www.Fisher.com
D200119X012
Type 2100 Pneumatic and Type 2100E Electric
Liquid Level Switches
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Educational Services 3. . . . . . . . . . . . . . . . . . . . . .
Installation
3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Procedures 3. . . . . . . . . . . . . . . . . . . .
Common Procedures for Either Switch 4. . . . .
Additional Procedures for Type
2100 Switch 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Procedures for Type
2100E Switch 5. . . . . . . . . . . . . . . . . . . . . . . . .
Calibration Check 5. . . . . . . . . . . . . . . . . . . . . . . . .
Principle of Operation 5
. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Test 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Type 2100 Switch Maintenance Procedure 8. . .
Type 2100E Switch Maintenance Procedure 10
Parts Ordering 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type 2100E Electrical Switch Component
Hazardous Area Classification information 15.
CSA 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATEX 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UL 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Scope of Manual
This instruction manual includes installation,
maintenance, and parts information for the Type
2100 pneumatic and Type 2100E electric liquid level
switches. Refer to separate instruction manuals
when you require information regarding related
valves, actuators, positioners, and accessories.
APPROXIMATE
SWITCHING POINT
W6102-1*/IL
Figure 1. Type 2100 Pneumatic Liquid Level Switch
APPROXIMATE
SWITCHING POINT
W6103-1*/IL
Figure 2. Type 2100E Electric Liquid Level Switch
Instruction Manual
Form 5039
December 2005
2100 and 2100E Liquid Level Switches
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
2
Table 1. Specifications
Input Signal
(1)
Liquid level
Minimum Process Liquid Specific Gravity
0.5 (consult your Emerson Process
Managementt sales office for specific gravity
below this value)
Output Signal
(1)
Type 2100 Switch: Output equal to supply
pressure when the switch is in the normal
position (flapper against nozzle). Output reduced
to approximately atmospheric pressure,
depending upon size of the bleed orifice and
piping configuration, when the switch is activated
Type 2100E Switch: Same as supply signal
Supply Signal
Type 2100 Switch: J 2.1 to 4.1 bar (30 to 60
psig), J 4.1 to 6.9 bar (60 to 100 psig), or J 6.9
to 10.3 bar (100 to 150 psig)
Type 2100E Switch: 11 amperes, 1/4
horsepower at 125/250 volts ac; 5 amperes
resistive, 3 amperes inductive at 28 volts dc
Supply Medium (Type 2100 Switch)
Air or natural gas
(4)
Steady-State Air Consumption
(1,2)
(Type 2100
Switch)
Less than 0.03 normal m
3
/hr (1.0 scfh) for all
supply pressures when the liquid level is 25.4 mm
(1 inch) below the normal switch position (flapper
against nozzle) for high-level switching or
25.4 mm (1 inch) above the normal switch
position for low-level switching
Maximum Working Pressure
J 2220 WOG
(3)
except J 350 WOG is the
maximum working pressure for sight window
construction
Operative Temperature Range
(1)
Type 2100 Switch: − 29 to 204_C (− 20 to
400_F)
Type 2100E Switch: − 29 to 82_C (− 20 to
180_F)
Displacer Diameter
102 mm (4 inches)
Process Connection Size
2220 WOG
(3)
: J 1-inch NPT female,
J 50.8 mm (2-inch) Schedule 80 buttwelding
ends, or J 50.8 mm (2-inch) Schedule 160
buttwelding ends
Type 2100 Switch Supply Pressure Connection
Size
1/4-inch NPT female
Type 2100E Switch Electrical Connection Size
1/2-inch NPT male
Hazardous Area Classification
The Type 2100 and 2100E switches have no
hazardous area approvals.
Approvals on the electrical switch component in
the Type 2100E, supplied by ITT NEO-DYN are
as follows:
APPROVED
EXP − Class I Division 1 Groups A,B,C,D
DI − Class II Division I Groups E,F,G
Class I Groups A,B,C,D
Class II Groups E,F, G
UL
Class I Groups A,B,C,D
Class II Groups E,F, G
ATEX
EEx d IIC
Refer to figures 7, 8, 9, and 10 for specific
hazardous classification information. Contact your
Emerson Process Management sales office if
additional information is required.
