Rosemount 2120 Vibrating Fork Liquid Level Switch Manual Supplement

Manual Supplement

00809-0200-4030, Rev BA

November 2012

Replacement and Calibration of
Rosemount 2120 Electronic Cassettes

Manual Supplement

NOTICE

November 2012

Refer to the Rosemount 2120 Reference Manual (Document Number 00809-0100-4030) for
more instructions. Manuals are available electronically on www.rosemount.com.

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

 The Rosemount 2120 is a liquid level switch. It must be installed, connected, commissioned,

operated, and maintained by suitably qualified personnel only, observing any national and
local requirements that may apply

 Ensure the wiring is suitable for the electrical current and the insulation is suitable for the

voltage, temperature, and environment

 Use the equipment only as specified. Failure to do so may impair the protection provided by

the equipment

 Any substitution of non-recognized parts may jeopardize safety and is under no

circumstances allowed

Explosions could result in death or serious injury

 Installation of the 2120 in a hazardous environment must be in accordance with the

appropriate local, national, and international standards, codes, and practices. Please review
the Product Certifications section for any restrictions associated with a safe installation

 Verify that the operating atmosphere of the 2120 is consistent with the appropriate

hazardous locations certifications

External surface may be hot

 Care must be taken to avoid possible burns

Process leaks could result in death or serious injury

 Install and tighten process connectors before applying pressure
 Do not attempt to loosen or remove process connectors while the 2120 is in service

Electrical shock could cause death or serious injury

 If the liquid level switch is installed in a high voltage environment and a fault condition or

installation error occurs, high voltage may be present on leads and terminals

 Use extreme caution when making contact with the leads and terminals
 Make sure that power to the 2120 is off while making connections

2

November 2012

OPERATION MODE

Dry On Mode

Dry
Wet

Wet On Mode

Dry
Wet

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

12

3

OUT

+

-

4

PLC/PNP

Isolate Supply
Before Removing

B

A

Manual Supplement

Replacement and calibration of electronic cassettes

When replacing a damaged or faulty cassette, it is necessary to calibrate the
replacement cassette to the operating frequency of the fork assembly.

Replacement sequence

If this replacement is taking place in a hazardous area, only qualified personnel should
perform the replacement. All work in hazardous areas must be carried out in
accordance to national and local codes of practice. Refer to the Rosemount 2120
manual (00809-0100-4030) for product certifications and safety instructions for
specific hazardous area installations.

Calibration of this device is complex and it may take several attempts before
calibration is successful.

On Intrinsically Safe (I.S.) approved versions of the 2120, it is recommended that
replacement and calibration be performed in a non-hazardous (safe) area.

Note

 In I.S. applications, NAMUR cassettes can only be replaced with NAMUR cassettes,

and 8/16 mA cassettes can only be replaced by 8/16 mA cassettes

 Non-I.S. cassettes can be interchanged with other non-I.S. cassettes, but the new

label must be fitted and the original part number transferred to the new label
(see “Electrical installation” on page 7 for connections to the electronic cassettes)

 Before starting the replacement and calibration procedure, ensure that any controlled

process will not be adversely affected

To replace the cassette, do the following:

1. Isolate and disconnect the power to the Rosemount 2120, and insulate the ends of
the wires. On a 2120 with a relay cassette, there may be more than one power
source.

2. Remove the cover and disconnect the wires, noting any connections (Figure 1) and
the exact mode switch position (Figure 2) on the cassette to be replaced.

3. Remove and retain the two fixing screws from the base of the cassette and unplug
the cassette.

4. Plug in the replacement cassette, refit the screws, reconnect the wires, and set the
mode switch to “Wet On” with a one second delay (Figure 3).

5. Reconnect the power to the 2120.

6. Proceed to “Calibration sequence” on page 5.

Figure 1. Top-down view of example cassette inside the housing

A. LED
B. Mode Switch and Time Delay

3

Manual Supplement

Dry On Wet On

Seconds Delay

0.3 0.3

30

10

3

30

10

1

3

1

Figure 2. Mode switch and setting on the existing cassette

This is an example of how the existing cassette may look.

Dry On Wet On

Here, the switch is set to “Dry On” with a one second delay.

Take note of the actual setting.

0.3 0.3
1

3
10
30

SETTING IS: ___________________________

1
3
10

30

Seconds Delay

Figure 3. Mode switch setting on the replacement cassette

Set the mode switch of the new cassette to “Wet On” with a
one second delay.

