Rosemount 3095 Product Manual

Model 3095

™

Multivariable
Level Controller

00809-0100-4741

English

Rev. AA

Product Manual

1Model 3095 Multivariable

™

Level Controller

NOTICE

Read this manual before working with the prod uc t. For perso nal and system
safety, and for optimum product performance, make sure you thoroughly
understand the conten ts before installing, using, or maintaining this product.

Within the United States, Rosemount Inc. ha s two tol l-free assistance numbers.
Customer Central: 1-800-999-9307 (

Technical support, quoting, and order-related questions.

North American 1-800-654-7768 (
Response Center: Equipment service needs.

For equipment s ervice or s upport n eeds outs ide the United State s, cont act your
local Rosemount representative.

7:00 a.m. to 7:00 p.m. CST)

24 hours a day – Includes Canada)

Rosemount Inc.

8200 Market Boulevard
Chanhassen, MN 55317 USA
Tel [phone]
Telex 4310012
Fax [phone]
© 1998 Rosemount, Inc.

http://www.rosemount.com

The products described in this document are NOT designed for nuclear­qualified applications.

Using non-nuclear qua lifi ed products in applications that require nuclear­qualified hardware or products may cause inaccurate readings.

For information on Rosemount nucle ar-qualified products, contact you r local
Rosemount Sales Representative.

SNF-0004

Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.
Coplanar and Multivariable are trademarks of Rosemount Inc.
Plantweb is a mark of the Fisher-Rosemount group of companies.
HART is a registered trademark of the HART Communica tion Found atio n.
Hastelloy C-276 is a registered trademark of Cabo t Corp.
Microsoft and Windows are registered trademarks of Microsoft Corp.

Cover Photo: 3095LC01

Fisher-Rosemount satisfie s all ob liga tio n s comin g from legisla tio n

Fisher-Rosemount satisfies all obligations coming from legislation

to harmonize product requi r em en ts in th e Eur opean Union.

to harmonize product requi r em en ts i n th e European Union.

T

N

I

E

D

R

P

IN

U.

A.

S.

Table of Contents

IMPORTANT

Procedures and instructions in this manual may require special precautions to
ensure the safety of the personnel performing the operations. Information that
raises potential safety issues is indicated by a warning symbol ( ). Refer to the

safety messages listed at the beginning of each section before performin g
an operation preceded by this symbol.

SECTION 1
Introduction

SECTION 2
Level Controller Overview
and Installation

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Level Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Before you Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Unpacking the Level Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Becoming Familiar with the Level Controller . . . . . . . . . . . . . . . . . 2-5

Bench Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Failure Mode Alarm vs. Saturation Output Values . . . . . . . . . . 2-7

Write Protect and Failure Mode Alarm Jumpers . . . . . . . . . . . . 2-7

General Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Mechanical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Bolt Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Example Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Open Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Open Tanks with Bubbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Closed Tanks with Dry Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Closed Tanks with Wet Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Tap Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Impulse Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Diaphragm Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Access Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Field Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Field Installation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Review Installation Considerations . . . . . . . . . . . . . . . . . . . . . . 2-19

Mount Controller and Install Bolts . . . . . . . . . . . . . . . . . . . . . . . 2-19

Make Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Install RTD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Check for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Field Wiring (Power and Signal) . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Install Field Wiring Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Replace Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

v

SECTION 3
Level Controller Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Level Variables and Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Level Controller Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

PID Controller Description and Details . . . . . . . . . . . . . . . . . . . . . . 3-3

AutoTuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Why Autotune? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Autotuner Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Alpha Adjustment for Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Adaptive Bias Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

When to Use Adaptive Bias Control . . . . . . . . . . . . . . . . . . . . . . 3-7

How ABC Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Local Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Mode Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SECTION 4
Level Controller
Configuration

Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Set Up the Level Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Place Controller into Out-of-Service (OOS) Mode . . . . . . . . . . . 4-2

Set Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Set Level Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Set Controller Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Additional Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Configure the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Set Range Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Set Control Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Set Control Action (Direct, Reverse) . . . . . . . . . . . . . . . . . . . . . . 4-5

Adaptive Bias Control (ABC) Settings . . . . . . . . . . . . . . . . . . . . 4-6

Set Power-Up Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Set Mode Shed Options (Failure Condition) . . . . . . . . . . . . . . . . 4-7

Set Manual Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Set Auto Output Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Choose Setpoint Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Additional Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Perform a Level Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Trim Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Level Trim Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Tune the Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Set Target Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Set Control Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Autotuner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

vi

SECTION 5
Troubleshooting
and Maintenance

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Level Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Communication Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Interpreting Level Controller Alarms and Error Conditions . . . 5-3