Shipping Weights
2220 WOG
(3)
Construction: 17.2 kg (38 pounds)
1. These terms are defined in ISA Standard S51.1.
2. Normal m
3
/hr—normal cubic meters per hour (0_C and 1.01325 bar, absolute); scfh—standard cubic feet per hour (60_F and 14.7 psia)
3. Water, Oil, Gas maximum working pressure rating designation in psi. Corresponds to Cold Working Pressure: the maximum pressure rating allowed under normal ambient temperature
conditions, which are usually understood to be − 29_C to 38_ C (− 20_F to 100_F). Refer to MSS SP-25.
4. Natural gas to contain no more than 20 ppm of H
2
S.
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
3
No person may install, operate or maintain a Type
2100 pneumatic or a Type 2100E electric liquid level
switch without first D being fully trained and qualified
in valve, actuator and accessory installation,
operation and maintenance, and D carefully reading
and understanding the contents of this manual. If
you have any questions about these instructions,
contact your Emerson Process Management sales
office.
Description
The on-off Type 2100 pneumatic switch (figure 1)
and the Type 2100E electric switch (figure 2)
operate shutdown valves or alarm systems when
liquid in a vessel reaches a predetermined level. The
Type 2100 switch uses an externally mounted
displacer that operates a nozzle-flapper to vent the
supply pressure when the switch is activated. The
nozzle-flapper has a soft seat for tight shutoff when
the switch is in its normal position (flapper against
the nozzle). The Type 2100E switch uses the
displacer torque to activate and deactivate an
electric switch for positive on-off service. The
displacer on each type can withstand up to 1-1/2
times the maximum working pressure, allowing it to
remain in the cage during hydrostatic testing.
Unless otherwise noted, all NACE references are to
NACE MR0175−2002.
Specifications
Specifications for the Type 2100 and 2100E
switches are shown in table 1.
WARNING
This product is intended for a specific
current range, temperature range and
other application specifications.
Applying different current, temperature
and other service conditions could
result in malfunction of the product,
property damage or personal injury.
Educational Services
For information on available courses for Type 2100
pneumatic and Type 2100E electric liquid level
switches, as well as a variety of other products,
contact:
Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158−2823
Phone: 800−338−8158 or
Phone: 641−754−3771
FAX: 641−754−3431
e-mail: education@emersonprocess.com
Note
Neither EmersonR, Emerson Process
Management, Fisher
R
, nor any of their
affiliated entities assumes
responsibility for the selection, use,
and maintenance of any product.
Responsibility for the selection, use,
and maintenance of any product
remains with the purchaser and
end-user.
Installation
Installation Procedures
The installation procedures include those common to
both the Type 2100 pneumatic and Type 2100E
electric liquid level switches and additional ones for
each switch.
WARNING
Always wear protective clothing,
gloves, and eyewear when performing
any installation operations to avoid
personal injury.
Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
If installing into an existing
application, also refer to the WARNING
at the beginning of the Maintenance
section in this instruction manual.
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
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A3619-1/IL
1/4-INCH NPT
OUTPUT PRESSURE
CONNECTION
1/4-INCH NPT
SUPPLY
PRESSURE
CONNECTION
BACK PLATE
(KEY 10)
STREET TEE
(KEY 34)
BLEED
ORIFICE
(KEY 35)
Figure 3. Detail of Optional Street Tee and Bleed Orifice
Common Procedures for Either Switch
The horizontal line forged on the displacer cage
indicates the approximate switching point (figures 1
and 2). When you mount the Type 2100 or Type
2100E switch, position it so that the horizontal line
corresponds to the horizontal level at which
switching is desired.
Before you install the Type 2100 or Type 2100E
switch, remove the plastic plugs from the process
connections. One of these plugs retains a paper
tube that protects the displacer and torque tube
during handling and shipping. This paper tube must
also be removed.
There are two process connections, one at the top
and one at the bottom of the cage. To mount the
switch, connect the appropriate top and bottom
process connections to the vessel using the required
size pipe. The pipe must be capable of supporting
the assembly and of withstanding the pressure
involved. Use accepted piping and welding practices
when making connections. Install isolating valves
between the vessel and cage. Plugs are furnished
for the unused process connections. However, one
of the plugs can be removed, and a bleed valve or
drain can be installed in one of the unused
connections.
Additional Procedures for Type 2100
Switch
If using natural gas as the pneumatic supply
medium, natural gas will be used in the pressure
connections of the unit to any connected equipment.
The unit will vent natural gas into the surrounding
atmosphere, unless it is remote vented.
