Emerson Rosemount 2521 Series User manual

Quick Start Guide
00825-0100-2521, Rev AB
October 2020
Rosemount™ 2521 Solids Level Switch
Vibrating Fork

Contents
Introduction.................................................................................................................................3
Mechanical installation...............................................................................................................10
Electrical installation.................................................................................................................. 15
Configuration.............................................................................................................................24
Operation...................................................................................................................................29
Maintenance.............................................................................................................................. 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.
•In explosion-proof/flameproof, increased-safety, and dust ignition-proof
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.
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) 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.
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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 2521 Solids Level Switch is used for monitoring the level of
bulk materials in all types of containers and silos.
The level switch can be used with all powdery and granulated bulk materials
that do not show a strong tendency to form crusts or deposits. The
detection of solids in a liquid is also possible.
Three different housing options are available:
•Standard
—for installations in non-hazardous area (ordinary locations)
—for dust-ignition proof installations in hazardous areas
•Type 'D'
—for flameproof/explosion-proof/dust-ignition proof installations in
hazardous areas (classified locations)
•Type 'DE'
—same as Type 'D' but with a terminal box (increased safety)
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.
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•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,
if it has an extended length, mount it vertically on top of a silo to monitor the
maximum filling limit.
The length of the fork can be up to 157.5 in. (4 m) with an extension tube or
up to 787 in. (20 m) with an extension cable.
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.
Note
The Rosemount 2521 Product Data Sheet has all dimensional drawings.
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Figure 1-1: Typical Installation Examples
A
B
C
C
C
D
A. Rosemount 2521 with the cable-extended fork length
B. Rosemount 2521 with the tube-extended fork length and thermal tube-
extension
C. Rosemount 2521 with the standard length fork
D. Optional sliding sleeve
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Figure 1-2: Detection of solids in water
A
C
D
B
B
B
A. Rosemount 2521 with the tube-extended fork length and thermal tube-
extension
B. Rosemount 2521 with the standard length fork
C. Optional sliding sleeve
D. Solids in water
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1.3 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 which varies depending on whether
the fork is covered or uncovered by a solids medium.
When the solids medium in the vessel (silo) falls away from the fork, it causes
a change of oscillation frequency that is detected by the electronics and the
output switches to indicate an 'uncovered' state.
When the solids medium in the vessel (silo) rises and covers the fork, it
causes a change of oscillation frequency that is detected by the electronics
and the output switches to indicate a 'covered' state.
The electrical output will vary depending on the electronics selected when
the Rosemount 2521 was ordered.
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2 Mechanical installation
2.1 Mounting considerations
Before mounting the level switch on a silo (or other vessel), review the safety
and pre-mounting sections.
2.1.1 Safety
General safety
1. Installation of this equipment shall be carried out by suitably trained
personnel, in accordance with the applicable code of practice.
2. If equipment is likely to come into contact with aggressive
substances, it is the user’s responsibility to take suitable precautions
that prevent it from being adversely affected, thus ensuring the type
of protection is not compromised.
a. Aggressive substances: Acidic liquids or gases that may
attack metals or solvents that may affect polymeric materials.
b. Suitable precautions: Regular checks as part of routine
inspections or establishing from a material's data sheet that it
is resistant to specific chemicals.
3. It is the responsibility of the installer to:
a. Take protective measures, such as fitting an angled shield
(reverse V shape) to the silo or selecting an extension tube
option, when there are high mechanical forces.
b. Ensure that the process connection is tightened by the
correct amount of torque and sealed to prevent process
leaks.
4. Technical data
a. The Rosemount 2521 Product Data Sheet has all the technical
specifications. See Emerson.com/Rosemount for other
language versions.
Hazardous area safety
The Rosemount 2521 Product Certifications document has safety
instructions and control drawings for hazardous area installations. See
Emerson.com/Rosemount for other language versions.
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2.1.2 Solids in Water
The detection of solids in water is supported by the Rosemount 2521S only.
An installation example can be seen in Figure 1-2.
2.1.3 Mechanical load
The load at the mounting point must not exceed 300 Nm (Rosemount 2521
with an extended length fork).
Figure 2-1: Maximum Mechanical Load
B
A
A. Mounting point
B. Mechanical load
2.1.4 Vertical installations
Table 2-1 provides the maximum fork lengths and the corresponding
maximum deviations from a normal vertical installation.