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

Process Sensor Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Electrical Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Remove the Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Remove the Sensor Module from the Electronics Housing . . . .5-13

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

Attach the Sensor Module to the Electronics Housing . . . . . . . . 5-14

Attach the Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

Reassemble the Process Sensor Body . . . . . . . . . . . . . . . . . . . . .5-16

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

SECTION 6
Level Controller
Specifications and
Reference Data

APPENDIX A
HART Communicator

APPENDIX B
Level Controller Accesso­ries and Options

Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Connections and hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Communicator Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Action Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Alphanumeric and Shift Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

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

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Online Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

HART Fast Key Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Model 1199 Remote Diaphragm Seals . . . . . . . . . . . . . . . . . . . . . B-2

Model 305 Integral Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

SST Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Transient Protection Terminal Block . . . . . . . . . . . . . . . . . . . . . B-2

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

Auto-Tuning (Option Code CC) . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Local Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Custom Configuration (Option Code C2) . . . . . . . . . . . . . . . . . . B-3

APPENDIX C
Approval Drawings

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

vii

viii

Section

1 Introduction

USING THIS MANUAL

This manual provides installation, configuration, troubleshooting, and
maintenance instructions for the Rosemount
Multivariable
275 HART

The rest of this manual consists of the following sections:
Section 2: Level Controller Overview and Installation introduces the

Level Controller and explains how to install it. This includes an
installation flowchart, installation considerations, and field installation.

Section 3: Level Controller Operation provides a summary of the Level
Controller’s features and functions.

Section 4: Level Controller Configuration provides information on the
configuration and commissioning of the Level Controller.

Section 5: Troubleshooting and Maintenance provides troubleshooting
instructions for dealing with potential mechanical or electrical difficulties.

Section 6: Level Controller Specifications and Reference Data
includes specification data for the Level Controller.

Appendix A: HART Communicator contains a Model 275 overview, a
HART Communicator menu tree for the Level Controller, and a table
of HART Communicator fast key sequences. A table of diagnostic
messages associated with this communicator is also included.

Appendix B: Level Controller Options and Accessories provides
information about the options and accessories available with the
Level Controller.

™

Level Controller and for its operation with the Model

®

Communicator.

®

Model 3095

SAFETY MESSAGES

Appendix C: Approval Drawings illustrates Factory Mutual (FM) and

Canada Standards (CSA) certified drawings.

Procedures and instructions in this manual may require special
precautions to ensure the safety of the personnel performing the
operations. Information that raises potential safety issues is
indicated by a warning symbol ( ).

Refer to the safety messages listed at the beginning of each section
before performing an operation preceded by this symbol.

1-1

Rosemount Model 3095 Multivariable™ Level Controller

1-2

Section

2 Level Controller Overview

and Installation

This section contains overview information about the Model 3095
Multivariable Level Controller system, an installation flowchart
showing the sequence of Level Controller installation and wiring,
installation considerations, and the field installation procedure.

SAFETY MESSAGES

Instructions and procedures in this section may require special
precautions to ensure the safety of the personnel performing the
operations. Information that raises potential safety issues is indicated
by a warning symbol ( ). Please refer to the following safety messages
before performing an operation preceded by this symbol.

Explosions could result in death or serious injury:

• Do not remove the instrum ent cove r in explosive atmospheres when the
circuit is alive.

• Bef ore connect ing a HART-based communicator in an explosive atmosphere,
make sure the instruments in the loop are installed in accordance with
intrinsically safe or non-incendive field wiring practices.

• Both controller covers must be fully engaged to meet explosi on-proo f requi remen ts.

• The unused condu it opening on the controller housing must be plugged and
sealed to meet explosion-proof requirements.

Failure to follow safe installation and servicing guidelines could result in death or
serious injury:

• Make sure only qualified personnel perform these procedures .

• Use the equipment only as specified in this manual. Failure to do so may impair
the protection provided by the equipment.

• Unauthor ized parts can affect product performance and may impair the
protection provided by the equipment.

Process leaks could result in death or serious injury:

• Inst all only the flange adapter O- ring designe d to seal with the corresponding
flange adapter.

• All four flange bolts must be installed and tight before applying pressure or
process leaks will result.

2-1

Rosemount Model 3095 Multivariable™ Level Controller

High voltage that may be present on leads co uld cause electri cal sh ock :

• Avoid contact with leads and terminals.

LEVEL CONTROLLER
OVERVIEW

FIGURE 2-1. Typical Level Controller
Installation Site.

