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Rosemount 3095, Product Manual

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Rosemount 3095 Product Manual Download Page 7

vii

SECTION 5
Troubleshooting 
and Maintenance

Safety Messages   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Level Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Communication Problems   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Interpreting Level Controller Alarms and Error Conditions . . . 5-3

Disassembly Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Process Sensor Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Electrical Housing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Remove the Electronics Board  . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Remove the Sensor Module from the Electronics Housing   . . . . 5-13

Reassembly Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Attach the Sensor Module to the Electronics Housing . . . . . . . . 5-14
Attach the Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Reassemble the Process Sensor Body  . . . . . . . . . . . . . . . . . . . . . 5-16

Return of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

SECTION 6
Level Controller 
Specifications and 
Reference Data

Functional Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Performance Specifications   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Physical Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Ordering Information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Options   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Accessories   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

APPENDIX A
HART Communicator

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Safety Messages   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Connections and hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Communicator Keys  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Action Keys  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Function Keys  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Alphanumeric and Shift Keys  . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Menus and Functions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Main Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Online Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
HART Fast Key Feature   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Diagnostic Messages   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

APPENDIX B
Level Controller Accesso-
ries and Options

Safety Messages   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Model 1199 Remote Diaphragm Seals . . . . . . . . . . . . . . . . . . . . . B-2
Model 305 Integral Manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
SST Mounting Brackets  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Transient Protection Terminal Block   . . . . . . . . . . . . . . . . . . . . . B-2

Options   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Auto-Tuning (Option Code CC)  . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Local Operator Interface   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Custom Configuration (Option Code C2)   . . . . . . . . . . . . . . . . . . B-3

APPENDIX C
Approval Drawings

Approval Drawings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Summary of Contents for 3095

Page 1: ...00809 0100 4741 English Rev AA Model 3095 Multivariable Level Controller P r o d u c t D i s c o n t i n u e d ...

Page 2: ......

Page 3: ...ical support quoting and order related questions North American 1 800 654 7768 24 hours a day Includes Canada Response Center Equipment service needs For equipment service or support needs outside the United States contact your local Rosemount representative The products described in this document are NOT designed for nuclear qualified applications Using non nuclear qualified products in applicati...

Page 4: ......

Page 5: ... Leg 2 13 Tap Considerations 2 15 Impulse Piping 2 15 Diaphragm Seals 2 15 Environmental Considerations 2 16 Access Requirements 2 16 Process Considerations 2 17 Electrical Considerations 2 18 Field Installation Procedure 2 19 Field Installation Equipment 2 19 Review Installation Considerations 2 19 Mount Controller and Install Bolts 2 19 Make Process Connections 2 19 Install RTD Assembly 2 20 Che...

Page 6: ...ew 4 1 Set Up the Level Calculation 4 2 Place Controller into Out of Service OOS Mode 4 2 Set Density 4 2 Set Level Units 4 2 Set Controller Height 4 4 Additional Options 4 4 Configure the Controller 4 5 Set Range Values 4 5 Set Control Type 4 5 Set Control Action Direct Reverse 4 5 Adaptive Bias Control ABC Settings 4 6 Set Power Up Output 4 6 Set Mode Shed Options Failure Condition 4 7 Set Manua...

Page 7: ...ional Specifications 6 1 Performance Specifications 6 4 Physical Specifications 6 5 Ordering Information 6 6 Options 6 7 Accessories 6 8 APPENDIX A HART Communicator Introduction A 1 Safety Messages A 1 Connections and hardware A 4 Communicator Keys A 6 Action Keys A 6 Function Keys A 7 Alphanumeric and Shift Keys A 7 Menus and Functions A 8 Main Menu A 8 Online Menu A 9 HART Fast Key Feature A 9 ...

Page 8: ...viii ...

Page 9: ... for dealing with potential mechanical or electrical difficulties Section 6 Level Controller Specifications and Reference Data includes specification data for the Level Controller Appendix A HART Communicator contains a Model 275 overview a HART Communicator menu tree for the Level Controller and a table of HART Communicator fast key sequences A table of diagnostic messages associated with this co...

Page 10: ...Rosemount Model 3095 Multivariable Level Controller 1 2 ...

Page 11: ...T based communicator in an explosive atmosphere make sure the instruments in the loop are installed in accordance with intrinsically safe or non incendive field wiring practices Both controller covers must be fully engaged to meet explosion proof requirements The unused conduit opening on the controller housing must be plugged and sealed to meet explosion proof requirements Failure to follow safe ...

Page 12: ...a PID algorithm whose output is a 4 20 mA analog signal A digital representation of the value of the 4 20 mA output may be obtained via HART digital communications Because the Level Controller is a multivariable device optional process variables can be measured and obtained as a secondary HART process variable The process variables available via HART are level DP control output CO and process temp...