Table 2-1: Maximum Vertical Deviation
Maximum deviation Maximum fork length
5° 157.5 in. (4000 mm)
45° 47.24 in. (1200 mm)
> 45° 23.62 in. (600 mm)
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2.1.5 Mounting location
Take time to assess a suitable mounting location. Avoid mounting the level
switch near the filling point, internal structures, and walls of a silo (or other
vessel). When mounting the extended length versions of the level switch, it
is especially important to consider internal structures. Forcing the level
switch into a small or congested space risks damage to the sensor and could
impair the protection it provides.
2.1.6 Sliding sleeve
Tighten both M8 screws with a torque of 20 Nm to establish a seal and
maintain the process pressure. See Figure 2-2.
Figure 2-2: Sliding Sleeve, M8 Screws
A
A. Two off M8 screws
2.1.7 Flange mounting
A suitable gasket must be fitted to provide a seal when the flanges are
tightened.
2.1.8 Tightening threaded process connections
When tightening the threaded process connection of a Rosemount 2521:
•Use an open-ended wrench on the hexagonal boss of the level switch or
the sliding sleeve.
•Never tighten by using the housing.
•Do not exceed the maximum torque of 80 Nm.
2.1.9 Hygienic applications
The food-grade materials are suitable for use under normal and predictable
hygienic applications (according to directive 1935/2004 Art.3). There are
currently no hygienic certifications for the Rosemount 2521.
2.1.10 Vibrating forks
Bending, shortening, or extending the forks will damage the level switch.
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2.1.11 Rotatable housing and fork orientation mark
The standard housing can be freely rotated to get the best position after
being mounted to a process. On type 'D' and 'DE' housings, a fixing screw
must first be loosened before the housing can be freely rotated. When the
best position is achieved, re-tighten the fixing screw. Never force the
rotation of the housing beyond the physical limits.
Figure 2-3: Housing Rotation and Fork Orientation Mark
A
C
B
A. Threaded process connection
B. Housing
C. Fork orientation mark on hexagonal boss (or sliding sleeve if fitted)
2.1.12 Orientation of cable glands
When the level switch is mounted horizontally, ensure the cable glands are
pointed downwards to avoid water getting inside the housing. Unused
conduit entries must be completely sealed with a suitably rated stopping
(blanking) plug.
2.1.13 Seals
Apply PTFE tape to the threaded process connection. This is required for a
silo (or other vessel) to maintain the process pressure.
2.1.14 Future maintenance
It is advisable to grease the screws of the housing cover (lid) when a
corrosive atmosphere is present. This will help prevent difficulties when the
cover needs to be removed during future maintenance tasks.
2.1.15 Switching point
Heavy bulk materials
The signal output switches over when the forks of the level switch are
covered a few millimeters.
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Light bulk materials
The signal output switches over when the forks of the level switch are
covered a few centimeters.
2.2 Mounting the level switch
Figure 2-4 shows how the level switch should be mounted.
Figure 2-4: Correct and Incorrect Mounting
A
B
A
B
C
E
F
G
D
OK
OK
H
A. Full-silo detection using the cable-extended fork length option
B. Empty-silo detection using the cable-extended or tube-extended fork
length option
C. Sliding sleeve option
D. Bulk solids slide downwards more easily when the device is mounted at
an angle (recommended)
E. Steel protection shield
F. Installation in the conical part is only suitable for solids material
(powder) that will not build-up on the forks
G. Incorrect installation - the fork orientation is not allowing solids material
to pass between the forks. Check the orientation mark on the hexagon is
either facing upwards or downwards
H. Incorrect installation - the socket is too long and allows the solids
material to easily accumulate inside it. The forks must protrude into the
silo sufficiently to correctly detect the level
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3 Electrical installation
3.1 Safety messages
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.
•In explosion-proof/flameproof, increased-safety, and dust ignition-proof
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.
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.
3.2 Wiring considerations
Note
See the Rosemount 2521 Product Data Sheet for the full electrical
specifications.
3.2.1 Handling
In cases of improper handling or handling malpractice, the electrical safety
of the device cannot be guaranteed.
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3.2.2 Installation regulations
Local regulations or VDE 0100 (Regulations of German Electrotechnical
Engineers) must be observed.
When using 24 V supply voltage, an approved power supply with reinforced
insulation to mains is required.
3.2.3 Fuse
Use a fuse as stated in the connection diagrams.
3.2.4 Residual Current Circuit Breaker (RCCB) protection
In case of a defect, the distribution voltage must automatically be cut-off by
an RCCB protection switch to protect against indirect contact with
dangerous voltages.
3.2.5 Power supply
Power supply switch
A voltage disconnection switch must be provided near the device.
Supply voltage
Compare the supply voltage applied with the specifications given on the
electronic module and nameplate before switching on the device.
3.2.6 Wiring
Field wiring cables
The diameter has to match the clamping range of the used cable gland.