The Model 3095 Multivariable Level Controller is a multivariable,
microprocessor-based, analog and digital output device for use in single
loop, level process applications.

The Level Controller directly measures differential pressure (DP) and
computes a separate process variable that represents level in a tank
above a reference point.

The Level Controller uses the level variable in a control function to
compute a control output value. The control function is a PID
algorithm whose output is a 4–20 mA analog signal. A digital
representation of the value of the 4–20 mA output may be obtained
via HART digital communications.

Because the Level Controller is a multivariable device, optional process
variables can be measured and obtained as a secondary HART process
variable. The process variables available via HART are level, DP,
control output (CO), and process temperature (PT).

Air Supply In

Air

Out

I/P Positioner

I/P

Inlet

Valve

Tank

Input

Pipe

Field Wiring

4–20 mA Control Signal

Model 3095

Level Controller

Tank

Outlet

Pipe

3095-3095_01A

2-2

Level Controller Overview and Installation

Figure 2-1 illustrates a single loop level control system. The single
control loop consists of:

• A level process.

• A Level Controller with a 4–20 mA control output signal.

• An electrical-to-pneumatic converting device such as a 3311 I/P.

• An optional positioner device to correct for valve displacement
before valve variations affect the process.

• An actuator device such as a valve.

Figure 2-2 is a more detailed diagram of the level process depicted in
Figure 2-1. The setpoint is the desired process value at which the user
wishes to maintain (control) the process. The error between the setpoint
and the actual process variable (as measured by the sensor) is used by
the controller to determine the value of its output.

The controller output is an electrical current (in mA) which is used by
an electrical-to-pneumatic device, such as an I/P, to control the position
of a valve. A positioner, which is mechanically connected to the moving
part of the valve, automatically adjusts its output pressure in order to
maintain a desired position that bears a predetermined relationship to
the input signal.

FIGURE 2-2. Level Controller
Process Diagram

SETPOINT

Level Target

Tank

Level

4–20 mA

PID

Valve
Position

NOTE

The Level Controller differs from a standard transmitter in
that the 4–20 mA output is a control output, not a differential
pressure (DP) output.

3095\3095_10A

2-3

Rosemount Model 3095 Multivariable™ Level Controller

BEFORE YOU BEGIN

FIGURE 2-3. Level Controller
Installation Flowchart.

Controller Product

START

Unpack the Level

Controller

Review the Level

Manual

Bench

Configure

?

No

B

Review the flowchart shown in Figure 2-3 before you begin installing
the Level Controller. This flowchart summarizes the tasks you should
complete to ensure a successful installation.

B

FIELD

INSTALLATION

(page 2-19

Review Installation

Considerations

Mount

Controller

Make Process

Connections

(Optional) Install

RTD Assembly

Check for Leaks

Complete Wiring

Yes

A

BENCH

CONFIGURE

(page 2-7)

Ensure jumper is

across output

terminals

Connect Bench

Power Supply

A

Connect

Model 275

(Page A-5)

Complete

Configuration

Tasks

(Section 3)

2-4

Remove jumper

from output

terminals

B

Controller

Configured

?

Yes

Perform a

Level Trim

Tune the Loop

DONE

No

Complete

Configuration

Tasks

(Section 3)

Level Controller Overview and Installation

UNPACKING THE LEVEL
CONTROLLER

BECOMING FAMILIAR
WITH THE LEVEL
CONTROLLER

The Level Controller arrives in either one or two shipping containers,
depending on the system ordered.

Level Controller

This box contains the Level Controller. If ordered, this package also
contains an RTD cable and optional mounting hardware. One Model
3095 Multivariable Level Controller Product Manual is included with
each order.

RTD Assembly (Optional)

This box contains the optional Series 68 or Series 78 RTD Assembly
and the Sensor Wiring Instruction Sheet.

When you unpack the Level Controller:

1. Place the shipping containers on a secure bench and open them,
taking care not to damage the contents.

2. Review the packing list to verify that all equipment was received.

3. Inspect the equipment and report any shipping damage to the
carrier.

Figure 2-1 on page 2-2 illustrates a typical Level Controller installation
site; Figure 2-4 shows the exploded view of the Model 3095 Level
Controller. Major components of the Level Controller system and the
Level Controller itself are identified in these figures.

2-5

Rosemount Model 3095 Multivariable™ Level Controller

FIGURE 2-4. Exploded View of the Level
Controller.

