Rosemount 1199 FFW Operating Manual

Reference Manual

00809-0100-4002, Rev DA

May 2017

Rosemount™ DP Level Transmitters and 1199 Diaphragm Seal Systems

Reference Manual

00809-0100-4002, Rev DA

1Section 1: Introduction

1.1 Using this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Product recycling/disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2Section 2: Understanding Remote Seal Systems

2.1 DP Level and remote seal system measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Terminology of system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Understanding seal system performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Contents

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2.3.1 Volume temperature effects (process temperature effects) . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3.2 Density temperature effects (head temperature effects). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3.3 System time response and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Balanced vs. Tuned-System assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 Specifying the right solution for vacuum applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5.1 Vacuum application overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5.2 Vacuum applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5.3 Seal system construction for vacuum applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5.4 Transmitter mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5.5 Fill fluid selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6 Diaphragm weld types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.1 Solid faceplate design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.2 Seam weld design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.3 Brazed design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.7 Differences between electronic remote sensors and capillary systems. . . . . . . . . . . . . . . . . . . . . . 10

2.8 Instrument Toolkit: seal ordering and application process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.9 Rosemount Thermal Range Expander: proper use and applications . . . . . . . . . . . . . . . . . . . . . . . . 11

2.10 Thermal optimizer: proper use and applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.10.1 Thermal optimizer limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.11 Submersible seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.11.1 Designed for top-down measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Content s

2.11.2 Submersible Seal features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3Section 3: Installation

3.1 Seals handling and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.1 Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.2 Capillary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Reference Manual

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3.1.3 Rosemount Thermal Range Expander. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.4 Heat tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3 Tagging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3.1 Max working pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4 FFW flush flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.4.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.4.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.5 RFW off-line flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.5.1 4.1-in. (104 mm) diaphragm diameter option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.5.2 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.5.3 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.6 EFW extended flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.6.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.6.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.7 PFW pancake seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.7.1 Capillary support tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.7.2 Process flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.7.3 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.7.4 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.8 FCW flush flanged seal—ring type joint (RTJ) gasket surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.8.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.8.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.9 RCW off-line ring type joint (RTJ) flanged seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.9.1 4.1-in. (104 mm) diaphragm diameter option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.9.2 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.9.3 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.10 FUW flush flanged groove type seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.10.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.10.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.11 FVW flush flanged tongue type seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.11.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.11.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.12 RTW off-line threaded type seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.12.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.12.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.13 HTS male threaded seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.13.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Contents

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3.14 SCW hygienic Tri-Clover Tri Clamp seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.15 SSW hygienic tank spud seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

3.16 STW hygienic thin wall tank spud seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.17 EES hygienic flanged tank spud extended seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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3.13.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.14.1 Clamp and gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.14.2 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.14.3 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.15.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.15.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.15.3 Tank preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.15.4 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

3.16.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.16.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.17.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.17.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.18 VCS Tri Clamp In-line seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.18.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.18.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.19 SVS VARIVENT compatible hygienic connection seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.19.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.19.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.20 SHP hygienic Cherry-Burrell “I” line seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.20.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.20.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.21 SLS dairy process connection–female thread seal per DIN 11851 . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.21.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.21.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.22 WSP saddle seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.22.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.22.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23 UCP union connection pipe mount seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.23.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.23.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

. . . . . . . 68

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3.24 PMW paper mill sleeve seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

3.24.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.24.2 Installation steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.25 CTW chemical tee seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Contents

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Reference Manual

00809-0100-4002, Rev DA

3.25.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.25.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.26 TFS wafer style In-line seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.26.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.26.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.27 WFW flow-thru flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.27.1 Parts required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.27.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4Section 4: Configuration

4.1 Calculating range points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.1.1 Remote seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.1.2 Zero-based lower range value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.1.3 Non-zero based lower range value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.1.4 Non-zero based lower range value (transmitter mounted above seal). . . . . . . . . . . . . . . 80

4.1.5 Non-zero based lower range value (Tuned-System assembly). . . . . . . . . . . . . . . . . . . . . . 81

4.1.6 Non-zero based lower range value (balanced system with transmitter between seals) 82

4.1.7 Non-zero based lower range value (balanced system with transmitter below seals) . . . 83

4.2 DP Level transmitter installation best practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.2.1 Open tank (zero based) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.2.2 Closed tank (non-zero based) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.2.3 Open tank example (zero-based lower range value) with HART Communicator . . . . . . 85