WARNING
Personal injury or property damage
may occur from an uncontrolled
process if the Type 2100 switch supply
medium is not clean, dry air or
noncorrosive gas. If clean, dry air, or
noncorrosive gas is not used, the
switch may become inoperative and
allow the level in a process vessel to
exceed safe limits. Install a 40 micron
filter and suitable equipment to dry the
supply medium and establish a
maintenance cycle to check the filter
and equipment.
If the existing supply medium is
corrosive, make sure the tubing and
instrument components that contact
the corrosive medium are suitable
corrosion-resistant materials, or use a
noncorrosive medium.
WARNING
Personal injury or property damage
may result from fire or explosion if
natural gas is used as the supply
medium and preventative measures
are not taken. Preventative measures
may include: Remote venting,
re-evaluating the hazardous area
classification, ensuring adequate
ventilation, and the removal of any
nearby ignition sources.
Refer to figure 5 except as noted.
1. Connect a supply pressure line to the 1/4-inch
NPT female connection located in the back plate
(key 10).
2. Install an output line between the supply pressure
line and the equipment to be operated by the switch.
3. Install a street tee and bleed orifice (keys 34
and 35, figure 3) or other fixed restriction in the
supply pressure line between the supply source and
the output signal line.
4. If a remote vent is required, remove the vent
assembly (key 23) from the 1/4-inch NPT female
vent connection and install a vent line to an area
where the operating medium can be safely
exhausted.
Note
The vent line should have as large a
diameter as possible with a minimum
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
5
number of bends and elbows. The vent
line should be as short as possible.
Protect the end of the vent pipe from
the entrance of rain, snow, insects, or
any other foreign material that may
plug the vent line. Inspect the vent line
opening periodically to ensure that it
is not plugged.
If necessary to change to a different supply
pressure, install a different nozzle according to steps
1 through 4 and 15 through 18 of the Type 2100
switch maintenance procedure.
To change switch action from low-level to high-level
switching or vice versa, reverse the positions of the
nozzle, flapper, and magnet according to steps 1
through 7 and 10 through 18 of the Type 2100
switch maintenance procedure.
To change switch mounting from right-hand to
left-hand or vice versa, perform steps 1 through 7
and 9 through 18 of the Type 2100 switch
maintenance procedure.
Additional Procedures for Type 2100E
Switch
Refer to figure 6.
To install for standard action, connect electrical
wires as shown in table 2.
To change switch action from low-level to high-level
switching, or vice versa, perform steps 1 through 4
and 13 through 17 of the Type 2100E maintenance
procedure.
To reverse action of the Type 2100E switch, refer to
table 2 and reinstall wiring for normally open (NO)
switches to normally closed (NC) and vice versa.
To change switch mounting from right-hand to
left-hand or vice versa, perform steps found in the
Type 2100 switch maintenance procedure.
Calibration Check
For either type of switch, calibration can be checked
by varying the level of the process liquid in the cage
and observing the switch operation.
If the process connection directly on top of the cage
is not piped to the tank, close the isolating valves
Table 2. Type 2100E Wiring Codes
Wire
Color
SPDT DPDT Switch 1 DPDT Switch 2
Red
Brown
Blue
Green
Black
Yellow
Purple
Normally Closed
Common
Normally Open
Ground
Normally Closed
Common
Normally Open
Ground
Ground
Normally Closed
Common
Normally Open
and fill the cage with process liquid through the top
connection. Verify that the switch operates as the
cage is being filled. Repeat the calibration procedure
if necessary.
Calibration can also be checked on the work bench.
Connect a flexible hose from one of the bottom
process connections to the bottom of a bucket. The
top process connection should be open. Fill the
bucket with process liquid. As the bucket is raised or
lowered, the liquid level in the displacer cage rises or
falls. Verify that the switch operates as the level is
varied. Repeat the calibration procedure if
necessary.
Dry calibration can be performed on the Type 2100E
using the following procedure:
Refer to figure 6.
1. Position the cage and displacer assembly (key 1)
so that the displacer is hanging downward.
2. Level the switch arm (key 40), if required.
3. Loosen the locknut (key 33) and adjust the
machine screw (key 31) until it contacts the switch.
4. For low-level dry calibration, tighten the locknut.
For high-level dry calibration, turn the machine
screw one additional full turn, then tighten the
locknut.