Housing

Terminal

Block

O-ring

Cover

Certification
Label

Electronics
Board

Nameplate

Module O-ring

Housing

Locking Screw

RTD Connector

Process Flange O-ring

Flange Adapter O-ring

Optional Flange Adapters

Sensor Module

Drain/Vent Valve

Coplanar Flange

Bolts

2-6

3095-3095A08B.EPS

Level Controller Overview and Installation

BENCH CONFIGURATION

Failure Mode Alarm vs.
Saturation Output Values

Write Protect and
Failure Mode
Alarm Jumpers

Before mounting the Level Controller in the field, the controller can be
configured on the bench using a Model 275 HART Communicator.

NOTE

For bench configuration, a jumper must be installed across the
output terminals.

Failure mode alarm output levels differ from the output values that
occur when applied pressure is outside the range points. When pressure
is outside the range points, the analog output continues to track the
input pressure until reaching the saturation value listed below; the
output does not exceed the listed saturation value regardless of the
applied pressure. For example, for pressures outside the 4–20 range
points, the output saturates at 3.9 mA or 20.8 mA.

When the controller diagnostics detect a failure, the analog output is
set to a specific alarm value that differs from the saturation value to
allow for proper troubleshooting.

Level 4–20 mA Saturation Value 4–20 mA Alarm Value

Low 3.9 mA 3.75 mA
High 20.8 mA 21.75 mA

These jumpers are both located on the electronics board just inside the
electronics housing cover (see Figure 2-5). Set these jumpers during the
commissioning stage on the bench to avoid exposing the controller
electronics to the plant environment after installation.

Once the controller has been configured, the configuration data can be
protected by moving the write protect (security) jumper. When this
jumper is installed, the controller does not allow any changes to its
configuration memory.

In the event of a critical hardware failure in the controller, the
controller automatically drives the analog output either below 3.75 or
above 21.75, depending on the position of the failure alarm jumper.

NOTE

This alarm jumper is different from a level measurement alarm
condition. As part of its normal operation, the Level Controller
continuously monitors its own operation. This automatic diagnostic
routine is a timed series of checks repeated continuously.

If the controller determines that a level measurement alarm exists, the
controller performs one of the two Mode Shed routines (user selected):

– the controller signal freezes at the current level
– the signal switches to a pre-determined mode shed level

See Chapter 4 for additional mode shed information.

When shipped from the factory, the write protect jumper is set to
“OFF,” and the alarm jumper is set to “LO.”

2-7

Rosemount Model 3095 Multivariable™ Level Controller

Use the following steps to change the jumper settings:

1. If the controller is installed, secure the loop and remove power.

2. Remove the housing cover opposite the field terminal side. Do not
remove the instrument cover in explosive atmospheres when the
circuit is alive.

3. Locate the jumper(s) on the output electronics board (see Figure
2-5), then move the jumper(s) to the desired setting.

4. Reattach the housing cover. Metal to metal contact is preferred.
Both controller covers must be fully engaged to meet explosion­proof requirements.

5. If the controller is installed, reapply power.

FIGURE 2-5. Write Protect and
Level Controller Alarm Jumpers.

SECURITY

OFF

ON

<
<

>

HI

>

LO

ALARM

NOTE
Security jumper not installed = Not Write Protect ed.
Alarm jumper not installed = High Alarm.

OUTPUT ELECTRONICS BOARD

3095-3095G05A, 3095H05A

2-8

Level Controller Overview and Installation

GENERAL INSTALLATION
CONSIDERATIONS

FIGURE 2-6. Dimensional Drawings
of Level Controller.

5.60

(142)

4.93

Meter Cover

(Optional)

0.75 (19)

Clearance for

Cover Removal

(125)

The accuracy of a level control measurement depends upon proper
installation of the controller and impulse piping. The piping between
the process and the controller must accurately transfer the pressure in
order to obtain accurate measurements.

Mount the controller close to the process and use a minimum of impulse
piping to achieve best accuracy. Keep in mind, however, the need for
easy access, safety of personnel, and a suitable controller environment.
(Refer to Figure 2-6 for Level Controller dimensions.) In general, install
the controller so as to minimize vibration, shock, and temperature
fluctuations.

The high pressure side of the level controller must always be plumbed
to the bottom of the tank. For open vessels, the low pressure side of the
Level Controller should be vented. For closed vessels, the low pressure
side must always be plumbed to the top of the tank.

The following sections discuss the factors to consider for a successful
Level Controller installation.