Page 13: ...ocess The error between the setpoint and the actual process variable as measured by the sensor is used by the controller to determine the value of its output The controller output is an electrical current in mA which is used by an electrical to pneumatic device such as an I P to control the position of a valve A positioner which is mechanically connected to the moving part of the valve automatical...

Page 14: ...troller Review the Level ControllerProduct Manual Bench Configure BENCH CONFIGURE page 2 7 Connect Bench Power Supply Connect Model 275 Page A 5 Complete Configuration Tasks Section 3 FIELD INSTALLATION page 2 19 Review Installation Considerations Mount Controller Make Process Connections DONE Yes No Tune the Loop Controller Configured No Complete Configuration Tasks Section 3 Yes Check for Leaks ...

Page 15: ... Series 68 or Series 78 RTD Assembly and the Sensor Wiring Instruction Sheet When you unpack the Level Controller 1 Place the shipping containers on a secure bench and open them taking care not to damage the contents 2 Review the packing list to verify that all equipment was received 3 Inspect the equipment and report any shipping damage to the carrier BECOMING FAMILIAR WITH THE LEVEL CONTROLLER F...

Page 16: ...Label Housing O ring Cover Housing Locking Screw Electronics Board Nameplate Sensor Module Coplanar Flange Optional Flange Adapters RTD Connector Drain Vent Valve Terminal Block Module O ring Bolts Flange Adapter O ring Process Flange O ring FIGURE 2 4 Exploded View of the Level Controller ...

Page 17: ...Set these jumpers during the commissioning stage on the bench to avoid exposing the controller electronics to the plant environment after installation Once the controller has been configured the configuration data can be protected by moving the write protect security jumper When this jumper is installed the controller does not allow any changes to its configuration memory In the event of a critica...

Page 18: ...e the jumper s on the output electronics board see Figure 2 5 then move the jumper s to the desired setting 4 Reattach the housing cover Metal to metal contact is preferred Both controller covers must be fully engaged to meet explosion proof requirements 5 If the controller is installed reapply power OUTPUT ELECTRONICS BOARD OFF ON ALARM SECURITY HI LO NOTE Security jumper not installed Not Write ...

Page 19: ...bed to the bottom of the tank For open vessels the low pressure side of the Level Controller should be vented For closed vessels the low pressure side must always be plumbed to the top of the tank The following sections discuss the factors to consider for a successful Level Controller installation FIGURE 2 6 Dimensional Drawings of Level Controller NOTE Dimensions are in inches millimeters 7 07 18...

Page 20: ...5 inch manifold flange bolts for mounting the Coplanar flange on a three valve manifold In this configuration the 1 75 inch bolts may be used to mount the flange adapters to the process connection side of the manifold Optional If flange adapters are ordered four 2 88 inch flange adapter bolts for mounting the flange adapters to the Coplanar flange Figure 2 7 shows the optional mounting bracket and...

Page 21: ...ons and Optional Mounting Accessories NOTE Dimensions are in inches millimeters INTEGRAL MOUNT MANIFOLD 6 25 159 3001 3051AO1A 3095 3095K04A 3095L04A 3051 305 3031A29B 3051 3051A29B A28A 3 54 90 TWO DIAPHRAGM SEALS ONE DIAPHRAGM SEAL LEVEL FLANGE PIPE MOUNTED WITH OPTIONAL BRACKET ...

Page 22: ...VALVE MANIFOLD MANIFOLD FLANGE BOLTS FLANGE ADAPTERS AND FLANGE ADAPTER BOLTS NOTE Dimensions are in inches millimeters 3095 3095D05M 3095C05A 3095C29A Description Qty Size in mm Flange bolts Flange adapter bolts Manifold flange bolts 4 4 4 1 75 44 2 88 73 2 25 57 2 88 73 x 4 CONTROLLER WITH OPTIONAL FLANGE ADAPTERS AND FLANGE ADAPTER BOLTS CONTROLLER WITH FLANGE BOLTS 1 75 44 x 4 ...

Page 23: ...the liquid will affect the pressure measured at the bottom The pressure at the bottom of the vessel is determined by the height of the liquid the density of the liquid plus the vessel pressure To measure true level the vessel pressure must be subtracted from the measurement This is accomplished by making a pressure tap at the top of the vessel and connecting this to the low side of a differential ...

Page 24: ... B Controller Height A or Controller Height C Controller Height E D Controller Height M N OPEN TANK OPEN TANK WITH BUBBLER CLOSED TANK WITH DRY LEG CLOSED TANK WITH WET LEG CONTROLLER ABOVE BOTTOM OF TANK CLOSED TANK WITH WET LEG CONTROLLER BELOW BOTTOM OF TANK CLOSED TANK WITH WET LEG CONTROLLER ABOVE BOTTOM OF TANK FIGURE 2 9 Example Installations 3095 3095_01A ...