November 2012

4

November 2012

Manual Supplement

Calibration sequence

This section describes what is required for calibration. Calibration sequence steps 3 to
13 are time dependent and must be carried out within the noted times. The purpose of
the time dependency and switching sequence is to prevent an accidental calibration
from occurring.

To calibrate the cassette, do the following:

1. Ensure that the forks are dry, and the mode switch is set to “Wet On” with a one

second time delay (Figure 3).

2. Check that the LED is flashing at a rate of one flash per second.

If it is on continuously, proceed to step 8.

3. Apply magnet to the test-point (as shown on page 6).

4. After a one second delay, the LED will be lit continuously.

5. Within one second, rotate the mode switch two steps clockwise.

6. After a two second delay, the LED will go out.

7. Within three seconds, rotate the mode switch two steps counter-clockwise.

Proceed to step 13.

8. Apply magnet to test point (as shown on page 6).

9. After a one second delay, the LED will flash at a rate of one flash per second.

10. Within one second, rotate the mode switch two steps clockwise.

11. After a two second delay, the LED will go out (stop flashing).

12. Within three seconds, rotate the mode switch two steps counter-clockwise.

13. After a two second delay, the LED should flash twice per second.

14. If the LED is flashing twice per second, the calibration has occurred correctly.

Remove the magnet from the test-point. After a one second delay, the unit will
return to normal operation. Proceed to step 17.

15. If the LED is flashing once per second or it is on continuously, the calibration has

failed. Remove the magnet from the test-point, wait ten seconds, and then repeat
from step 2.

16. If the LED stays off after the two second delay of step 13, the sensor is not working

correctly. Check that the sensor forks are clean and dry. Also, verify there is nothing
jamming or touching the sensor. If no fault is found with the sensor, the entire unit
should be returned for repair.

17. Set the mode switch to the original setting noted in Figure2 and wait five seconds.

18. Replace the cover and check that the system works.

5

Manual Supplement

TP

TP

TP

S

N

S

N

(OUTPUT ON)

(OUTPUT ON)

(OUTPUT OFF)

(OUTPUT OFF)

NO MAGNET

MAGNET

~

20 - 264Vac
50 - 60Hz 2VA
20 - 60Vdc 0.5W
Output Rating:
Load 20 - 500mA

Supply

www.rosemount.com

MAX PROCESS TEMPERATURE: 150°C

MADE IN UNITED KINGDOM

MAX WORKING PRESSURE AT 20°C: 0.25 bar

DIRECT LOAD SWITCHING

MAGNETIC

TEST
POINT

41001029

*41001029*

2120D0AS1NAAA

~

20 - 264Vac
50 - 60Hz 2VA
20 - 60Vdc 0.5W
Output Rating:
Load 20 - 500mA

Supply

www.rosemount.com

MAX PROCESS TEMPERATURE: 150°C

MADE IN UNITED KINGDOM

MAX WORKING PRESSURE AT 20°C: 0.25 bar

DIRECT LOAD SWITCHING

MAGNETIC

TEST

POINT

41001029

*41001029*

2120D0AS1NAAA

MAGNETIC

TEST

POINT

S

N

S

N

(OUTPUT ON)

(OUTPUT ON)

(OUTPUT OFF)

(OUTPUT OFF)

NO MAGNET

MAGNET

Figure 4. Magnetic test point (metal housing)

Figure 5. Magnetic test point (glass-filled nylon housing)

November 2012

6

November 2012

Direct Load
Switching

WARNING

Isolate Supply
Before Removing

OPERATION MODE

Dry On Mode

Dry
Wet

Wet On Mode

Dry
Wet

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

123

LINE

LOAD

PE

(Ground)

Neutral

Live

0V

Fuse 2A(T)

R

I

L

R = External load (must be fitted)
U = 20 - 264 V ~ (ac) (50/60Hz)

I

OFF

< 4

mA at 20 °C (24 - 230 Vac)

I

OFF

< 6

mA at -40 to 80 °C (20 - 264 Vac)

I

L

=

20 - 500

mA

U = 20 - 60 V (dc))
I

OFF

< 4 mA

IL =

20 - 500 mA

DPST

+V

= 5 A, 40 ms (inrush)

I

PK

= 5 A, 40 ms (inrush)

I

PK

= Load On

= Load Off

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

Dry On Wet On

Seconds Delay

0.3 0.3

30

10

3

30

10

1

3

1

Fuse

2A(T)

N L

0V

+V

I

L

<4mA

DPST

U

N L

0V

+V

Fuse
2A(T)

I

L

12V

DPST

Fuse
2A(T)

N L

0V

+V

I

L

<4mA

DPST

Manual Supplement

Electrical installation

Before use, check that suitable cable glands and blanking plugs are fitted and
fully tightened.

