Emerson Rosemount 3101 User manual

Quick Start Guide
00825-0100-4840, Rev CD
August 2019
Rosemount™ 3101, 3102, and 3105
Ultrasonic Liquid Level Transmitters

Contents
About this guide...........................................................................................................................3
The Rosemount 3101, 3102, and 3105.........................................................................................5
Considerations before installation................................................................................................7
Electrical installation.................................................................................................................. 10
Configuring the transmitter....................................................................................................... 21
Product Certifications.................................................................................................................36
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1 About this guide
This installation guide provides basic guidelines for the Rosemount 3101,
3102, and 3105 Ultrasonic Level Transmitters. It does not provide
instructions for detailed configuration, diagnostics, maintenance, service,
troubleshooting, or installations. Refer to the Rosemount 3101, 3102, and
3105 Reference Manual for more instructions. Manuals are available
electronically on Emerson.com
WARNING
Failure to follow these installation guidelines could result in death or
serious injury.
Make sure the transmitter is installed by qualified personnel and in
accordance with applicable code of practice. Use the equipment only as
specified in this manual. Failure to do so may impair the protection
provided by the equipment.
Explosions could result in death or serious injury.
Installation of the transmitters in a hazardous environment must be in
accordance with the appropriate local, national, and international
standards, codes, and practices. Please review the Product Certifications
section for any restrictions associated with a safe installation. 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. Verify that the operating
atmosphere of the transmitter is consistent with the appropriate
hazardous locations certifications.
External surface may be hot.
Care must be taken to avoid possible burns.
Process leaks could result in death or serious injury.
Install and tighten switches before applying pressure. Do not attempt to
loosen or remove flange bolts while the transmitter is in service.
Electrical shock could cause death or serious injury.
Make sure that the transmitter is not powered when making connections.
If the liquid level switch is installed in a high voltage environment and a
fault condition or installation error occurs, high voltage may be present
on leads and terminals.
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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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2 The Rosemount 3101, 3102, and 3105
The Rosemount 3101, 3102, and 3105 are 4–20 mA loop-powered level
transmitters designed for continuous liquid level measurements in tanks or
open flow channels.
They can be connected directly to a plant control system, or used with a
Rosemount 3490 Series Control Unit for programmable control
functionality. The Rosemount 3105 may be mounted in a hazardous area if
powered from a protected power supply.
2.1 Theory of operation
The transmitter is designed to be mounted above a liquid and uses
ultrasonic pulses to continuously measure the distance to the liquid surface.
The microprocessor-controlled electronics calculates distance to the liquid
level from the time delay between the transmitting and receiving of signals.
When programmed with the bottom reference of the application – usually
the bottom of a tank (Figure 2-1) – the transmitter calculates the liquid
depth (level) and outputs the level as a 4–20 mA signal (and a digital HART®
signal on the 3102 and 3105).
The Rosemount 3101 measures level only. The Rosemount 3102 and 3105
can calculate distance-to-surface, contents (volume), or open channel flow,
and then output the result as a 4–20 mA signal and a digital HART signal.
An LCD screen inside the enclosure displays the selected measurement.
Programming is achieved using integral buttons inside the enclosure (all
models) or by remote communication using HART (on the 3102 and 3105
only).
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Figure 2-1: Typical Application
F
A
B
C
G
20mA
4mA
EE
D D
A. Rosemount 3100 Series Transmitter
B. Rosemount 3490 Series Control Unit
C. 4–20 mA signal
D. Relay
E. Pump
F. Bottom reference
G. 4–20 mA and HART signal
Note
HART is available on the Rosemount 3102 and Rosemount 3105.
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3 Considerations before installation
The Rosemount 3100 Series may be used for level and volume measurement
in open or closed tanks, or open channel flow measurement.
The glass-filled nylon housing version of the transmitter must be installed in
a location where it is protected from ultraviolet radiation to prevent long
term degradation of the plastics used (e.g., shrouded from direct sunlight).
Note
See also Product Certifications for special conditions for safe use.
3.1 Safety considerations
•Installation must be carried out by suitably trained personnel in
accordance with the applicable code of practice.
•If the equipment is likely to come into contact with aggressive
substances, it is the responsibility of the user to take suitable precautions
that prevent it from being adversely affected, thus ensuring that the type
of protection is not compromised.
•Aggressive substances are acidic liquids or gases that may attack metals
or solvents that may affect polymeric materials.