Page 25: ...troller toward the process connection for liquid Avoid high points in liquid lines Make sure both impulse legs are the same temperature Use impulse piping large enough to avoid friction effects and prevent blockage Vent all gas from liquid piping legs Avoid purging through the controller Keep corrosive or hot above 250 F 121 C process material out of direct contact with the sensor module and flang...

Page 26: ... rotated to improve field access to the two compartments To rotate the housing less than 90 degrees release the housing rotation set screw and turn the housing not more than 90 degrees from the orientation shown in Figure 2 7 on page 2 11 To rotate the housing more than 90 degrees follow steps 1 6 of the disassembly procedure on page 5 11 CAUTION Rotating the housing more than 90 degrees without p...

Page 27: ...ter is distinguished by its unique groove Use only the O ring designed to seal with the corresponding flange adapter Use only the O ring designed to seal with the corresponding flange adapter Failure to install proper flange adapter O rings can cause process leaks FIGURE 2 10 Flange Adapter O rings When compressed Teflon O rings tend to cold flow which aids in their sealing capabilities Whenever f...

Page 28: ...ge of at least 16 5 V dc is required Quick troubleshooting check there must be at least 11 0 V dc across the controller terminals If a single power supply is used to power more than one Level Controller the power supply used and circuitry common to the controllers should not have more than 20 ohms of impedance at 1200 Hz For CSA approval power supply must not exceed 42 4 V dc FIGURE 2 11 Power Sup...

Page 29: ...ocation and install flange or flange adapter bolts Only use bolts supplied with the Level Controller or sold by Rosemount Inc as a spare part to the Level Controller Unauthorized parts can affect product performance and may impair the protection provided by the equipment 1 Finger tighten the bolts 2 Torque the bolts to the initial torque value see Table 2 2 using a cross pattern 3 Torque the bolts...

Page 30: ...Controller RTD connector First fully engage the black cable connector then screw in and tighten the cable adapter until metal to metal contact occurs see photos 3 Optional If using an armored shielded cable install the armored cable compression seal as illustrated below and use a pliers to tighten the cap onto the compression fitting 4 Make all necessary wiring connections inside the RTD Flat Conn...

Page 31: ...iring rated for at least 194 F 90 C 1 Remove the cover on the side marked FIELD TERMINALS on the electronics housing Do not remove the instrument cover in explosive atmospheres when the circuit is alive 2 Connect the lead that originates at the positive side of the power supply to the terminal marked PWR Be sure to include loop resistance Avoid contact with leads and terminals 3 Connect the lead t...

Page 32: ...dance Methods for grounding the controller case include External Ground Assembly This assembly is included with the transient protection terminal block The External Ground Assembly can also be ordered as a spare part 03031 0398 0001 Internal Ground Connection Inside the FIELD TERMINALS side of the electronics housing is the Internal Ground Connection screw This screw is identified by a ground symb...

Page 33: ... of the Level Controller LEVEL VARIABLES AND VALUES The 3095 Level Controller measures differential pressure DP and uses that measurement to calculate process level The level calculation is completed by the sensor microprocessor using the following equation The calculation uses values for density gravity and transmitter location compared to the bottom of the vessel as specified by the operator The...

Page 34: ...citance sensor technology and microprocessor based sensor correction coefficients delivery for 0 075 accuracy for the DP sensor There is no need to calibrate the DP sensor All Model 3095 Level Controllers are factory calibrated from LRL to URL The Level Controller uses the DP input to calculate the Primary Variable which is Level Instead of calibration the user simply completes a Level Trim after ...

Page 35: ...ut of service manual auto Provides a bumpless transfer between mode transitions Initiates Setpoint Rate Limits and Setpoint Tracking Initiates power up variables Initiates Adaptive Bias and Manual Bias The controller algorithm is updated three times per second Although the Level Controller can perform several tasks in Auto Mode some specific tasks must be completed in Manual or Out of Service mode...

Page 36: ...rameters after the user enters the required autotuning setup information Level Controller Parameter or Task Required Mode Level Parameters MAN OOS Control Type and Action MAN OOS Setpoint Adjustment ALL Setpoint Limits ALL Setpoint Tracking ALL Control Setup ALL Control Gain ALL Controller Output MAN OOS Autotuner Setup AUTO MAN OOS Autotuner Alpha AUTO MAN OOS Invoke Auto tuning AUTO MAN Manual O...

Page 37: ...ight of a poorly tuned loop FIGURE 3 3 Example of a Poorly Tuned Loop A properly tuned loop results in significant reductions in process variability as shown in Figure 3 4 FIGURE 3 4 Example of the Same Loop After Autotuning PROCESS RESULTS BEFORE AUTOTUNING 0 20 40 60 80 100 120 0 500 1000 1500 2000 A d justedTim e Sec ControlSignal LEVEL ofTANK HEIGHT AUTOTUNING 0 20 40 60 80 100 120 0 200 400 6...