4.20

(107)

Certification

Label

3.12
(79)

4.09

(104)

½–14 NPT Conduit

Connection (2 Places)

0.75 (19)

Clearance for

Cover Removal

Controller

Circuitry

This Side

Nameplate

Drain/Vent

Valve

6.4

(163)

½–14 NPT on Optional Mounting

Adapters. Adapters Can Be

Rotated to Give Connection Centers

of 2.00 (51), 2.125 (54), or 2.25 (57).

NOTE
Dimensions are in inches (m illimeters).

Controller

Connections

This Side

Housing
Rotation

Set Screw

7.07

(180)

8.17

(208)

¼–18 NPT on Coplanar Flange

for Pressure Connection

without the Use of

Mounting Adapters

3095-G05A, H05A

2-9

Rosemount Model 3095 Multivariable™ Level Controller

MECHANICAL
CONSIDERATIONS

Mounting Considerations

TABLE 2-1. Controller Weight.

Bolt Installation Guidelines

The Level Controller may be direct-mounted, mounted with one or two
remote diaphragm seals, mounted with a level flange, or attached to a
two-inch pipe with an optional mounting bracket. Figure 2-7 illustrates
Level Controller mounting configurations; Figure 2-6 shows the Level
Controller dimensions.

The Level Controller total weight varies depending on the components
ordered (see Table 2-1). This weight must be securely supported.

Component Weight lb (kg)

Level Controller
SST Mounting Bracke t
12 ft (3.66 m) RTD Shielded Cable
12 ft (3.66 m) RTD Armored Cab le
24 ft (7.32 m) RTD Shielded Cable
24 ft (7.32 m) RTD Armored Cab le

6.0 (2.7)

1.0 (0.4)

0.5 (0.2)

1.1 (0.5)

1.0 (0.4)

2.2 (1.0)

The following guidelines have been established to ensure a tight
flange, adapter, or manifold seal. Use only bolts supplied with the
controller or sold by Rosemount Inc. as a spare part to the Level
Controller. Unauthorized parts can affect product performance and
may impair the protection provided by the equipment.

™

The Level Controller is shipped with the Coplanar

flange installed
with four 1.75-inch flange bolts. The following bolts also are supplied
to facilitate other mounting configurations:

• Four 2.25-inch manifold/flange bolts for mounting the Coplanar
flange on a three-valve manifold. In this configuration, the

1.75-inch bolts may be used to mount the flange adapters to the
process connection side of the manifold.

• (Optional) If flange adapters are ordered, four 2.88-inch
flange/adapter bolts for mounting the flange adapters to the
Coplanar flange.

Figure 2-7 shows the optional mounting bracket and mounting
configurations. Figure 2-8 shows mounting bolts and bolting
configuration for the Level Controller with the Coplanar flange.

Stainless steel bolts supplied by Rosemount Inc. are coated with a
lubricant to ease installation. Carbon steel bolts do not require
lubrication. Do not apply additional lubricant when installing
either type of bolt. Use the equipment only as specified in this manual.
Failure to do so may impair the protection provided by the
equipment. Bolts supplied by Rosemount Inc. are identified by the
following head markings:

Carbon Steel Head Markings (CS)

B7M

Stainless Steel Head Markings (SST)

2-10

316

316

R

B8M

STM

316 316

SW
316

3051-3031I06A

FIGURE 2-7. Mounting Configu rati ons and Opt ion al Mo unti ng Acces so ries .

Level Controller Overview and Installation

LEVEL FLANGE

INTEGRAL MOUNT MANIFOLD

3.54
(90)

6.25

(159)

PIPE MOUNTED WITH

OPTIONAL BRACKET

ONE DIAPHRAGM SEAL

NOTE
Dimensions are in inches (millimeters).

TWO DIAPHRAGM SEALS

3001-3051AO1A, 3095-3095K04A, 3095L04A 3051\305-3031A29B, 3051-3051A29B, A28A

2-11

Rosemount Model 3095 Multivariable™ Level Controller

FIGURE 2-8. Coplanar Mounting Bolts and Boltin g Co nfig ura tion s for Coplanar Flange.

1.75 (44) x 4
CONTROLLER WITH

FLANGE BOLTS

Description Qty.

Flange bolts
Flange/adapter bolts
Manifold/flange bolts

4
4
4

Size in.

(mm)

1.75 (44)

2.88 (73)

2.25 (57)

2.88 (73) x 4

CONTROLLER WITH
OPTIONAL FLANGE ADAPTERS
AND FLANGE/ADAPTER BOLTS

NOTE
Dimensions are in inches (millimeters).