4.2.4 Closed tank example (non-zero based lower range value) . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.2.5 Scale display with HART Communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5Section 5: Fill Fluids Specifications

5.1 Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.1.1 Specialized processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.1.2 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2 Fill fluid selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2.1 Type of fill fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2.2 Maximum and minimum temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2.3 Process pressure and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.3 Fill fluids vapor pressure curve graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.3.1 How to use the vapor pressure curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.3.2 Fill fluid selection example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.3.3 Fill fluid specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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6Section 6: Maintenance and Troubleshooting

6.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6.3 Service support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

AAppendix A: Specifications and Reference Data

A.1 Rosemount 1199 Direct Mount Seal Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

A.2 Rosemount 1199 Remote Mount Seal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

A.3 Dimensional drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

A.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

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6.1.1 Return of materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

A.1.1 Rosemount 1199 Direct Mount Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

A.2.1 Rosemount 1199 Remote Mount Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

A.2.2 Capillary/fill fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

BAppendix B: Product Certifications

B.1 Rosemount 3051S/3051S ERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

B.1.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

B.1.2 Ordinary Location Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

B.1.3 Installing Equipment in North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

B.1.4 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

B.1.5 Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

B.1.6 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

B.1.7 International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

B.1.8 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

B.1.9 China. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

B.1.10 EAC - Belarus, Kazakhstan, Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

B.1.11 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

B.1.12 Republic of Korea . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

B.1.13 Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

B.1.14 Additional Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

B.2 Rosemount 3051S Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

B.2.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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B.2.2 Telecommunication compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

B.2.3 FCC and IC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

B.2.4 Ordinary Location Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

B.2.5 Installing Equipment in North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

B.2.6 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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B.2.7 Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

B.2.8 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.9 International. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.10 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.11 China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.12 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.13 EAC – Belarus, Kazakhstan, Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.14 Republic of Korea . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.2.15 Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

B.3 Rosemount 3051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

B.3.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

B.3.2 Ordinary Location Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

B.3.3 North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

B.3.4 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

B.3.5 International. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

B.3.6 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

B.3.7 China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

B.3.8 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

B.3.9 Technical Regulations Customs Union (EAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

B.3.10 Combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

B.3.11 Conduit Plugs and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

B.3.12 Additional Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

B.4 Rosemount 2051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

B.4.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

B.4.2 Ordinary Location Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

B.4.3 North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

B.4.4 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

B.4.5 International. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

B.4.6 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

B.4.7 China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

B.4.8 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

B.4.9 Technical Regulations Customs Union (EAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

B.4.10 Combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

B.4.11 Additional Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

B.5 Rosemount 3051 Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.5.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

B.5.2 Telecommunication compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

B.5.3 FCC and IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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B.6 Rosemount 2051 Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

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B.5.4 Ordinary Location Certification from FM Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

B.5.5 Installing in North America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

B.5.6 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

B.5.7 Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

B.5.8 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.9 International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.10 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.11 China. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.12 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.13 EAC - Belarus, Kazakhstan, Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

B.5.14 Korea. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

B.6.1 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

B.6.2 Telecommunication compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

B.6.3 FCC and IC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

B.6.4 Ordinary Location Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

B.6.5 Installing in North America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

B.6.6 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

B.6.7 Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

B.6.8 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.9 International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.10 Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.11 China. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.12 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.13 EAC - Belarus, Kazakhstan, Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

B.6.14 Korea. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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NOTICE

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Rosemount™ DP Level Transmitters and 1199 Diaphragm Seal Systems

Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure the contents are fully understood before installing, using, or maintaining this product.

For technical assistance, contacts are listed below:

Customer Central

Technical support, quoting, and order-related questions

United States — 1-800-999-9307 (7:00 am to 7:00 pm CST)

Asia Pacific — 65 777 8211

Europe/Middle East/Africa — 49 (8153) 9390

North American Response Center

Equipment service needs

1-800-654-7768 (24 hours—includes Canada)

Outside of these areas, contact your local Emerson

™

representative.

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Failure to follow these installation guidelines could result in death or serious injury.

 Make sure only qualified personnel perform the installation.

Explosions could result in death or serious injury.