Page 38: ...ay and bias The Level Controller informs the user when tuning is completed successfully and asks the user to accept or reject the calculated tuning parameters If accepted the new parameters must then be sent to the Level Controller to be used If the Level Controller is not able to successfully calculate new tuning parameters the Level Controller aborts the Autotune procedure and informs the user o...

Page 39: ...yond the selected ABC region the ABC algorithm initiates the required control element response that will return the level to the selected ABC region By providing a larger allowable level range ABC reduces the number of required level changes to be made by the control element Limit cycle elimination reduces control element operation which may significantly extend the operating life of the control e...

Page 40: ...ll always show the current Mode Auto Manual or Out of Service OOS If the device experiences a failure the LOI will flash FAIL every two seconds The Z and S buttons allow the user to change the Mode and the setpoint and to select PVs When the display is in operational mode i e automatically scrolling through display data press any button to begin configuration mode When in configuration mode press ...

Page 41: ...he diagnostics determines that the level measurement is in a failed condition the controller allows the user to select a mode shed directing the controller to set the control element in a safe position The Level Controller will remain at the mode shed position until the failed signal clears or until re positioned by the user If the Level Controller determines that its ability to control the loop i...

Page 42: ...Rosemount Model 3095 Multivariable Level Controller 3 10 ...

Page 43: ...ctual level measurement matches the observed tank level 4 Tuning the Loop These tasks set the gain reset rate and bias parameters for the PID equation The tasks differ depending on whether or not you have purchased the Autotuning feature If you completed a Configuration Data Sheet and your Level Controller is factory configured tasks 1 and 2 are done you need only perform a level trim and tune the...

Page 44: ...lue when OOS mode was entered until the OOS mode is exited The Model 3095 Level Controller is shipped in OOS mode Before configuring the controller ensure that the controller is in the OOS mode Out of Service Factory Default OOS Out of Service Valid Options OOS AUTO MAN NOTE To complete a change of mode press the SEND key on the HART Communicator Set Density Density This selection sets the nominal...

Page 45: ...ight B Controller Height A or Controller Height C Controller Height E D Controller Height M N OPEN TANK OPEN TANK WITH BUBBLER CLOSED TANK WITH DRY LEG CLOSED TANK WITH WET LEG CONTROLLER BELOW BOTTOM OF TANK CLOSED TANK WITH WET LEG CONTROLLER ABOVE BOTTOM OF TANK FIGURE 4 1 Guidelines for Determining Controller Height L 3095 3095_01A ...

Page 46: ... to 300 meters Additional Options The following options are not required for Level Controller operation Set Damping The Level Controller has electronic damping that can change the response time of the level measurement to smooth the level reading when there are rapid input variations Level Damping High damping values filter out process noise but response time is increased Low damping values decrea...

Page 47: ...e not used for this control type Quick Lookup Table PID Proportional plus Integral plus Derivative control This algorithm use the P gain I reset and D derivative factors for the control algorithm Manual Bias and Adaptive Bias are not used for this control type PD Proportional plus Derivative control This algorithm use the P gain and D derivative factors for the control algorithm Manual Bias is als...

Page 48: ...ory Default Off Valid Range On Off ABC Static Error This selection sets the minimum amount that the level must differ from the setpoint before the ABC algorithm changes the bias level This parameter is set in level units Factory Default 1 0 inch Valid Range 0 0 to 20 in ABC Stability Threshold The stability threshold is the user defined limit on the rate of change of level When inside this limit t...

Page 49: ...onds to 8 mA 25 3 20 4 mA 4 mA 8 mA Factory Default 0 Valid Range 2 5 to 112 5 3 6 to 22 mA Shed Return This selection determines whether the controller returns from the mode shed routine if the failed level measurement condition ends Factory Default Return Valid Options Return no return Set Manual Output Manual Rate Limit Output rate limits define the maximum rate of change of the control output ...

Page 50: ...t Hi Limit CAUTION Selecting a setpoint near the top of the tank is not recommended Overshoot potential at PID control could cause overflow Setpoint Lo Limit Setpoint Setpoint is the defined setpoint for the controller when in AUTO Automatic mode When in AUTO mode the controller uses the selected Control Type and control parameters to maintain the level at the target setpoint Factory Default Level...

Page 51: ...N the new target setpoint will automatically change to 82 inches when the operator switches back to automatic mode Factory Default Tracking Disabled Valid Options Tracking Disabled Tracking Enabled Setpoint Rate Limit Setpoint rate limit defines the maximum ramp rate at which changes in the setpoint are acted on For example assume that the setpoint rate limit is set to 5 inches per second When an ...