Isolate supply before connecting the switch or removing the electronics.

The Protective Earth (PE) terminal must be connected to an external
earthing system.

Direct load switching electronics cassette (two-wire, red label)

High level Dry = ON Low level Wet = ON

DPST

U

12V

I

L

N L

0V

LED on continuously

Fuse

2A(T)

+V

LED flashes each

second

LED on continuously

LED flashes each

second

7

Manual Supplement

OPERATION MODE

Dry On Mode

Dry
Wet

Wet On Mode

Dry
Wet

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

12

3

OUT

+

-

4

PLC/PNP

Isolate Supply
Before Removing

PE

(Ground)

0VO/P

U = 20 - 60 V (dc)
I < 4 mA + I

L

I

L (MAX

)

= 0 - 500 mA

U

OUT(ON)

= U - 2.5 Vac (20 °C)

I

L (OFF)

< 100A

+V

Fuse 2A(T)

= 5 A, 40 ms (inrush)

I

PK

U

OUT(ON)

= U - 2.75 Vac (-40 to 80 °C)

OUT

-

+

PLC

+

I/P



U

<3V

I

L

OUT

-

+

PLC

+

I/P

I

L

<100 A

OUT

-

+

+



U

<3V

I

L

Fuse

1A(T)

R

OUT

-

+

+

I

L

Fuse

1A(T)

R

< 100 A

PNP/PLC electronics cassette (three-wire, yellow label)

High level Dry = ON Low level Wet = ON

Dry On Wet On

0.3 0.3
1

3
10
30

Seconds Delay

1
3
10

30

Dry On Wet On

0.3 0.3
1

3
10
30

Seconds Delay

November 2012

1
3
10

30

8

PLC (positive input)PNP dc

LED on

continuously

OUT

-

+

<100 A

I

L

I/P

+

PLC

OUT

-

+

R

I

Fuse
1A(T)

LED flashes each

L

< 100 A

+

second

OUT

-

+



U

<3V

I

L

I/P

+

PLC

OUT

-

+



U

<3V

R

Fuse

I

1A(T)

L

+

LED on

continuously

LED flashes each

second

November 2012

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

Dry On Wet On

Seconds Delay

0.3 0.3

30

10

3

30

10

1

3

1

NC NOC

NC NOC

NC NOC

Relay output electronics cassette (DPCO, green label)

Manual Supplement

(Ground)

Warnin g

LN

123

N

Live

0V

OPERATION MODE

Seconds Delay

Dry On

Wet On

0.3 0.3
1
3

10

30

Fuse 0.5 (T)PE

DPST

U = 20...264 V ~ (ac)

I < 6 mA

U = 20...60 V (dc)

+V

I < 6 mA

Dry

Wet

1

3

10

Dry
30

Wet

(50/60 Hz)

Dry On

Wet O n

Isolate Supply Before Removing

NOCNC

45

6

789

C

= 30 V

= 240 W

NC

Induct ive Load

cos φ = 0.4 ;
L/R = 7 ms

I

ac

U

P

dc

U

P

NC NO

Resistive Load

cos φ = 1 ;
L/R = 0 ms

I

= 5 A

MAX

ac

U

= 250 V

MAX

P

= 1250 VA

MAX

dc

U

MAX

P

MAX

C

MAX

MAX

MAX

MAX

MAX

= 3.5 A

NOCNC

RELAY

NO

= 250 V

= 875 VA

= 30 V

= 170W

High level Dry = ON Low level Wet = ON

NC NOC

LED on continuously

NC NOC

LED flashes each

second

NC NOC

NC NOC

LED on continuously

NC NOC

LED flashes each

second

9

Manual Supplement

OPERATION MODE

Dry On Mode

Dry
Wet

Wet On Mo d e

Dry
Wet

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

12

+-

EN 50227 / NAMUR

ION= 2.2 . .. 2.5 mA
I

OFF

= 0.8 ... 1.0 mA

+

-

A certified intrinsically safe
isolating am plifier to IE C 60 9 4 7-5-6

Ex

Ex

8V
dc

+

-

>2.2 mA

NAMUR electronics cassette (light blue label)

High level Dry = ON Low level Wet = ON

Dry On Wet On

0.3 0.3

1
3
10
30

Seconds Delay

1
3
10

30

Dry On Wet On

0.3 0.3
1

3
10
30

Seconds Delay

November 2012

1

3

10

30

LED on continuously

Note

 This cassette is suitable for Intrinsically Safe applications and requires a certified

 This electronics cassette is also suitable for non-hazardous (safe) area applications.