 Do not remove the transmitter cover in explosive atmospheres when the circuit is live.  Before connecting a 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 transmitter covers must be fully engaged to meet explosion-proof requirements.  Verify the operating atmosphere of the transmitter is consistent with the appropriate hazardous

locations certifications.

Electrical shock could cause death or serious injury.

 If the sensor is installed in a high-voltage environment and a fault or installation error occurs, high

voltage may be present on the transmitter leads and terminals.

 Use extreme caution when making contact with the leads and terminals.

Process leaks could result in death or serious injury.

 Install and tighten all four flange bolts before applying pressure.  Do not attempt to loosen or remove flange bolts while the transmitter is in service.  Replacement equipment or spare parts not approved by Emerson for use as spare parts could reduce

the pressure retaining capabilities of the transmitter and may render the instrument dangerous.

 Use only bolts supplied or sold by Emerson as spare parts.

Improper assembly of manifolds to traditional flange can damage sensor module.

 For safe assembly of manifold to traditional flange, bolts must break back plane of flange web (i.e.,

bolt hole) but must not contact module housing.

Sensor module and electronics housing must have equivalent approval labeling in order to maintain hazardous location approvals.

 When upgrading, verify sensor module and electronics housing certifications are equivalent.

Differences in temperature class ratings may exist, in which case the complete assembly takes the lowest of the individual component temperature classes (for example, a T4/T5 rated electronics housing assembled to a T4 rated sensor module is a T4 rated transmitter.)

The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings.

For information on Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.

Individuals who handle products exposed to a hazardous substance can avoid injury if they are informed of and understand the hazard. If the product being returned was exposed to a hazardous substance as defined by OSHA, a copy of the required Material Safety Data Sheet (MSDS) for each hazardous substance identified must be included with the returned goods.

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Section 1 Introduction

1.1 Using this manual

This manual is designed to assist in installing, operating, and maintaining the Rosemount™ 1199 Diaphragm Seal Systems for Pressure Transmitters and diaphragm seal systems that are part of Rosemount DP Level Transmitters including the Rosemount 3051SAL, Rosemount 3051L and Rosemount 2051L. The manual contains information about the seal system assemblies that are not covered in the corresponding transmitter manuals. For information regarding transmitter configuration, operation, and maintenance, reference the appropriate transmitter manual.

The information is organized into the following categories:

 Section 2: Understanding Remote Seal Systems provides an overview of Remote Seal Systems.

 Section 3: Installation contains mechanical and electrical installation instructions.

 Section 4: Configuration outlines how to range a DP Level Remote Seal System.

 Section 5: Fill Fluids Specifications describes the offering of fill fluids available with Remote Seal

Systems.

 Section 6: Maintenance and Troubleshooting provides techniques for cleaning and maintaining the

system as well as addressing the most common operating problems.

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 Appendix A: Specifications and Reference Data provides performance, functional, and physical

specifications, as well as dimensional drawings, and ordering information.

 Appendix B: Product Certifications contains intrinsic safety approval information, European ATEX

directive information.

See Rosemount DP Level Transmitters and 1199 Seal Systems Product Data Sheet information on specific Rosemount Remote Seals.

A remote seal system consists of a pressure transmitter, a remote diaphragm, and either a direct mount or capillary style connection filled with a secondary fill fluid.

1.2 Product recycling/disposal

Recycling of equipment and packaging should be taken into consideration and disposed of in accordance with local and national legislation/regulations.

for more detailed

Introduction

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Introduction

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Understanding Remote Seal Systems

Section 2 Understanding Remote Seal

Systems

DP Level and remote seal system measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3

Terminology of system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3

Understanding seal system performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4

Balanced vs. Tuned-System assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

Specifying the right solution for vacuum applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8

Diaphragm weld types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

Differences between electronic remote sensors and capillary systems . . . . . . . . . . . . . . . . . . . . . . . page 10

Instrument Toolkit: seal ordering and application process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10

Rosemount Thermal Range Expander: proper use and applications . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Thermal optimizer: proper use and applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 12

Submersible seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13

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2.1 DP Level and remote seal system measurement

DP Level is a reliable measurement solution for measuring level, density, interface, or mass of a process media inside a tank.

Remote seal system measurement is unaffected by agitation, foam, or internal obstacles. Remote diaphragm seals extend limitations due to process conditions such as high and low temperatures, corrosive processes, viscous mediums, and hygienic applications.

2.2 Terminology of system components

Figure 2-1 lists the basic components for seal assemblies.