Page 52: ...rst adjust the level to the value you wish to trim at Once the process stabilizes perform an offset trim You will be asked to select the level engineering units and then enter the level value observed with a sight glass or other visual reference Once the level offset trim is complete you may notice that the controller height in the level setup parameters has changed This is how the level offset tr...

Page 53: ...controller gain value This value is used for all four control types P PI PID PD Gain is a proportional calculation value higher numbers result in larger gain action Factory Default 1 0 Valid Range 0 0 to 100 0 Reset This selection sets the controller reset value This value is only used if the Control Type is set to PI or PID This setting is used as the integral time for the PID or PI algorithm equ...

Page 54: ...t be done in a region of the tank that is representative of the control region Autotuning is a two step process First the tuner estimates the process gain delay and demand by working the process opening and closing the valve under live process conditions Second the proposed tuning parameters calculated values for gain reset rate and bias are calculated using the process conditions loop performance...

Page 55: ...en the autotuner opens and closes the valve Factory Default 0 Valid Range 0 625 to 105 Tuning Output Max Valve This selection sets the upper output value used when the autotuner opens and closes the valve Factory Default 0 Valid Range 0 625 to 105 Tuning Lo Limit Level The level low limit is how far the level will travel on the low side during tuning as measured from the bottom of the tank This va...

Page 56: ...e Perform Auto Tune menu 2 Select Yes from Start Auto Tune Yes No 3 The HART Communicator displays the level value and tuning state When the tuning process completes the HART Communicator displays Complete Should the level process go beyond the tune level limits plus overshoot or go beyond the time out period the tuner will abort and display a Tuning Aborted message Accept Auto Tune The calculated...

Page 57: ...y Do not remove the instrument cover in explosive atmospheres when the circuit is alive Before connecting a HART based communicator in an explosive atmosphere make sure the instruments in the loop are installed in accordance with intrinsically safe or non incendive field wiring practices Both controller covers must be fully engaged to meet explosion proof requirements The unused conduit opening on...

Page 58: ...r O ring designed to seal with the corresponding flange adapter High voltage that may be present on leads could cause electrical shock Avoid contact with leads and terminals Symptom Corrective Action No Communication between the HART Communicator and the Level Controller LOOP WIRING HART protocol communication requires a loop resistance value between 250 1100 ohms inclusive Check for adequate volt...

Page 59: ...e Replace the sensor module as described on page 5 11 Contact your Field Service Center Sensor Module is Not Updating The 10 pin ribbon cable may be disconnected or the device electronics may have undergone a component or software failure Contact your Field Service Center Sensor Module is Not Responding The 10 pin ribbon cable may be disconnected or the device electronics may have undergone a comp...

Page 60: ...e input to the device If an overpressure underpressure condition exists correct it If not replace the sensor module as described on page 5 11 DP below LRL Working Pressure above URL These displays indicate that the device absolute pressure reading exceeds its sensor limits by more than 10 There are two possible causes either the device is overpressured underpressured or it has a sensor malfunction...

Page 61: ... paths in oil filled pressure devices can be created Possible causes include Physical damage to the isolator diaphragms Process fluid freezing Isolator corrosion due to an incompatible process fluid A device with oil fill fluid loss may continue to perform normally for a period of time Sustained oil loss will eventually cause one or more of the operating parameters to exceed published specificatio...

Page 62: ...not use higher than the specified voltage to check the loop or damage to the device may result Check the output voltage of the power supply at the device It should be 11 to 55 V dc at the device terminals DEVICE ELECTRONICS Connect a Model 275 to check the sensor limits to ensure calibration adjustments are within the sensor range and that calibration is correct Make sure the post connectors are c...

Page 63: ...k the sensor limits to ensure calibration adjustments are within the sensor range and that calibration is correct Make sure the post connectors are clean Confirm that the electronics housing is properly sealed against moisture If the electronics are still suspect substitute new electronics IMPULSE PIPING Check for entrapped gas in liquid lines and for liquid in gas lines Make sure that process flu...

Page 64: ... correct Check for leaks or blockage Check to ensure that blocking valves are fully open and that bypass valves are tightly closed Check for entrapped gas in liquid lines and for liquid in gas lines Check for sediment in the device process flange Make sure that process fluid has not frozen within the process flange DEVICE ELECTRONICS Connect a Model 275 to check the sensor limits to ensure calibra...

Page 65: ...frozen within the process flange DEVICE ELECTRONICS Connect a Model 275 to check the sensor limits to ensure calibration adjustments are within the sensor range and that calibration is correct Confirm that damping is correctly set Confirm that the electronics housing is properly sealed against moisture SENSING ELEMENT The sensing element is not field repairable and must be replaced if found to be ...

Page 66: ...etached by removing the four flange bolts and the two alignment screws that secure it CAUTION To prevent damage which may lead to inaccurate measurements do not scratch puncture or depress the isolating diaphragms Isolating diaphragms can be cleaned with a soft rag mild cleaning solution and clear water rinse CAUTION To prevent damage which may lead to inaccurate measurements do not use any chlori...