•Suitable precautions are regular checks as part of routine inspections, or
establishing, from the material's data sheet, that it is resistant to specific
chemicals.
•The equipment must only be cleaned with a damp cloth; do not use
solvents.
•The equipment is not intended to be repaired by the user and is to be
replaced by an equivalent certified unit. Repairs should only be carried
out by the manufacturer or approved repairer.
•The transmitter is double insulated, and therefore Protective Earthing is
not required. The cable shield/screen should be connected to a suitable
ground (earth) at one end only (see Connecting the cable(s) to the
transmitter).
•If the equipment is used in a manner not specified by the manufacturer,
the protection afforded by the equipment may be impaired.
•To ensure electro-magnetic compatibility in any European member
state, it should not be installed in a residential area.
•It is not advisable to mount the transmitter near to a source of electrical
noise such as a variable-speed drive or other high-powered electrical
device.
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3.2 Environmental considerations
•The Rosemount 3105 transmitter is Intrinsically Safe (IS) approved for
hazardous area installations.
•The Rosemount 3101, 3102, and 3105 are designed for open or closed
tank installation. They are weatherproof and protected against the
ingress of dust.
•Avoid installing the transmitters near heat sources.
Figure 3-1: Environmental Considerations
OKOK OK
3.3 Mounting considerations
•Mount the transmitter above the liquid using the 2-in. thread provided,
but no closer than 12-in. (0.3 m) to the surface. The transmitter does not
detect any liquid surface closer than 12-in. (0.3 m) to the transmitter
face.
•The transmitter should be mounted vertically to ensure a good echo
from the liquid surface. The beam half angle is six degrees (see Figure
4-5).
•Obstructions in the tank, or well, may generate echoes which can be
confused with the real liquid surface echo. Obstructions within the beam
angle generate strong false echoes. Wherever possible, the transmitter
should be positioned to avoid false echoes.
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•To avoid detecting unwanted objects in the tank or well, it is advisable to
maintain a distance sideways of at least 1.3-in. from the center line of the
transmitter for every foot (11 cm per meter) range to the obstruction
(Figure 4-5).
•No false echoes are generated if the transmitter is located near the side
of the tank or well on condition that the wall is smooth and free of
protrusions. However, there will still be a reduction in the echo size. It is
recommended that the transmitter be mounted no closer than 12 in.
(0.3 m) to the wall to avoid a large reduction in the echo size .
•If the transmitter is mounted in an enclosed tank with a domed top,
avoid mounting the transmitter in the center of the tank roof because
this could act as a parabolic reflector and create unwanted echoes.
•Avoid applications where heavy condensation could form on the
transmitter face.
•If the transmitter is mounted in a stand-off or nozzle, the transmitter
face should protrude at least 0.2-in.(5 mm) into the tank.
•If the transmitter is used in environments where direct sunlight can
cause high temperatures on exposed surfaces, a sun-shade is
recommended.
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4 Electrical installation
4.1 Connecting the cable(s) to the transmitter
The Rosemount 3100 Series is a two-wire loop-powered transmitter
accepting power supplies as follows:
•The 3101: 12 to 30 Vdc
•The 3102: 12 to 40 Vdc
•The 3105: 12 to 40 Vdc(non-hazardous area), 12 to 30 Vdc (hazardous
area)
Note
•To comply with the CSA approval requirements, the Rosemount 3101
and 3102 must be powered from a Rosemount 3490 Series Control Unit
or a class 2 separate extra-low voltage (SELV) source.
•Other devices may reset if connecting the transmitter to a multi-drop
system while the loop is powered. De-energize the loop to avoid devices
being reset.
Each transmitter is supplied with two cable entries. A suitable conduit
system or cable gland must be used to maintain the weather-proof rating
and hazardous area protection. Any unused entry must be sealed with a
suitably rated blanking plug.
A two-core, shielded/screened cable is required for external power supply
and output signal connections. The cable is not supplied.
4.1.1 Hazardous area installation (Rosemount 3105 only)
When the Rosemount 3105 is used with a Rosemount 3490 Series Control
Unit, no additional safety barriers are required. If powering the Rosemount
3105 from any other source, ensure a suitable Intrinsically Safe (IS) barrier is
fitted in the non-hazardous (safe) area. The barrier must be chosen such that
its output parameters Uo, Io, and Po are less than Ui, Ii, and Pi of the
transmitter.