The cross-section has to match the clamping range of the connection
terminals and the maximum current must be considered.
All field wiring must have insulation suitable for at least 250 Vac.
The temperature rating must be at least 194 °F (90 °C).
Use a shielded cable when there are electrical interferences present that are
higher than stated in the EMC standards. Otherwise, an unshielded
instrumentation cable can be used.
Guiding the cables in the terminal box
The field wiring cables must be cut to a length to be able to properly fit them
into the terminal box.
Connection terminals
When preparing cable wires for connection to terminals in a standard or type
'D' housing, the wire insulation must be stripped to show no more than 0.31
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in. (8 mm) of the copper strands. For Type 'DE' housings, remove insulation
of no more than 0.35 in. (9 mm). Always check that the power supply is
disconnected or switched-off to avoid coming into contact with dangerous
live parts.
Connection terminals
When preparing cable wires for connection to terminals, the wire insulation
must be stripped to show no more than 0.31 in. (8 mm) of the copper
strands. Always check that the power supply is disconnected or switched-off
to avoid coming into contact with dangerous live parts.
3.2.7 Cable glands, conduits, and blanking plugs in hazardous area
installations
General installation
•Installation of this equipment shall be carried out by suitably trained
personnel, in accordance with the applicable code of practice.
•Seal the un-used conduit entries with a suitably rated blanking plugs.
•Use only factory-supplied parts, where applicable.
•A suitable strain-relief must be provided for the wiring cables when the
level switch is installed with the factory-supplied cable glands.
•The diameter of the wiring cable must match to the clamping range of
the cable clamp.
•For parts that are not factory-supplied, it is the responsibility of the
installer to ensure:
—The parts have a certification and type of protection that is
equivalent to the approval of the level switch.
—The parts have an ambient temperature range that complies with the
specification of the level switch plus 10 Kelvin.
—The parts must be installed in accordance with the installation
instructions of the part manufacturers.
Installation of a flameproof or explosion-proof Rosemount 2521 with a
conduit system
In a conduit system, single electric conductors are installed in a certified pipe
system. This pipe system must also have a flameproof or explosion-proof
construction.
For ATEX and IECEx approvals, both enclosure of the level switch and pipe
system need to be isolated from each other by using a certified flameproof
or explosion-proof seal. The seal must be installed directly in, or at, the
conduit entries of the level switch. Unused conduit entries must be sealed
using suitably certified blanking elements (stopping plugs).
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For FM and CSA approvals, both enclosure of the level switch and pipe
system need to be isolated from each other by using a certified flameproof
seal. The seal must be installed within 18 inches of the enclosure wall.
Unused conduit entries must be sealed using suitably certified blanking
elements (stopping plugs).
3.2.8 Relay and transistor protection
Provide protection for relay contacts and output transistors to protect the
device against inductive load surges.
3.2.9 Static charging
The Rosemount 2521 must be grounded to avoid a static electrical build-up.
This is particularly important for applications with pneumatic conveying and
non-metallic containers.
3.3 Wiring the level switch
Figure 3-1: Connections Overview for Standard and Type 'D' Housings
2
345
1B
A
C
A. Internal ground terminal - electronics connected to housing
B. Connection terminals
C. Protective conductor terminal - Protective Earth (PE)
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Figure 3-2: Connections Overview for Type 'DE' Housings
A
B
A. Connection terminals (in a terminal box for increased safety).
The fixing torque is 0.5 - 0.6 Nm
B. Protective conductor terminal - Protective Earth (PE)
3.3.1 Wiring the SPDT relay
Power supply:
•19 to 230 Vac (50/60 Hz) +10% 8 VA
•19 to 55 Vdc +10% 1.5 W
Signal output (floating SPDT relay):
•Maximum 250 Vac, 8 A, non-inductive
•Maximum 30 Vdc, 5 A, non-inductive
Fuse on signal output: maximum 10 A, slow or fast, HBC, 250 V
Figure 3-3: SPDT Power Supply and Signal Output Connections
34
125
PE Signal output
Power supply
+-
LN
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3.3.2 Wiring the DPDT relay
Power supply:
•19 to 230 Vac (50/60 Hz) +10%, 18 VA
•19 to 36 Vdc (for I.S. approvals) or to 55 Vdc +10%, 2 W
Signal output (floating DPDT relay):
•Maximum 250 Vac, 8 A, non-inductive
•Maximum 30 Vdc, 5 A, non-inductive
Fuse on signal output: maximum 10 A, slow or fast, HBC, 250 V
Figure 3-4: DPDT Power Supply and Signal Output Connections
34
125 7 8 9
PE Signal output
Power supply
+-
LN
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