Page 67: ...nics Board The device electronics are located behind the cover opposite the terminal side CAUTION To prevent damage to the circuit board remove power from the device before removing the electronics cover To remove the electronics board 1 Remove the housing cover opposite the field terminal side Do not remove the instrument cover in explosive atmospheres when the circuit is alive 2 Loosen the two c...

Page 68: ...le connector completely inside the internal shroud The shroud protects the cable from damage that might occur when the housing is rotated CAUTION Do not remove the housing until the cable connector has been completely tucked inside the internal shroud Damage to the sensor module ribbon cable may occur if the connector does not rotate with the sensor module 3095LC04 3095LC05 ...

Page 69: ...cable 7 Unscrew the housing from the module making sure the shroud and sensor cable do not catch on the housing Damage can occur to the cable if the internal shroud and sensor cable rotate with the housing Carefully pull the shroud and sensor ribbon cable assembly through the housing opening CAUTION If the Coplanar flange has been removed take care not to damage the isolating diaphragm after disas...

Page 70: ...s housing onto the module and guide the internal shroud and cable through the housing and into the external shroud 4 Fasten the housing to the module by turning clockwise CAUTION To prevent damage to the cable connector watch the cable and shroud as you attach the housing to the module Make sure the cable connector does not slip out of the internal shroud and begin to rotate with the housing Reins...

Page 71: ...the electronics board 2 Align the post receptacle connectors with the posts inside the electronics housing 3 Insert the electronics board into the housing and tighten the captive mounting screws 4 Replace the electronics housing cover Metal to metal contact is preferred Both device covers must be fully engaged to meet explosion proof requirements 3095LC04 3095LC02 ...

Page 72: ...8 inch process flange adapter bolts Tighten the bolts in a cross pattern following the procedure outlined above Use two 2 88 inch bolts and two 1 75 inch bolts for gage pressure configurations After tightening the bolts should protrude through the top of the module housing If the bolts do not extend all the way through the module housing you have used a bolt of incorrect length Replace the bolt wi...

Page 73: ...e a Return Material Authorization RMA number The center will also ask for the name of the process material the product was last exposed to CAUTION People who handle products exposed to a hazardous substance can avoid injury if they are informed and understand the hazard If the product being returned was exposed to a hazardous substance as defined by OSHA a copy of the required Material Safety Data...

Page 74: ...Rosemount Model 3095 Multivariable Level Controller 5 18 ...

Page 75: ...terminal voltage of 11 55 V dc Humidity Limits 0 100 relative humidity Overpressure Limit 0 psia to a maximum of 1 600 psia 11032 kPa Static Pressure Limit Operates within specifications between static line pressures of 0 0 psia through 800 psia 5516 kPa maximum Load Limitations Loop resistance is determined by the voltage level of the external power supply as described by 2000 0 11 4 20 mA dc 55 ...

Page 76: ... Class II Division 1 Groups E F and G Suitable for Class III Division 1 indoor and outdoor hazardous locations CSA enclosure Type 4X Factory Sealed Provides nonincendive RTD connection for Class I Division 2 Groups A B C and D Approved for Class I Division 2 Groups A B C and D Install in accordance with Rosemount Drawing 03095 1024 D Combination of Approval Code C and the following Intrinsically S...

Page 77: ...t control signal All failure mode settings are user selectable Gross failures will drive the analog output high or low according to the user selecteable alarm jumper Turn on Time Digital measured variables will be within specifications 12 14 seconds after power is applied to controller Digital and analog control output will be functional within 12 14 seconds after a measured value is obtained Temp...

Page 78: ... 0 035 of URL 0 125 of span spans from 30 1 to 100 1 Static Pressure Effects Zero error 0 10 of URL per 1 000 psi 6894 kPa Span error 0 20 of reading per 1 000 psi 6894 kPa Stability 0 1 of URL for 12 months Process Temperature RTD Sensor errors caused by the RTD are not included The level controller is compatible with any PT100 RTD conforming to IEC 751 Class B which has a nominal resistance of 1...

Page 79: ...ion Code FC 3 inch Stainless Steel ANSI Class 300 Flange Flange Style Code 0 and Option Code FD DIN DN 50 PN 40 Stainless Steel Flange Flange Style Code 0 and Option Code FP DIN DN 80 PN 40 Stainless Steel Flange Flange Style Code 0 and Option Code FQ Remote Seal Flange Style Code 0 and Option Code S1 or S2 Refer to Model 1199 Remote Seals Product Data Sheet PDS 4016 RTD Process connection varies ...