Principle of Operation
The Type 2100 switch (figure 4) is an external,
cage-mounted, pneumatic liquid level switch. When
the switch is in the normal position with the flapper
against the nozzle, output pressure cannot bleed off
and remains the same as full supply pressure.
Rising liquid level exerts a buoyant force on the
displacer, producing a torque in the torque tube.
When this torque exceeds the torque exerted on the
flapper by the magnet, the flapper snaps away from
the nozzle. This action allows output pressure to
bleed through the nozzle faster than supply pressure
can enter through the bleed orifice.
2100 and 2100E Liquid Level Switches
Instruction Manual
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A3619-2/IL
Figure 4. Principle of Operation for High-Level Type 2100 Switch
The reduced pressure in the output signal line
activates the shutdown or alarm system. When the
liquid level lowers, the falling displacer forces the
flapper into the field of the magnet, letting the
magnet snap the flapper against the nozzle and
causing output pressure to build to full supply
pressure.
On applications where low-level switch operation is
required, the nozzle, flapper, and magnet are
positioned on the opposite side of the torque tube so
that downward displacer travel moves the flapper
away from the nozzle.
The Type 2100E switch is an external,
cage-mounted, electric liquid level switch. Rising
liquid level exerts a buoyant force on the torque tube
that either activates or deactivates an electrical
SPDT (single-pole, double-throw) or DPDT
(double-pole, double-throw) switch depending on the
required switching action. Falling liquid level
deactivates or activates the same switch depending
on the required action.
Maintenance
Switch parts are subject to normal wear and must be
inspected and replaced when necessary. The
frequency of inspection and replacement depends
on the severity of service conditions.
Refer to figure 5 for maintenance of the Type 2100
switch and figure 6 for maintenance of the Type
2100E switch.
WARNING
Always wear protective clothing,
gloves, and eyewear when performing
any maintenance procedures to avoid
personal injury.
The displacer is a sealed container
inside the cage. A displacer penetrated
by process fluid may retain pressure
or hazardous fluid for an extended
period. Such a displacer may contain
pressure as a result of being in a
pressurized vessel, or it may contain
fluid that becomes pressurized due to
changes in temperature and/or it may
contain fluid that is hazardous or
flammable. The sudden release of
pressure, contact with hazardous fluid,
fire, or explosion resulting in personal
injury can occur if a displacer that is
retaining pressure or process fluid is
punctured or subjected to heat. Handle
the cage (with displacer inside) with
care in removing, storing, or
disposing, taking into consideration
the characteristics of the process fluid.
To avoid personal injury and damage
to the process system caused by the
sudden release of pressure, contact
with hazardous fluid, fire, or explosion,
isolate and drain the displacer cage.
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
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Table 3. Type 2100 Troubleshooting Guide
Fault Possible Cause Correction
1. Nozzle-flapper throttles (flapper moves in
response to change in liquid level but does
not completely cap or uncap nozzle).
1.1 Nozzle adjusted too high. 1.1 If nozzle prevents flapper from coming in
full contact with magnet, repeat the
Calibration procedure.
Perform the Calibration Check procedure to
ensure that the unit operates properly.
1.2 Verify that the top surface of the magnet is
parallel with the flapper and that the magnet
is in full contact with the flapper when the
flapper is against the magnet. If the above
conditions do not exist, repeat the Calibration
procedure.
Perform the Calibration Check procedure to
ensure that the unit operates properly.
2. Nozzle-flapper fails to snap open. 2.1 Liquid level not changing in the expected
direction.
2.1 Be certain liquid level in the displacer
cage is changing in the expected direction.
3. Nozzle-flapper leaks when shut off. 3.1 Surface of nozzle seat or nozzle worn or
damaged.
3.2 Nozzle adjusted too low.
3.3 Incorrect alignment of nozzle and flapper.
3.1 Inspect surface of flapper seat (key 11,
figure 5), and nozzle (key 6, figure 5); replace
parts if necessary.
3.2 Inspect nozzle-flapper when flapper is
being held by magnet. If nozzle is not seated
on flapper seat, loosen locknut (key 33, figure
5) and rotate nozzle counterclockwise until it
is seated.
3.3 Inspect surface of nozzle seat (key 11,
figure 5). This surface should be parallel with
the opening in the end of the nozzle (key 6,
figure 5). Correct as necessary.
4. Switch fails to activate upon high or low
level depending on action selected.