Figure 2-1. Components on a Two and Single Seal Assembly

Two seal assembly Single seal assembly

Understanding Remote Seal Systems

A. Pressure, differential pressure, or multivariable transmitter B. Process flange C. Remote diaphragm

D. Capillary E. Flushing connection F. D ir ec t mou nt

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Figure 2-2. FFW Seal and Components

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A. Process flange B. Diaphragm

C. Gasket D. Flushing connection

2.3 Understanding seal system performance

2.3.1 Volume temperature effects (process temperature effects)

Fill fluids expand or contract with temperature changes, creating a volume change that is absorbed by the diaphragm seal and is seen as back pressure at the transmitter. This back pressure creates a shift in the transmitter reading. For symmetrical or balanced systems, this error is usually minimal due to the back pressure being equal on both sides. However, head temperature effect is still present.

Note

Other factors that affect seal temperature effect include diaphragm thickness, seal type and size, capillary length and inner diameter.

Figure 2-3 on page 5 shows how diaphragm size can affect the measurement reading at the transmitter.

For smaller seal sizes, such as the 1 additional 12.1 inH

has 0.5 inH stable reading.

O error. Using a larger diaphragm can drastically improve performance and provides a more

O error. Moving to the 2-in. size gives 1.7 inH2O and the largest 3-in. size shown only

/2-in. size, the amount of back pressure on the transmitter causes an

Note

Calculations done in Instrument Toolkit™ with Silicone 200 fill fluid with Rosemount™ 3051 Transmitter.

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Figure 2-3. Back Pressure on Diaphragm Causing Error

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1½-in.

diapraghm

12.1 inH2O

(307 mmH

HEAT

diapraghm

(43 mmH

2-in.

1.7 inH2O

HEAT

3-in.

diapraghm

0.5 inH2O

(13 mmH

HEAT

Note

Diaphragm temperature effects decrease as seal size increases.

2.3.2 Density temperature effects (head temperature effects)

Density temperature effect is due to the change in specific gravity of the fill fluid caused by a change in ambient temperature. When installed, the weight of the fill fluid will produce an initial pressure read by the transmitter, equaling the height between the high and low connection taps multiplied by the fill fluid's specific gravity. As ambient temperature changes, the fill fluid specific gravity will change causing the weight of the fill fluid to change, thus changing the pressure read by the transmitter. Density effect will be seen in both

Tu ne d- S ys te m transmitter regardless of where the transmitter is mounted.

™

Assemblies and Balanced System Assemblies and will have the same impact on the

2.3.3 System time response and performance

The time response of a system is based on the type of transmitter, its sensor range, the length and inner diameter (ID) of the capillary, and the viscosity of the fill fluid (which is directly affected by the process and ambient temperatures). These factors all play a role in the overall performance of any seal system. The relationship between system time response and temperature error is illustrated in Figure 2-4. It can be seen that changing the capillary ID has an inverse affect between the time response and temperature effect of a capillary system. As the capillary ID is increased, the time response of the system decreases while the temperature effect increases.

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Figure 2-4. Response Time vs. Total Performance Example

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Note

Calculations conducted using Instrument Toolkit. Parameters: Silicone 200 fill fluid, Rosemount 3051CD2 Transmitter, 15 ft. capillary length, 2-in. FFW Seal, and calibrated at 25 °C.

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2.4 Balanced vs. Tuned-System assemblies

A balanced remote seal system is a symmetrical system that utilizes equal seals and capillary length on the high and low pressure sides of the transmitter. Since the capillary lengths are the same, each side ideally has the same amount of fill fluid, minimizing or completely eliminating the seal temperature effect due to equal pressure on both sides of the transmitter diaphragm. The balanced systems are still affected by the head pressure as shown in Figure 2-5.

Figure 2-5. Balanced System

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+3.6 inH2O

(9.0 mbar)

No error Seal temperature effect

(Cancels out)

+3.6 inH2O

(9.0 mbar)

Head temperature effect

Total temperature effect

on system

Note

Temperature effects were calculated in Instrument Toolkit using a 2-in. (DN 50) FFW seal, Silicone 200, 10 ft. (3 m) between the taps, over a 50 °F (28 °C) temperature change.