2.25 (57) x 4

1.75 (44) x 4

CONTROLLER W ITH 3 -VALVE MANIFOLD

MANIFOLD/FLANG E BOLTS

FLANGE ADAPTERS

AND FLANGE/ADAPTER BOLTS

3095-3095D05M, 3095C05A, 3095C29A

2-12

Level Controller Overview and Installation

EXAMPLE
INSTALLATIONS

Open Tanks

Open Tanks with Bubbler

Closed Tanks with Dry Leg

Figure 2-9 illustrates example installations for the Model 3095 Level
Controller. “H” and “L” in the examples correspond to the H and L
stamped on the Level Controller sensor module and indicate which way
the controller is to be installed.

In open vessels a pressure controller mounted near the bottom of the
tank will measure the pressure corresponding to the height of the fluid
above it.

The connection is made to the high pressure side of the controller. The
low pressure side is vented to atmosphere.

Process Connections Options: Impulse piping; one diaphragm seal,
(capillary or direct mount) level flange.

A “bubbler” system using a top-mounted controller can be used in open
vessels. This system consists of an air supply, a constant flow regulator,
a controller, and tube extending down into the vessel.

Air is bubbled through the tube at a constant flow rate. The pressure
required to maintain flow is determined by the vertical height of the
liquid above the tube opening, process density, and local gravity.

Process Connections Option: Impulse piping,

In closed vessels, the pressure above the liquid will affect the pressure
measured at the bottom. The pressure at the bottom of the vessel is
determined by the height of the liquid, the density of the liquid, plus
the vessel pressure.

Closed Tanks with Wet Leg

To measure true level, the vessel pressure must be subtracted from the
measurement. This is accomplished by making a pressure tap at the top
of the vessel and connecting this to the low side of a differential pressure
controller. Vessel pressure is now equally applied to both the high and
low sides of the controller. The resulting differential pressure is
determined by liquid height, process density, and specific gravity.

If the gas above the liquid does not condense, the piping for the low side
of the controller will remain empty. Calculations for determining the
controller height will be the same as those shown for open vessel
bottom mounted controllers.

Process Connections Options: Impulse piping; one diaphragm seal
(capillary or direct mount); two diaphragm seals, level flange.

If the gas above the liquid condenses, the piping for the low side of the
controller will slowly fill up with liquid. To eliminate this potential
error, the pipe is purposely filled with a convenient reference fluid.

The reference fluid exerts a head pressure on the low side of the
controller.

Process Connections Options: Impulse piping; one diaphragm seal
(capillary or direct mount); two diaphragm seals, level flange.

2-13

Rosemount Model 3095 Multivariable™ Level Controller

FIGURE 2-9. Example Install ati ons .

H

L

Controller Height = C

Controller Height = A

or

Controller Height = -B

Controller Height = A

or

Controller Height = -B

OPEN TANK

CLOSED TANK

WITH DRY LEG

A

H

L

B

L

H

C

OPEN TANK

WITH BUBBLER

H

L

A

B

L

H

Controller Height = E + D

E

L

2-14

M

N

CLOSED TANK WITH WET LEG,

CONTROLLER B E LOW BOTTOM OF TANK

D

CLOSED TANK WITH WET LEG,

CLOSED TANK WITH WET LEG,

CONTROLLER ABO VE BO T TOM OF TANK

CONTROLLER ABO VE BO T TOM OF TANK

Controller Height = M - N

H

L

H

3095-3095_01A

Level Controller Overview and Installation

TAP CONSIDERATIONS

Impulse Piping

When the Level Controller is oriented on its side, the Coplanar™ flange
may be mounted to ensure proper venting or draining. Mount the flange
so that the drain/vent connections are on the top half of the flange for
liquid service.

CAUTION

In elevated temperature services, it is important that temperatures at
the Coplanar process flanges not exceed 250 °F (121 °C).

The piping between the process and the controller must accurately
transfer the pressure in order to obtain accurate control. In this
pressure transfer, there are five possible sources of error: leaks, friction
loss (particularly if purging is used), trapped gas in a liquid line, and
temperature-induced or other density variation between the legs.

The best location for the Level Controller in relation to the process pipe
depends on the process itself. Consider the following guidelines in
determining controller location and placement of impulse piping:

• Keep impulse piping as short as possible.

• Slope the impulse piping at least one inch per foot (8 centimeters
per meter) upward from the controller toward the process
connection for liquid.

• Avoid high points in liquid lines.

• Make sure both impulse legs are the same temperature.

• Use impulse piping large enough to avoid friction effects and
prevent blockage.

• Vent all gas from liquid piping legs.

• Avoid purging through the controller.