IS parameters: Ui = 30 V, li = 120 mA, Pi = 0.82 W, Li = 108 mH, Ci = 0 nF
The sum of the capacitance and the inductance of the transmitter and the
connecting cable must not exceed the maximum specified for the barrier
chosen.
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4.1.2 Connect the cable(s) to the transmitter
Note
•The Rosemount 3101 and 3102 are not intrinsically safe and are for use
in non-hazardous (Ordinary Location) installations only.
•If HART communications are required (available on the Rosemount 3102
and 3105), a 250 Ohm (minimum), 0.25 W load resistor must be
installed in the loop.
•When using the Rosemount 3102 or 3105 transmitter with a Rosemount
3490 Series Control Unit, this resistor is not required.
Figure 4-1: Wiring Diagram for Rosemount 3101
C
E0 Vdc
12 to 30 Vdc
A
B
D
A. Maximum cable length is 9,750 ft. (3,000 m)
B. Connect the cable shield/screen to ground (earth) in the control room
C. Cable thickness: Ø0.15 to 0.31 in. (Ø4 to 8 mm)
D. Twisted-pair, screened wires minimum size: 0.22 mm2 (24 SWG/23
AWG); Maximum: 1.5 mm2 (16 SWG/18 AWG)
E. minimum of 12 Vdc is required at the transmitter for it to operate
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Figure 4-2: Wiring Diagram for Rosemount 3102
A
E
C
D
B
0 Vdc
12 to 40 Vdc
F
A. Maximum cable length is 9,750 ft. (3,000 m)
B. Connect the cable shield/screen to ground (earth) in the control room
C. Cable thickness: Ø0.15 to 0.31-in. (Ø4 to 8 mm)
D. Twisted-pair, screened wires minimum size: 0.22 mm2 (24 SWG/23
AWG); maximum: 1.5 mm2 (16 SWG/18 AWG)
E. Minimum of 12 Vdc is required at the transmitter for it to operate
F. Transmitter terminals:
1(+): +24 Vdc
2(-): 0 Vdc
3+4: Relay 1(SPST)
5+6: Relay 2 (SPST)
7+8: Remote temperature sensor
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Figure 4-3: Wiring Diagram for Rosemount 3105
A
E
C
D
B
F
0 Vdc
G
A. Maximum cable length is 9,750 ft. (3,000 m)
B. Connect the cable shield/screen to ground (earth) in the control room
C. Cable thickness: Ø0.15 to 0.31 in. (Ø4 to 8 mm)
D. Twisted-pair, screened wires minimum size: 0.22 mm2 (24 SWG/23
AWG); maximum: 1.5 mm2 (16 SWG/18 AWG)
E. Minimum of 12 Vdc is required at the transmitter for it to operate
F. Transmitter terminals:
1(+): +24 Vdc
2(-): 0 Vdc
7+8: Remote temperature sensor
G. 12 to 40 Vdc (non-IS application) or 12 to 30 Vdc from barrier (IS
application)
Procedure
1. Make sure that the power supply is disconnected.
2. Undo the three cover screws and then lift the transmitter housing
cover.
The cover on the metal housing can rest on the hinge. Place an object
under the cover to prevent the transmitter from tipping.
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3. Pass the cable through the cable gland/conduit.
4. Connect the cable wires:
a) For the 3101, connect wires according to the Figure 4-1.
b) For the 3102, connect wires according to the Figure 4-2.
c) For the 3105, connect wires according to the Figure 4-3.
5. Connect the cable shield/screen to a suitable ground (earth) at one
end only.
6. Replace the cover, tighten the cable gland, and connect the power
supply.
4.2 Mounting the transmitter above a liquid surface
A two-in. thread is provided to mount the transmitter. The thread form is
either BSPT or NPT, and is clearly marked on the hexagon of the transmitter
body.
To help with an installation, flange accessories and bracket kits are available
from Emerson. The accessory flanges supplied are manufactured from PVC
and are a full face design. Care must be taken when installing to raised face
mating flanges on the tank or vessel to prevent distortion of the PVC flange
by overtightening the bolts (see Installing in a tank with a nozzle or stand-
off).
Refer to the Rosemount 3101, 3102, and 3105 Product Data Sheet for
accessory ordering information.
4.2.1 Bracket mounting
The bracket kit contains a stainless steel angle bracket and PVC threaded
disc, which may be used to mount the transmitter on a support over the
liquid surface.