Tuned-Systems assemblies are asymmetrical remote seal systems with one seal directly mounted to the high side of the differential pressure transmitter, and the other side connected to a seal via capillary. Another possible Tuned-System assembly is any remote seal system with unequal lengths of capillary or two different remote seals on the high and low pressure connections. Due to the unequal lengths of capillary, there are seal temperature effects. However, this seal temperature effect counters the head pressure from the oil-filled capillary and reduces total temperature effects on the entire system.

Figure 2-6. Tuned-System Assembly

Head temperature effect

Seal temperature effect

Total temperature effect

on system

Understanding Remote Seal Systems

+3.6 inH2O

(9.0 mbar)

-1.7 inH2O (4.2 mbar)

+1.9 inH2O

(4.7 mbar)

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Note

Temperature effects were calculated in Instrument Toolkit using a 2-in. (DN 50) FFW seal, Silicone 200, 10 ft. (3 m) between the taps, over a 50 °F (28 °C) temperature change.

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2.5 Specifying the right solution for vacuum applications

2.5.1 Vacuum application overview

When a vessel is operating in a vacuum (negative gauge pressure), it is important to specify the correct transmitter remote seal system to measure level accurately and reliably. Failure to do so can result in output drift or complete system failure. The combination of high process temperature and vacuum process pressure conditions creates additional requirements when specifying the transmitter remote seal system.

2.5.2 Vacuum applications

There are three primary transmitter-seal system components necessary to successfully specify vacuum application solutions:

 Seal system construction  Fill fluid selection  Transmitter mounting position

2.5.3 Seal system construction for vacuum applications

Emerson™ offers welded-repairable or all-welded vacuum system construction styles on diaphragm seal assembles.

The all-welded vacuum construction was designed specifically for vacuum applications. In this construction, the sensor module gaskets are removed and a disk is welded over the sensor isolators. This eliminates the possibility of air being drawn into the seal system in deep vacuum conditions. This premium design is strongly suggested for vacuum pressures below 6 psia (310 mmHga).

2.5.4 Transmitter mounting position

Mounting the pressure transmitter at or below the bottom vessel tap is an important factor to ensure a stable measurement with vacuum applications. The static pressure limit for a differential pressure transmitter is 0.5 psia (25 mmHgA), which ensures the transmitter sensor module fill fluid remains within the liquid phase of the vapor pressure curve.

If the vessel static limit is below 0.5 psia, mounting the transmitter below the bottom tap provides a capillary fill fluid head pressure on the module. A general rule is to always mount the transmitter approximately 3 ft. (1 m) below the bottom tap of the vessel.

2.5.5 Fill fluid selection

When the process is under vacuum conditions, the fill fluid can vaporize at a lower temperature than when it is under normal atmospheric or greater pressure. Each fill fluid has a specific vapor-pressure curve. The vapor-pressure curve indicates the pressure and temperature relationship where the fluid is in a liquid or a vapor state. Proper seal operation requires the fill fluid to remain in a liquid state.

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For vacuum applications, specify fluids that are specifically designed for use in these types of applications such as Silicone 704 for vacuum applications, Silicone 705 for vacuum applications, or

UltraTherm

™

805 for vacuum applications. These fluids have been specially processed to deliver the maximum vapor pressure curve performance possible. For more information on Rosemount Diaphragm Seal fill fluids, reference the Rosemount 1199 Fill Fluid Specifications Tec hnical Note

2.6 Diaphragm weld types

Weld-type is factory-determined as best for the seal typed specified. PFW and FFW seals have ordering options that specify welding options.

2.6.1 Solid faceplate design

The solid faceplate design is used when diaphragm and upper housing material are the same.

A. Material A B. Upper housing

C. Diaphragm D. TIG weld point

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2.6.2 Seam weld design

A seam weld design is used when the upper housing material is different from the diaphragm material. The seam welded design has a hermetic weld at the inner diameter of the diaphragm and a TIG weld at the outer edge. The diaphragm floats on the upper housing over the gasket surface area and could tear if

a metallic gasket were used.

A. Material A B. Material B C. Upper housing

2.6.3 Brazed design

This process uses a brazing ring where the metals are brazed to attach the diaphragm to the upper housing. This allows the gasket surface area to solidify as it is melted to the upper housing.

This option is used with Tantalum diaphragm when a metallic gasket is required.