• Keep corrosive or hot (above 250 °F (121 °C)) process material out
of direct contact with the sensor module and flanges.

• Prevent sediment deposits in the impulse piping.

• Avoid conditions that might allow process fluid to freeze within
the process flange.

Diaphragm Seals

Because instrument response time is directly proportional to capillary
length, and the fill fluid volume in the capillary changes with
temperature to affect the output, care must be taken to optimize
performance:

• Keep the capillary length as short as possible.

• Mount a controller with one seal at the same level, or below the
seal and process connection. Use direct mount when possible.

• In vacuum applications, mount the controller below the lower tap
to ensure proper operation. This requirement applies to both one­and two-seal systems.

• Avoid mounting seals and capillaries in direct sunlight.

• Keep the capillary lengths equal when two seals are involved.

• Rezero the controller on a seasonal basis.

• Never attempt to disconnect the seals or capillaries. Doing so will
void the warranty.

2-15

Rosemount Model 3095 Multivariable™ Level Controller

ENVIRONMENTAL
CONSIDERATIONS

Access Requirements

Process Flange Orientation The process flanges must be oriented so that process connections can be

Housing Rotation The electronics housing may be rotated to improve field access to the

Mount the Level Controller to minimize ambient temperature changes.
Section 6: Level Controller Specifications and Reference Data
lists the Model 3095 temperature operating limits. Mount the Level
Controller to avoid vibration and mechanical shock, and to avoid
external contact with corrosive materials.

When choosing an installation location and position, take into account
the need for access to the controller.

made. In addition, consider the possible need for testing the controller.

CAUTION

Drain/vent valves must be oriented so that process fluid is directed
away from technicians when the valves are used.

two compartments. To rotate the housing less than 90 degrees, release
the housing rotation set screw and turn the housing not more than 90
degrees from the orientation shown in Figure 2-7 on page 2-11. To
rotate the housing more than 90 degrees, follow steps 1–6 of the
disassembly procedure on page 5-11.

CAUTION

Rotating the housing more than 90 degrees without performing the
disassembly procedure may damage the Level Controller sensor module.

Terminal Side of
Electronics Housing

Circuit Side of
Electronics Housing

Wiring connections are made through the conduit openings on the top
side of the Level Controller housing. The field terminal side is marked
on the housing.

Mount the Level Controller so that the terminal side is accessible.
A 0.75-inch clearance is required for cover removal.

Install a conduit plug on the unused side of the conduit opening.
The circuit compartment should not routinely need to be opened when

the unit is in service; however, provide 0.75 inches minimum clearance
if possible to allow access.

2-16

Level Controller Overview and Installation

Unique O-ring

Grooves

MODEL 3051/2024/3001/3095/Level Contro lle r

MODEL 1151

Flange Adapter

O-ring

Flange Adapt er

O-ring

3051-0569A01A

Process Considerations

FIGURE 2-10. Flange Adapter O-rings.

Level Controller process connections on the controller flange are ¼–18
NPT. Flange adapter unions with ½–14 NPT connections are available as
options. These are Class 2 threads; use your plant-approved lubricant or
sealant when making the process connections. The process connections

1

on the controller flange are on 2

/8-inch (54-mm) centers to allow direct

mounting to a three- or five-valve manifold. By rotating one or both of

1

the flange adapters, connection centers of 2, 2

/8, or 2¼ inches (51, 54,

or 57 mm) may be obtained.
There are two styles of Rosemount flange adapters, each requiring a

unique O-ring, as shown below. Each flange adapter is distinguished
by its unique groove. Use only the O-ring designed to seal with the
corresponding flange adapter.

Use only the O-ring designed to seal with the corresponding flange
adapter. Failure to install proper flange adapter O-rings can cause
process leaks.

When compressed, Teflon® O-rings tend to cold flow, which aids in their
sealing capabilities. Whenever flanges or adapters are removed, visually
inspect the Teflon O-rings. Replace them if there are any signs of
damage, such as nicks or cuts. If they are undamaged, they can be
reused. If the O-rings are replaced, the flange bolts may need to be
retorqued after installation to compensate for cold flow. Refer to the
process sensor body reassembly procedure on page 5-16.

2-17

Rosemount Model 3095 Multivariable™ Level Controller

ELECTRICAL
CONSIDERATIONS

FIGURE 2-11. Power Supply
Load Limitations.

The signal terminals are located in a compartment of the electronics
housing separate from the controller electronics. Figure 2-11 illustrates
power supply load limitations for the controller.