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Figure 4-4: Bracket Mounting
C
A
B
A. Stainless steel bracket
B. No. 4X 13 long self tap screws (x3), carbon steel (zinc plated)
C. PVC disc
Procedure
1. Attach bracket to the disc using the three screws provided.
2. Attach the assembled bracket and disc to a rigid support over the
liquid surface.
The bracket may be bolted to a suitable crossmember. Ensure the
transmitter is perpendicular to the surface to maximize the return
echo size.
3. Use PTFE tape on the transmitter’s screw thread.
4. Insert the transmitter into the disc.
5. Tighten to a torque of 1.5 ft-lb (2 N-m) using the transmitter’s
hexagon. Do not use the transmitter housing to tighten.
4.2.2 Installing in a tank with a nozzle or stand-off
Prerequisites
Use PTFE tape on the screw thread of the transmitter.
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Figure 4-5: Flange Mounting
A
B
D
C
A. Transmitter is mounted vertically (maximum deviation of 3-in.)
B. Use non-metallic fitting or flange
C. 6-in. beam half angle
D. 1.3-in./ft (11 cm/m), minimum of 12-in. (0.3 m)
Procedure
1. If the tank has a flanged nozzle or stand-off:
The instrument (accessory) flanges supplied by Emerson are
manufactured from PVC and are a full face design. Care must be
taken when installing to a raised face mating flange on the tank or
vessel to prevent distortion of the PVC flange by overtightening the
bolts.
a) Attach the transmitter to a non-metal instrument flange
using the threaded connection.
b) Tighten to a torque of 1.5 lb-ft (2 N-m) using the transmitter’s
hexagon.
c) Ensure that the gasket is sitting correctly on the nozzle/tank
flange.
d) Lower the assembled transmitter and instrument flange onto
the tank flange, and secure with appropriate bolting to a
suitable torque for the flanges.
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If mating to a raised face flange (RF) on the tank nozzle or
stand-off, tighten to a maximum torque of 10 lb-ft (13.6 N-m)
2. If the tank has a threaded nozzle or stand-off:
a) Attach the transmitter to the nozzle/stand-off using the
threaded connection.
b) Tighten to a torque of 1.5 lb-ft (2 N-m) using the transmitter’s
hexagon.
If the transmitter face does not protrude into the vessel, refer to the
installation section in the Reference Manual for further information.
4.2.3 Open channel flow installations
Mount an ultrasonic transmitter over an area of clear liquid. Avoid mounting
the transmitter directly over any inlet stream. Never suspend the transmitter
by the cable.
Positioning of the transmitter is critical and should be the correct distance
upstream from the flow structure as stated in the relevant standard for your
country.
For example, in the ISO standards, the distance should be four to five times
the maximum height of the water (H) for a thin plate weir, or three to four
times Hmax for a flume. For optimum accuracy, the transmitter’s front face
should be positioned at a height equal to the sum of the maximum flow
depth plus the transmitter dead band of 12.2-in. (300 mm) plus an extra 2-
in. (50 mm).
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Figure 4-6: Choosing the Height Position Above a Flow
A
B
C
A. Transmitter front face
B. Hmax
C. Transmitter bottom reference = Hmax + 12.2-in. (300 mm) + 2-in. (50
mm)
Note
It is important that the bottom reference of the transmitter should be
related to the datum of the primary measuring device (Figure 4-7).
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Figure 4-7: Bottom Reference of a Flume or Weir
A
C
D
B
A. Transmitter bottom reference
B. Primary device (e.g. flume, weir) invert
C. Approach channel
D. Flow direction
Note
When setting the bottom reference on a ‘V’- notch weir (Figure 4-8), it is
important the true invert is used and not the meniscus level.
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Figure 4-8: Bottom Reference of ‘V’-notch Weir
A
B
A. Transmitter bottom reference (i.e. true invert)
B. Meniscus level
Note
•The transmitter should be mounted in a location where it will not to
"drown" (refer to the relevant standard for further information).
•If the flow structure permits, mount the transmitter within the flow
channel or chamber. Shroud the transmitter from direct sunlight for
maximum accuracy and stability.
•The Rosemount 3102 and Rosemount 3105 have the option of a Remote
Temperature Sensor (RTS). This temperature sensor should be mounted
in a location where it can get an accurate air temperature measurement
and is protected from sunlight. (See Quick Installation Guide for further
RTS installation information).
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