 Do not exceed 8 Vdc

10

-

+

<1.0 mA

LED flashes each

second

isolating barrier. See the Rosemount 2120 Reference Manual (
for Intrinsically Safe approvals

It can only be interchanged with the 8/16 mA cassette.

-

+

>2.2 mA

LED on continuously

-

+

<1.0 mA

LED flashes each

second

00809-0100-4030)

November 2012

+

Dry On Wet On

Seconds Delay

0.3 0.3

3

30

10

1

3

30

10

1

+

> 15 mA

+

+

> 15 mA

+

< 8.5 mA

8/16 mA electronics cassette (dark blue label)

OPERATION MODE

11 - 30 V (dc)

U

=

ION=

=

I

OFF

Dry On Wet On

0.3 0.3
1

3
10
30

Seconds Delay

15 ... 17 mA

7.5 ... 8.5 mA

Ex

12

PE

(Ground)

Dry On Mode

Dry
Wet

Wet
Dry

Wet On Mode

3

Manual Supplement

8/16 mA

1
3
10

30

Ex

High level Dry = ON Low level Wet = ON

LED on continuously

-

-

Drives 4-20 m

A Analog Input

< 8.5 mA

LED flashes each

second

+

A certified intrinsically safe barrier
must be used to meet IS requirements

+

LED on continuously

Dry On Wet On

0.3 0.3
1

3
10
30

Seconds Delay

1
3
10

30

LED flashes each

second

Note

 This cassette is suitable for Intrinsically Safe applications and requires a certified

isolating barrier. See the Rosemount 2120 Reference Manual (

00809-0100-4030)

for Intrinsically Safe approvals

 This cassette is also suitable for non-hazardous (safe) area applications. It can only be

interchanged with a NAMUR cassette

11

Manual Supplement

Tr ou bl es ho oti ng

If there is a malfunction, see Table 1 for information on possible causes.

Table 1. Troubleshooting chart

Faul t Symptom/Indication Action/Solution

Check the power supply; (check load on direct
load switching electronics model)

This is normal – wait 5 seconds

Fit the factory supplied cassette (page 3)
and then calibrate (page 5)

Does not
switch

Incorrect
switching

Faul ty
switching

No LED; no power

LED flashing See LED indication

Fork is damaged Replace the 2120

Thick encrustation on the fork Clean the fork with care

5 second delay when changing
mode/delay

Dry = On, Wet = On set incorrectly Set the correct mode on the electronics cassette

Turbulence Set a lo nger switchi ng time delay

Excessive electrical noise Suppress the cause of the interference

Cassette has been fitted from another
Rosemount 2120

LED indication

When the LED is red and flashing, it indicates the 2120 may be uncalibrated,

successfully calibrated, has an electrical load problem, or has an internal PCB fault.
See Table 2 for further information.

November 2012

Table 2. LED flash rate

LED Flash Rate Switch St atus

Continuous Output state is on

1 every second Output state is off

1 every 2 seconds Uncalibrated – see “Calibration sequence” on page 5

1 every 4 seconds Load fault; load current too high; load shor t circuit

2 times every second Indication of successful calibration

3 times every second Internal PCB fault (microprocessor, ROM, or RAM)

Off Problem (e.g. supply)

12

November 2012

Manual Supplement

13

Manual Supplement

November 2012

14

November 2012

Manual Supplement

15

Manual Supplement

00809-0200-4030, Rev BA

November 2012

Rosemou nt Inc.

8200 Market Boulevard
Chanhassen, MN USA 55317
T (US) [phone]
T (Intnl) [phone]
F [phone]

Emerson Process Management
Asia Pacific Priva te Limited

1 Pandan Crescent
Singapore 128461
T (65) 6777 8211
F (65) 6777 0947/65 6777 0743

Emerson Process Management
GmbH & Co. OHG

Argelsrieder Feld 3
82234 Wessling Germany
T 49 (8153) 9390, F49 (8153) 939172

Beijing Rosemount Far East
Instrument Co., Limited

No. 6 North Street, Hepingli,
Dong Cheng Distric t
Beijing 100013, China
T (86) (10) 6428 2233
F (86) (10) 6422 8586

© 2012 Rosemount Inc. All rights reserved. All marks property of owner.
The Emerson logo is a trade mark and service mark of Emerson Electric Co
Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.