The dc power supply should provide power with less than 2% ripple.
The total resistance load is the sum of the resistance of the signal leads
and the load resistor, actuator, indicator, and related pieces. Note that
the resistance of intrinsic safety barriers, if used, must be included.

NOTE

A loop resistance between 250–1100 ohms inclusive is required to
communicate with a HART Communicator. With 250 ohms of loop
resistance, a power supply voltage of at least 16.5 V dc is required.
Quick troubleshooting check: there must be at least 11.0 V dc across the
controller terminals.

If a single power supply is used to power more than one Level
Controller, the power supply used, and circuitry common to the
controllers, should not have more than 20 ohms of impedance at 1200 Hz.

For CSA approval, power supply must not exceed 42.4 V dc.

Loop resistance is determined by the voltage level of the external power supply, as described by:
Max. Loop Resistance = Power Supply Voltage–11.0–Actuator Voltage

0.022

(1)

2000

Load (Ohms)

0

11.0 16.5

HART protocol communicat ion requi res a loop resista nc e valu e
between 250–1100 ohms, inclusive.

(1) Actuator Voltage is the maximum voltage drop across the actuator device.
(1) For CSA approval, power supply must not exceed 42.4 V dc.

4–20 mA dc

Operating Region

35.2

42.4

Power Supply Voltage

55

(2)

3051-0103A

2-18

Level Controller Overview and Installation

FIELD INSTALLATION
PROCEDURE

Field Installation
Equipment

Review Installation
Considerations

Mount Controller and
Install Bolts

The field installation procedure involves mounting the Level
Controller, connecting it to the process, and completing the field wiring.

The following equipment and tools are not provided with the Level
Controller. Be sure to review this list before field installing the controller.

• Installation tools

• Field wire between the power supply and the Level Controller
and between the Level Controller and the actuator device

• Actuator device

• Barriers or seals required for hazardous locations

• Conduit

• 2-in. mounting pipe or saddles

• Power supply

• 3- or 5-valve manifold

• Impulse piping

• Tie wraps

• Load resistor

Review the installation considerations described on pages 2-9 through
2-18 in this section to determine the location for the Level Controller.

Mount the Level Controller in the desired location, and install flange or
flange/adapter bolts. Only use bolts supplied with the Level Controller
or sold by Rosemount Inc. as a spare part to the Level Controller.
Unauthorized parts can affect product performance and may impair the
protection provided by the equipment.

TABLE 2-2. Bolt Installation
Torque Values.

Make Process
Connections

1. Finger-tighten the bolts.

2. Torque the bolts to the initial torque value (see Table 2-2) using a
cross-pattern.

3. Torque the bolts to the final torque value (see Table 2-2) using the
same cross-pattern.

Bolt Material Initial Torque Value Final Torque Value

Carbon Steel (CS) 300 in-lb (407 n-m) 650 in-lb (881 n-m)
Stainless Steel (SST) 150 in-lb (203 n-m) 300 in-lb (407 n-m )

When installing the controller to one of the mounting brackets, torque
the mounting bracket bolts to 125 in-lb (169 n-m).

Connect the Level Controller to the process. All four flange bolts must
be installed and tight before applying pressure, or process leakage will
result. When properly installed, the flange bolts protrude through the
top of the module housing. Attempting to remove the flange bolts while
the controller is in service will result in process leaks.

2-19

Rosemount Model 3095 Multivariable™ Level Controller

Install RTD Assembly

FIRST, FULLY ENGAGE
THE BLACK CABLE
CONNECTOR

The external RTD assembly is optional and not required for Level
Controller operation. The RTD Assembly allows you to read
temperatures as a HART variable only.

To install the Series 68 or Series 78 RTD Assembly:

1. Mount the RTD Assembly in the desired location. Refer to the
appropriate differential producer standard concerning
recommended RTD installation location.

2. Connect the RTD cable to the Level Controller RTD connector.
First, fully engage the black cable connector, then screw in
and tighten the cable adapter until metal to metal contact occurs
(see photos).

SECOND, SCREW IN AND
TIGHTEN THE CABLE ADAPTER
UNTIL METAL TO METAL
CONTACT OCCURS

2-20

3095-069AB, 068AB, 067AB

THIRD, SCREW IN AND TIGHTEN
THE STRAIN RELIEF CLAMP

3. (Optional) If using an armored, shielded cable, install the
armored cable compression seal as illustrated below, and use a
pliers to tighten the cap onto the compression fitting

4. Make all necessary wiring connections inside the RTD Flat
Connection Head as explained in the Sensor Wiring Instructions
included with the RTD.