinary) locations.
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.
Process leaks could result in death or serious injury.
•Ensure the level switch is handled carefully. If the process seal is
damaged, gas or dust might escape from the silo (or other vessel)
Any substitution of non-recognized parts may jeopardize safety. Repair,
e.g. substitution of components, etc. may also jeopardize safety and is
under no circumstances allowed.
•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.
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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.
Individuals who handle products exposed to a hazardous substance can
avoid injury if they are informed of and understand the hazard.
•If the product being returned was exposed to a hazardous substance as
defined by Occupational Safety and Health Administration (OSHA), a
copy of the required Safety Data Sheet (SDS) for each hazardous
substance identified must be included with the returned level switch.
1.2 Applications
A Rosemount™ 2501 Solids Level Switch is used for monitoring the level of
bulk materials in all types of containers and silos.
The level switch can be equipped for process overpressure (1) and low
pressure, and also for very high or low process temperatures.
The level switch can be used with different paddle shapes and sizes to
monitor fine and medium solids in bulk materials. See Table 4-1 for a guide
to the minimum density requirements.
Typical applications are:
•Building materials
—Lime, extruded polystyrene foam (XPS), molding sand, etc.
•Food and beverage
—Milk powder, flour, salt, etc.
•Plastics
—Plastic granulates, etc.
•Timber
•Chemicals
The level switch has a threaded, flanged, or Tri Clamp process connection for
mounting it onto a silo (or other vessel). You can mount it on a side wall of
the silo, so that it is level with the filling limit to be monitored. Alternatively,
(1) Overpressure (or blast overpressure) is the pressure caused by a shock wave over and
above normal atmospheric pressure.
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if it has an extended length, mount it vertically on top of a silo to monitor the
maximum filling limit.
The length of the paddle can be up to 158 in. (4 m) with an extension tube or
up to 394 in. (10 m) with an extension rope.
The use of a sliding sleeve is recommended so that the switching point can
be changed easily during the live operation of the level switch.
Figure 1-1: Typical Installation Examples
A B C
D
E
F
G
A. Rosemount 2501R or 2501S with the rope-extended fork length
B. Rosemount 2501M with the tube extension and optional sliding sleeve
C. Rosemount 2501L with the pendulum shaft
D. Rosemount 2501L with the boot-shaped vane paddle
E. Rosemount 2501J
F. Rosemount 2501K
G. Optional sliding sleeve
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1.3 Measurement principles
Using a synchronous motor, the paddle (measuring vane) is driven to rotate
360 degrees.
When the vane of the paddle is not covered by a solids medium, a spring
pulls the motor and it switches a lug to the left position (Figure 1-2, top
illustration). The signal output indicates an 'uncovered' state and the motor
rotates the paddle.
When a solids medium covers the vane of the paddle, and causes the
rotation to stop, the lug is switched to the right position (Figure 1-2, bottom
illustration). The signal output indicates a 'covered' state due to a rising level
of material, and the motor is stopped until the vane becomes uncovered.
Figure 1-2: Switching Lug Function
B
A C D
A. Switching lug in left position ('uncovered' state)
B. Switching lug in right position ('covered' state)
C. Switch for stopping the motor
D. Switch for signal output
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The electrical outputs vary depending on the power supply selected when
the Rosemount 2501 was ordered. See the Rosemount 2501 Product Data
Sheet for the Power Supply option codes, and Electronics for an overview of
the outputs.
1.4 Functions
1.4.1 Selection guide
Table 1-1: Rosemount 2501 Selection Guide
Type of
installation
Model option codes
2501L 2501M 2501R 2501S 2501K 2501J
Full silo detection * *(1) * * * *
On-demand
detection
* *(1) * *
Empty silo
detection
* *(1) * *
Vertical
mounting
* * * *(1) *
Angled mounting
(top)
* *(2) *
Horizontal
mounting
* * *
Angled mounting
(bottom)
* *
(1) Consider the maximum permitted mechanical traction force.
(2) Available only with the "bearing at tube end" option.
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1.4.2 Shaft sealing and metal material
Table 1-2: Shaft Sealing and Metal Material
Application Sealing material(1) Metal Bearing
NBR FPM PTFE ALU(2) SST 304
(1.4301)
(3)
SST
Animal feed press * * *
Synthetic granules,
powders
* *
Salt * * *
Dust filter
(for up to 392 °F)
* *
Dust filter
(for up to 302 °F)
* *
Bitumen * *
Cement * *
Wood chip dryer * *
Pressure conveying
vessel, 8 bar
* *
Sugar * *
Flour * *
Carbon black * *
(1) Selection varies, depending on process temperature and pressure:
NBR: Maximums are 80 °C and 0.8 bar.
FPM: Maximums are 150 °C and 0.8 bar.
PTFE: Maximums are 250 °C and 0.8 bar, 80/150/250 °C and 5/10 bar.
(2) Aluminum.
(3) 316L (1.4404) stainless steel is recommended in particular cases.
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1.4.3 Electronics
Table 1-3: Electronics
Power supply SPDT(1) DPDT(2) FSH/
FSL(3)
Output
delay(4)
Fail safe
alarm
Ac
version
24 or 48 Vac or
115 or 230 Vac
* - - - -
Dc
version
24 Vdc * - - - -
Universal
voltage
24 Vdc /
22 .. 230 Vac
- * * * option
(1) Single-Pole-Double-Throw contacts.
(2) Double-Pole-Double-Throw contacts.
(3) Selectable Fail Safe High or Fail Safe Low alarm output. See Wiring the universal
voltage version and Jumper Settings for Fail Safe High or Low.
(4) Adjustable time delay for the switched outputs.
Switched signal output
The ac-voltage or dc-voltage versions of the level switch output a 'covered
paddle' or 'uncovered paddle' status signal through SPDT relay contacts.
See Wiring the ac and dc voltage versions for details.
The universal-voltage version of the level switch outputs a 'covered paddle'
or 'uncovered paddle' status signal through DPDT relay contacts.
See Wiring the universal voltage version for details.
When using the universal-voltage version of the level switch, there is an
adjustable delay for the switched signal output. Setting a delay helps to
prevent false switching of the output when there is movement of the bulk
material in a silo (or other vessel). See Figure 4-1 for details.
Fail safe alarm
The fail-safe alarm option makes it possible for the level switch to indicate a
fault using the alarm relay.
The following faults are indicated:
•Motor failure
•Gear failure
•Electronics failure (for motor power supply)
•Supply voltage failure
•Terminal wiring defect
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