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Quick Start Guide

00825-0100-2521, Rev AB

October 2020

Rosemount

™

2521 Solids Level Switch

Vibrating Fork

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Summary of Contents for Rosemount 2521 Series

Page 1: ...Quick Start Guide 00825 0100 2521 Rev AB October 2020 Rosemount 2521 Solids Level Switch Vibrating Fork ...

Page 2: ...Contents Introduction 3 Mechanical installation 10 Electrical installation 15 Configuration 24 Operation 29 Maintenance 33 Quick Start Guide October 2020 2 Quick Start Guide ...

Page 3: ...oting 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 u...

Page 4: ... 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...

Page 5: ...ned 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 Stan...

Page 6: ...xtended 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 dime...

Page 7: ...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 October 2020 Quick Start Guide Quick Start Guide 7 ...

Page 8: ...ater 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 Quick Start Guide October 2020 8 Quick Start Guide ...

Page 9: ...he 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 wil...

Page 10: ...ble 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...

Page 11: ... 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 October 2020 ...

Page 12: ... 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...

Page 13: ... 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 i...

Page 14: ... 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 o...

Page 15: ...over 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 Ensur...

Page 16: ...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 ca...

Page 17: ...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 leve...

Page 18: ...y 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 3 4 5 1 B A C A Intern...

Page 19: ... 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 3 4 1 2 5 PE Signal output Power supply L N October 2020 Quick Start Guide Quick Start Gu...

Page 20: ... 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 3 4 1 2 5 7 8 9 PE Signal output Power supply L N Quick Start Guide October 2020 20 Quick Start Guide ...

Page 21: ...nal output Maximum 0 4 A Load in example from PLC relay bulb etc Fuse on power supply maximum 4 A slow or fast HBC 250 V Figure 3 5 3 Wire PNP Power Supply and Signal Output Connections 1 2 3 PE Load Power supply L N October 2020 Quick Start Guide Quick Start Guide 21 ...

Page 22: ... 5 A fixed Load in example from PLC relay bulb etc Fuse on power supply maximum 4 A slow or fast HBC 250 V Note See the Rosemount 2521 Product Data Sheet for the full electrical specifications Figure 3 6 2 Wire Power Supply and Load Connections 1 2 PE Power supply L N Load Quick Start Guide October 2020 22 Quick Start Guide ...

Page 23: ...AMUR IEC 60947 5 6 Power supply 7 to 9 Vdc Signal output 1 mA or 2 2 mA switched output Figure 3 7 NAMUR Power Supply and Signal Output Connections 1 2 PE Power supply October 2020 Quick Start Guide Quick Start Guide 23 ...

Page 24: ...SH signal output When the level switch is used to indicate full silo set to Fail Safe High A power failure or line break is regarded as full silo signal as protection against overfilling FSL signal output When the level switch is used to indicate empty load set to Fail Safe Low A power failure or line break is regarded as empty silo signal as protection against running dry Figure 4 1 FSL and FSH S...

Page 25: ...ments of solids during filling or emptying operations By default T1 and T2 are configured for 0 seconds no delays Turning the T1 potentiometer clockwise increases the time delay for when the output switches from a sensor covered free state Turning the T2 potentiometer clockwise increases the time delay for when the output switches from free sensor covered Figure 4 2 Delay Settings A B A Potentiome...

Page 26: ... to the Falling Arrow fail safe position A power failure or line break is regarded as a full silo signal for protection against overfilling Rising arrow fail safe When the Rosemount 2521 is used to indicate an empty load set the PCB switch to the Rising Arrow fail safe position A power failure or line break is regarded an as empty silo signal as protection against running dry Figure 4 3 Rising and...

Page 27: ...ing B switch position down factory default C Electronics PCB for the SPDT relay option Table 4 1 Approximate minimum bulk density on setting Setting A Low sensitivity Setting B High sensitivity Rosemount 2521S standard sensitivity 9 lb ft3 150 g l 3 lb ft3 50 g l Rosemount 2521H high sensitivity option V1 4 5 lb ft3 75 g l 1 2 lb ft3 20 g l Rosemount 2521H enhanced sensitivity option V2 or V3 1 1 ...

Page 28: ... potentiometer towards Min Vibrating fork gets less sensitive Turn potentiometer towards Max Vibrating fork gets more sensitive Figure 4 5 Sensitivity Settings with Potentiometer A B C D A Potentiometer for adjusting the sensitivity B Minimum sensitivity C Maximum sensitivity D Sensitivity setting is not possible Quick Start Guide October 2020 28 Quick Start Guide ...

Page 29: ...4 5 3 4 5 1 3 1 3 1 3 1 3 1 2 1 2 1 2 1 2 FSL FSH FSL FSH A B C D E F A Setting Fail Safe High or Fail Safe Low B SPDT relay electronics C DPDT relay electronics D 3 wire PNP electronics E 2 wire electronics F LED for output signal Note See Configuring the signal output FSH and FSL for how to select a FSH or FSL setting October 2020 Quick Start Guide Quick Start Guide 29 ...

Page 30: ... 1 2 1 2 A B C D A Setting Rising or Falling fail safe B NAMUR electronics IEC 60947 5 6 C LED for output signal D Uncovered and covered fork sensors Note See Configuring the signal output fail safe Rising or Falling for how to select a Rising or Falling fail safe setting Quick Start Guide October 2020 30 Quick Start Guide ...

Page 31: ...lfunctions while installed in a silo or other storage vessel A test button is on the electronic PCB see Figure 5 4 Figure 5 4 Location of Test Button A B A Test button B LED for diagnostics When the fork is not covered with solids material pressing the test button stops the vibration and the signal output switches to indicate a covered fork sensor state October 2020 Quick Start Guide Quick Start G...

Page 32: ... the fork is clean and switching the output signal as expected When the LED is blinking the fork sensor is measuring weak vibrations A gradual decrease in the vibration indicates a possible increase in the build up of solids material on the fork If the LED continues to blink after cleaning the fork try a higher sensitivity setting When the LED is constantly on the vibration has stopped This indica...

Page 33: ...tted the lid can be removed while circuits are alive 6 2 Regular checks for safety To ensure robust safety in hazardous locations and with electrical safety the following items must be regularly checked depending on the application Mechanical damage or corrosion of the field wiring cables or any other components housing side and sensor side Tight sealing of the process connection cable glands and ...

Page 34: ...n test A frequent function test may be required depending on the application Observe all relevant safety precautions related to work safety e g electrical safety process pressure etc This test does not prove if the level switch is sensitive enough to measure the material of the application Function tests are done by covering the forks with a suitable solids material and monitoring if a correct cha...

Page 35: ...October 2020 Quick Start Guide Quick Start Guide 35 ...

Page 36: ... 6340 Baar Switzerland 41 0 41 768 6111 41 0 41 768 6300 RFQ RMD RCC Emerson com Asia Pacific Regional Office Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 65 6777 8211 65 6777 0947 Enquiries AP Emerson com Middle East and Africa Regional Office Emerson Automation Solutions Emerson FZE P O Box 17033 Jebel Ali Free Zone South 2 Dubai United Arab Emirates 971 4 8118100 971 4 886546...

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