D. Diaphragm E. TIG weld point F. Se am wel d p oi nt

A. Material A B. Tantalum C. Upper housing

Understanding Remote Seal Systems

D. Brazing ring E. Diaphragm

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2.7 Differences between electronic remote sensors and capillary systems

Rosemount 3051S Electronic Remote Sensors (ERS™) System technology utilizes two Rosemount 3051S Pressure Transmitters connected via an electrical wire instead of a single pressure transmitter with remote seals and capillary tubing. As the Rosemount 3051S ERS System calculates the differential pressure between the two transmitters, capillary tubing is not needed, and thus eliminates all head temperature affects on the system. Seals are not required, but may still be necessary on certain applications that include high temperature, corrosive, or viscous processes. For more information, refer to the Rosemount 3051S Series Product Data Sheet

Figure 2-7. ERS vs. Capillary

Rosemount 3051S ERS Traditional capillary system

A. Non-proprietary electrical cable B. Oil-filled capillary system

2.8 Instrument Toolkit: seal ordering and application process

Rosemount Instrument Toolkit Software is an instrumentation specification tool that can be used to assist in product selection. This program analyzes application and process conditions against a configured Rosemount model number and calculates the total system performance including expected head and seal temperature effects and system response times.

Visit the Emerson website for information on how to obtain and use Instrument Toolkit.

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2.9 Rosemount Thermal Range Expander: proper use and applications

Figure 2-8. Rosemount Thermal Range Expander

The Rosemount Thermal Range Expander increases the application range where DP Level technology can be used by expanding the ambient and process temperature ranges of the system.

Traditional remote seal systems are filled with a single fill fluid to operate in applications with varying ambient and process conditions. Silicone 704 and 705 are commonly used fluids for hot process applications going above 570 °F (300 °C); these fluids must be kept above 32 °F (0 °C) and 68 °F (20 °C), respectively, in order to properly transmit the pressure signal to the transmitter. This can prove to be difficult for outdoor installations where extremely cold ambient conditions cause these fill fluids to gel.

The Rosemount Thermal Range Expander is a seal system that uses two different fill fluids to extend the operating temperature range of the system. A high temperature fill fluid, which is next to the hot process, is kept warm enough to stay responsive. A second fill fluid, located on the other side of the intermediate diaphragm, operates over a wide ambient temperature range. The Rosemount Thermal Range Expander can operate in ambient temperatures as low as –75 °C (–103 °F), and process temperatures up to 410 °C (770 °F). This improves response time up to 46 percent and eliminates the need for mechanical heat tracing.

The Rosemount Thermal Range Expander can be used with any Rosemount 3051S DP Level configuration including Balanced Systems, Tuned-System Assembles, Electronic Remote Sensors (ERS), or direct mounted to a transmitter.

Figure 2-9. Rosemount Thermal Range Expander Fill Fluids

A. Intermediate diaphragm B. High temperature fill fluid (viscous) C. Ambient temperature fill fluid

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Figure 2-10. Rosemount Thermal Range Expander Temperature Operating Range

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2.10 Thermal optimizer: proper use and applications

Figure 2-11. Thermal Optimizer

The thermal optimizer keeps fill fluids from gelling in cold ambient temperatures by using high process temperatures to heat the transmitter and capillary.

High temperature silicone fill fluid has a low temperature limit in ambient conditions below 32 °F (0 °C). The thermal optimizer allows direct mounting down to –94 °F (–70 °C).

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212 °F (100 °C)

176 °F (80°C)

140 °F (60 °C)

104 °F (40 °C)

68 °F (20 °C)

32 °F (0 °C)

-4 °F (-20 °C)

-40 °F (-40 °C)

-76 °F (-60 °C)

-112 °F (-80 °C)

212 °F (100 °C)

176 °F (80°C)

140 °F (60 °C)

104 °F (40 °C)

68 °F (20 °C)

32 °F (0 °C)

-4 °F (-20 °C)

-40 °F (-40 °C)

-76 °F (-60 °C)

-112 °F (-80 °C)

32 °F (0 °C)

122 °F (50 °C)

302 °F (150 °C)

482 °F (250 °C)

622 °F (350 °C)

842 °F (450 °C)

401 °F (205 °C)

185 °F (85 °C)

599 °F (315 °C)

-58 °F (-50 °C)

91 °F (33 °C)

Process temperature °F (°C)

Ambient temperature °F (°C)

Process temperature °F (°C)

122 °F (50 °C)

302 °F (150 °C)

482 °F (250 °C)

622 °F (350 °C)

842 °F (450 °C)