Page 80: ...t RTD Input with 24 ft 7 32 m of Shielded Cable Intended for use with conduit RTD Input with 12 ft 3 66 m of Armored Shielded Cable RTD Input with 24 ft 7 32 m of Armored Shielded Cable Code Controller Housing Material Conduit Entry Size A B C J K L Polyurethane covered Aluminum 14 NPT Polyurethane covered Aluminum M20 3 1 5 CM20 Polyurethane covered Aluminum PG 13 5 316 SST 14 NPT 316 SST M20 3 1...

Page 81: ... C2 is ordered the customer specifies level parameters and controller configuration parameters in addition to the standard configuration parameters Requires a completed Configuration Data Sheet 00806 0100 4741 Code Software Functionality L Level Control Code Options CC FA FB FC FD FP FQ P1 P2 Q4 Q8 C2 S1 S2 S5 DF Autotuner Level Flange SST 2 in ANSI Class 150 Vertical Mount Level Flange SST 2 in A...

Page 82: ...lve Manifolds Anderson Greenwood Co Packaged Separately Description Part Number Carbon Steel M4AVIC 01151 0150 0001 316 SST M4AVIS 01151 0150 0002 Temperature Sensors and Assemblies Fisher Rosemount offers many types of temperature sensors and assemblies Contact your Fisher Rosemount Sales Engineer for a product data sheet Model 333 HART Tri Loop HART to Analog Signal Converter The Model 333 HART ...

Page 83: ...mation that potentially raises safety issues is indicated by a warning symbol Please refer to the following safety messages before performing an operation preceded by this symbol Explosions could result in death or serious injury Verify that the operating environment is consistent with the appropriate hazardous locations certifications Before connecting a HART based communicator in an explosive at...

Page 84: ...terial 2 Fill Fluid 3 Flange Material 4 Flange Type 5 Drain Vent Material 6 O Ring Material 7 RS Type 8 RS Fill Fluid 9 RS Isolator Material Number of Rmt Seals 1 Control Type 2 Control Action 3 Out HI Limit 4 Out LO Limit 1 MORE CONTROL SETUP 2 P Gain 3 I Reset 4 D Rate 5 Derivitative Filter 6 Bias 7 Balance Time 8 Adaptive Bias Control 9 ABC Static Error ABC Stability Threshold 1 Setpoint 2 Setp...

Page 85: ... 2 4 Overshoot 6 2 4 3 4 DP Sensor Trim 6 3 4 2 P Gain 6 2 1 2 DP USL 6 1 2 5 PT Damping 6 1 3 4 DP Unit 6 1 2 2 PT LSL 6 1 3 7 DP 6 1 2 1 PT Sensor Trim 6 1 3 5 Date 6 4 3 5 PT USL 6 1 3 6 Density 6 1 1 1 2 PT Unit 6 1 3 3 Deriv Fltr 6 2 1 5 PT 6 1 3 2 Descriptor 6 4 3 3 Perform Auto Tune 6 2 4 4 Density Unit 6 1 1 1 1 Power up Out 6 2 3 6 Drain vent matl 6 4 2 5 Process Gain 6 2 4 9 Factory Trim...

Page 86: ...ve atmosphere make sure the instruments in the loop are installed in accordance with intrinsically safe or non incendive field wiring practices NOTE The HART Communicator needs a minimum of 250 ohms resistance in the loop to function properly The HART Communicator does not measure loop current directly Function HART Communicator Fast Key Sequences Function HART Communicator Fast Key Sequences Soft...

Page 87: ...AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA 275 0275J01A 1100 V RL 250 V I P PWR OUT Level Controller Terminal Block User Provided Power Supply see page 2 16 ...

Page 88: ...If a device is not found the communicator displays the message No Device Found Press OK If a HART compatible device is found the communicator displays the Online Menu with device ID and tag Directional Keys Use these keys to move the cursor up down left or right The right arrow key also selects menu options and the left arrow key returns to the previous menu HOT Key Use this key to quickly access ...

Page 89: ...rform two functions fast selection of menu options refer to HART Fast Key Feature in this section and data entry Some menus require data entry Use the Alphanumeric and Shift keys to enter all alphanumeric information into the HART Communicator If you press an Alphanumeric key alone from within an edit menu the bold character in the center of the key appears These large characters include the numbe...

Page 90: ... the APEX Radar Gauge automatically loads the current gauge data to the HART Communicator Transfer The Transfer option provides access to options for transferring data either from the HART Communicator memory to the APEX Radar Gauge device or vice versa Transfer is used to move offline data from the HART Communicator to the gauge or to retrieve data from a gauge for offline revision Frequency Devi...

Page 91: ...s Instead of stepping your way through the menu structure using the Action Keys you can press a HART Fast Key sequence to move from the Online Menu to the desired variable or function On screen instructions guide you through the rest of the screens The HART Fast Key sequences are made up of the series of numbers corresponding to the individual options in each step of the menu structure For example...