4.1 Foreign material in cage.
4.2 Clamp and shaft assembly loose on torque
tube assembly.
4.3 Torque tube assembly failure.
4.1 Flush cage to remove foreign material.
4.2 Perform step 4 of reassembly procedure
in maintenance section. Tighten clamp nut on
clamp and shaft assembly to between 20 and
27 NSm (15 and 20 lbSft).
4.3 Perform operational test procedure
Replace torque tube assembly if it fails
operational test.
For Type 2100, shut off and bleed
supply pressure from the switch
before attempting any maintenance
procedures. For Type 2100E, shut off
the power to the electric switch
assembly before attempting any
maintenance procedures.
Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
The displacer cage should be flushed periodically to
remove deposits or sludge that may affect proper
operation. The frequency of flushing depends on the
nature of the process liquid. Before flushing, close
the isolating valves and drain the cage. Flush from
one of the top connections to one of the bottom
connections. Also, remove the pipe plug (key 2) or
the bushing and sight window (keys 4 and 5), and
flush from a top connection through the pipe plug or
sight window connection.
Inspect the vent or vent screen (key 23) or vent line
periodically to ensure that the vent or vent line is not
plugged.
Table 3 lists various Type 2100 switch problems and
possible solutions for them. The table is valid for
either high-level or low-level switching action and for
any supply pressure range. If a correction step
requires replacement of worn or damaged parts,
2100 and 2100E Liquid Level Switches
Instruction Manual
Form 5039
December 2005
8
refer to the appropriate maintenance procedure in
this manual for disassembly and reassembly
instructions.
Type 2100E switch problems are solved through
common electrical troubleshooting procedures. Fault
4 of table 3 is also pertinent for the Type 2100E.
Operational Test (Types 2100 and
2100E)
Establish a periodic operational test of the switch to
ensure that:
a. the torque tube is functioning as a continuous
spring element;
b. there is an absence of excessive friction;
c. there is no contact with the mechanical stops,
and;
d. the torque tube is still effectively transmitting
force and motion to the Type 2100 flapper and
clamp assembly, or to the Type 2100E switch
arm assembly.
This test should be conducted with no process fluid
in the cage using the following procedures:
1. Make sure the Type 2100 switch flapper and
clamp assembly (key 12, figure 5) or the Type
2100E switch arm (key 40, figure 6) is tight on the
shaft of the torque tube assembly (key 7).
2. Grasp and lift, then immediately release, the
following:
D The Type 2100 switch flapper and clamp
assembly (key 12, figure 5), 10 to 13 mm (0.375 to
0.5 inch) from the nozzle (key 6, figure 5), or
D The Type 2100E switch arm (key 40, figure 6),
10 to 13 mm (0.375 to 0.5 inch) from the contact of
the electric switch assembly (key 49, figure 6).
3. The torque tube spring system is functional if the
Type 2100 switch flapper and clamp assembly, or
the Type 2100E switch arm, bounces at least two
cycles in a reversing rotary motion.
Type 2100 Switch Maintenance
Procedure
WARNING
Refer to the WARNING at the
beginning of the Maintenance section.
WARNING
When disconnecting any of the
pneumatic connections, natural gas, if
used as the supply medium, will seep
from the unit and any connected
equipment into the surrounding
atmosphere. Personal injury or
property damage may result from fire
or explosion if preventative measures
are not taken, such as adequate
ventilation and the removal of any
nearby ignition sources.
Refer to figure 5.
1. Drain the liquid from the cage and displacer
assembly (key 1), then isolate it from the process.
Shut off the supply pressure and bleed any trapped
supply and output pressure from the nozzle block
assembly (key 8).
2. Loosen the cover screws (key 17) and remove
the cover (key 15). Replace the cover gasket
(key 16) and the cover screw gaskets (key 20) if
necessary.
Note
Magnetic attraction between the
magnet (key 14) and the flapper (key
12) can be adversely affected by the
presence of foreign material between
the magnet and flapper. Before
performing any inspection or
correction step, inspect the magnet. If
necessary, clean the magnet
thoroughly. If cleaning requires
removing the magnet or magnet
bracket (key 13), perform step 17 of the
maintenance procedure; then perform
the calibration check procedure to
ensure that the unit operates properly.
3. Loosen the nut holding the flapper and clamp
assembly (key 12) to the shaft of the torque tube
assembly (key 7). Remove the flapper and clamp
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