185 °F (85 °C)

-58 °F (-50 °C)

401 °F (205 °C)

-69 °F (-56 °C)

-76 °F (-60 °C)

68 °F (20 °C)

662 °F (350 °C) 68 °F (20 °C)

68 °F (20 °C)

698 °F (370 °C)

77 °F (25 °C)

00809-0100-4002, Rev DA

Figure 2-12. Fill Fluid Temperature Limits

Thermal optimizer with Silicone 704 Thermal optimizer with Silicone 705

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2.10.1 Thermal optimizer limitations

2.11 Submersible seal

2.11.1 Designed for top-down measurement

Understanding Remote Seal Systems

Figure 2-12 shows the process and ambient temperature limits for the thermal optimizer with Silicone

704 and Silicone 705 Fill Fluids respectively. The shaded areas represent the temperature limitations; applications outside of the shaded area cannot be used with a thermal optimizer.

For example, an application with an ambient temperature of 50 °F (10 °C) and a process temperature of 300 °F (149 °C) is within the limits, a thermal optimizer can be used in this application.

However, an application with an ambient temperature of 120 °F (40 °C) and a process temperature of 464 °F (240 °C) is outside of the limits. These high temperatures would be detrimental to the transmitter electronics.

The submersible seal consists of a bellows-style seal and is designed for measuring level in top-down applications with small tank connections, specifically 1.5-in. NPT threaded connections or 2- to 4-in. flanges. For tanks with larger connections or open process measurements, an RTW seal should be specified as it will provide a more accurate measurement.

Apart from traditional DP Level transmitters, this new design has both the seal and capillary submersed in the process as shown below. Traditional DP Level seal systems are side mounted to tanks such that the diaphragm seal is the only wetted material that comes in direct contact with the process fluid.

This assembly can only be ordered with Rosemount in-line transmitters for gage measurements. Differential and absolute measurements are not available.

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2.11.2 Submersible Seal features

 Specifically designed for top-down process measurements  Bellows-style seal absorbs pressures efficiently for smaller process connections  Threaded or flanged process connections  Uses proven and reliable DP Level remote seals  Up to 30 ft. (9,1m) of capillary

Figure 2-13. Rosemount Submersible Seal attached to a Rosemount 3051T Wireless Pressure

Tra ns mit te r

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A. Seal body B. Bellows C. Outer tube

D. Fill fluid E. Process fluid

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Section 3 Installation

Seals handling and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17

Tagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

Max working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 18

FFW flush flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19

RFW off-line flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29

EFW extended flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33

PFW pancake seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42

FCW flush flanged seal—ring type joint (RTJ) gasket surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 45

RCW off-line ring type joint (RTJ) flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48

FUW flush flanged groove type seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 50

FVW flush flanged tongue type seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 51

RTW off-line threaded type seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 53

HTS male threaded seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55

SCW hygienic Tri-Clover Tri Clamp seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56

SSW hygienic tank spud seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58

STW hygienic thin wall tank spud seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61

EES hygienic flanged tank spud extended seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 62

VCS Tri Clamp In-line seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 63

SVS VARIVENT compatible hygienic connection seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 64

SHP hygienic Cherry-Burrell “I” line seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 65

SLS dairy process connection–female thread seal per DIN 11851 . . . . . . . . . . . . . . . . . . . . . . . . . . . page 66

WSP saddle seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 67

UCP union connection pipe mount seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 69

PMW paper mill sleeve seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 71

CTW chemical tee seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 73

TFS wafer style In-line seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 74

WFW flow-thru flanged seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 75

Installation

May 2017

Additional specialized remote seals are available. Contact Emerson information on these seals.

3.1 Seals handling and installation

3.1.1 Diaphragm

The remote seal diaphragm is designed to withstand pressure and wear from process, but outside of process connection conditions, remote seals are delicate and should be handled with care.

The protective cover should remain on the seal until the moment before installation. Try to avoid touching the diaphragm with fingers or objects and refrain from setting the diaphragm side of the seal down on a hard surface.

Installation

™

Technical Support for installation

Installation

May 2017

Even minor dents or scratches in the diaphragm material may impair the performance of the seal system assembly. Care should be taken to ensure the seal diaphragm is not dented or damaged during seal installation.

3.1.2 Capillary

When unpacking or handling seal system assemblies, do not lift the seal or transmitter by gripping the capillaries. Avoid sharply bending or crimping the capillary tubing. The minimum bending radius of the capillary tubing is 3-in. (8 cm).