Page 92: ...tten Device write protected Do you still want to shut off Device is in write protect mode Press YES to turn the HC off and lose the unsent data Display value of variable on hotkey menu Asks whether the value of the variable should be displayed adjacent to its label on the hotkey menu if the item being added to the hotkey menu is a variable Download data from configuration memory to device Prompts ...

Page 93: ...d Online device disconnected with unsent data RETRY or OK to lose data There is unsent data for a previously connected device Press RETRY to send data or press OK to disconnect and lose unsent data Out of memory for hotkey configuration Delete unnecessary items There is no more memory available to store additional hotkey items Unnecessary items should be deleted to make space available Overwrite e...

Page 94: ...for a previously connected device which must be sent or thrown away before connecting to another device Use up down arrows to change contrast Press DONE when done Gives direction to change the contrast of the HC display Value out of range The user entered value is either not within the range for the given type and size of variable or not within the min max specified by the device message occurred ...

Page 95: ...ol Explosions could result in death or serious injury Do not remove the instrument cover in explosive atmospheres when the circuit is alive Both controller covers must be fully engaged to meet explosion proof requirements The unused conduit opening on the controller housing must be plugged and sealed to meet explosion proof requirements Failure to follow safe installation and servicing guidelines ...

Page 96: ...eady in the field The Rosemount spare part number for the transient protection terminal block is 03095 0964 0002 Installation Procedure The transient protection terminal block is shipped installed when ordered at the same time as the Level Controller Use the following procedure to install this terminal block when this option is ordered as a spare part or retrofit 1 Remove the cover above the side ...

Page 97: ...upplied blank as standard An optional Local Operator Interface LOI is available The LOI allows the user to locally change the setpoint and basic controller setup and provides local display of process variables Custom Configuration Option Code C2 Custom factory configuration allows a customer to receive a Model 3095 Level Controller configured for their specific application A Configuration Data She...

Page 98: ...Rosemount Model 3095 Multivariable Level Controller B 4 ...

Page 99: ...rawing Number 03095 1025 Rev G Page C 2 Index of I S F M for 3095 Drawing Numbers 03095 1020 Rev AA Page C 5 Model 3095MV Explosion Proof Installation Drawing Canadian Standards Association Drawing Number 03095 1024 Rev D Page C 11 Index of I S CSA for 3095 Drawing Number 03095 1021 Rev AA Page C 14 ...

Page 100: ...Rosemount Model 3095 Multivariable Level Controller C 2 FIGURE 3 1 Explosion Proof Drawing Factory Mutual 3095 1025A01A ...

Page 101: ...C 3 Approval Drawings FIGURE 3 1 continued 3095 1025A02A ...

Page 102: ...Rosemount Model 3095 Multivariable Level Controller C 4 FIGURE 3 1 continued 3095 1025A03A ...

Page 103: ...C 5 Approval Drawings FIGURE 3 2 Index of I S F M for 3095 3095 1020A01A ...

Page 104: ...Rosemount Model 3095 Multivariable Level Controller C 6 FIGURE 3 2 continued 3095 1020A02A ...

Page 105: ...C 7 Approval Drawings FIGURE 3 2 continued 3095 1020A03A ...

Page 106: ...Rosemount Model 3095 Multivariable Level Controller C 8 FIGURE 3 2 continued 3095 1020A04A ...

Page 107: ...C 9 Approval Drawings FIGURE 3 2 continued 3095 1020A05A ...

Page 108: ...Rosemount Model 3095 Multivariable Level Controller C 10 FIGURE 3 2 continued 3095 1020A06A ...

Page 109: ...C 11 Approval Drawings FIGURE 3 3 Model 3095 Multivariable Level Controller Explosion Proof Installation Drawing 3095 1024A01A ...

Page 110: ...Rosemount Model 3095 Multivariable Level Controller C 12 FIGURE 3 3 continued 3095 1024A02A ...

Page 111: ...C 13 Approval Drawings FIGURE 3 3 continued 3095 1024A03A ...

Page 112: ...Rosemount Model 3095 Multivariable Level Controller C 14 FIGURE 3 4 Index of I S CSA for 3095 3095 1021A01A ...

Page 113: ...C 15 Approval Drawings FIGURE 3 4 continued 3095 1021A02A ...

Page 114: ...Rosemount Model 3095 Multivariable Level Controller C 16 FIGURE 3 4 continued 3095 1021A03A ...

Page 115: ...49 7001 1998 Rosemount Inc P R INT E D IN U S A http www rosemount com 00809 0100 4741 Fisher Rosemount Limited Heath Place Bognor Regis West Sussex PO22 9SH England Tel 44 1243 863 121 Fax 44 1243 867 5541 Fisher Rosemount Singapore Pte Ltd 1 Pandan Crescent Singapore 128461 Tel 65 777 8211 Fax 65 777 0947 Tlx RS 61117 FRSPL ...

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