3.1.3 Rosemount Thermal Range Expander

The Rosemount™ Thermal Range Expander system uses the heat from the process in order to keep both fluids within the system functioning properly; therefore insulation is not always required. However, it is always best practice to insulate systems to keep them functioning with optimum performance. The Rosemount Thermal Range Expander should never be insulated above the line marked on the seal itself.

Figure 3-1. Rosemount 3051SAL with Rosemount Thermal Range Expander Insulation Guidelines

Rosemount 3051SAL with Thermal Range Expander

Reference Manual

00809-0100-4002, Rev DA

Marking: “Do Not Insulate Above this Line”

Ok to

Insulate

3.1.4 Heat tracing

When using heat or steam tracing, exercise caution if PVC coating is added onto capillary, as PVC coating should not be exposed to temperatures above 212 °F (100 °C) to avoid the possibility of thermal breakdown. Best practice for heat and steam tracing is to regulate the temperature slightly above the maximum ambient temperature for a consistent result. To avoid accuracy effects and thermal stress, the capillary should not be partially heated.

Do Not

Insulate

Installation

Reference Manual

00809-0100-4002, Rev DA

NEVER attempt to disconnect the seals or capillaries from the transmitter or loosen bolts. Doing so will result in loss of fill fluid and will void the product warranty.

Failing to recognize incorrect materials during installation may cause process leaks, which can result in damage to the diaphragm seal system or death and/or serious injury to personnel. Proper wetted material is required for specific process materials.

3.2 Gaskets

When installing remote seal systems which employ a gasket or a gasket and flushing connection ring, make sure the gasket is aligned properly on the gasket sealing surface. The user is responsible to ensure the gasket used does not exceed the temperature limits of the process. Failure to properly install the gasket may cause process leaks, which can result in death or serious injury.

In addition, make sure the gasket does not press down upon the diaphragm face. Anything pressing on the diaphragm will be read by the transmitter as pressure. A misaligned gasket may cause a false reading.

Installation

May 2017

The intermediate gasket between the seal and lower housing is supplied when the lower housing or flushing connection is provided. The default gaskets are listed in Tab l e 3 -1 based on seal type. The process gasket must be supplied by the end user. Tantalum diaphragms are not supplied with default gasket, so a gasket option must be selected when applicable.

If a lower housing is supplied, then the following gaskets are the default gaskets for each seal unless another gasket option is selected.

Table 3-1. Gaskets Materials

Seal type Gaskets

Flanged seals assemblies

FFW Thermo-Tork® TN-9000

RFW Klinger C-4401

EFW No gasket is supplied

PFW Thermo-Tork TN-9000

FCW No gasket is supplied

RCW Klinger C-4401

FUW/FVW No gasket is supplied

Threaded seal assemblies

RTW Klinger C-4401

HTS No gasket is supplied

Hygienic seal assemblies

(1)

SCW

SSW Ethylene propylene O-ring

STW Ethylene propylene O-ring

EES No gasket is supplied

(1)

VCS

(1)

SVS

SHP No gasket is supplied

(1)

SLS

(1)

MLS

No gasket is supplied

Installation

May 2017

Table 3-1. Gaskets Materials

Specialty seals

WSP Klinger C-4401

UCP Barium-Sulfate filled PTFE O-ring

CTW No gasket is supplied

TFW No gasket is supplied

WFW Klinger C-4401

1. Ensure to use EHEDG approved gasket for EHEDG conformity.

Note

The end-user is responsible for choosing a gasket and ensuring the process temperature does not exceed the temperature limits of the gasket used. Failure to properly install the gasket may cause process leaks, which can result in death or serious injury.

3.3 Tagging

Each remote seal system is tagged in accordance with the end-user requirements. The remote seal model number is identified on the transmitter label, shown in Figure 3-2, 3-3, and 3-4.

Reference Manual

00809-0100-4002, Rev DA

Figure 3-2. Rosemount 3051S Sample Label

Figure 3-3. Rosemount 3051 Sample Label

Figure 3-4. Rosemount 2051 Sample Label

3.3.1 Max working pressure

The maximum working pressure (MWP) of the seal system assembly is stamped on the transmitter neck tag. This can be dependent upon the maximum pressure rating of the seal system or transmitter upper range limit.

Installation

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