Rosemount DP Level Transmitters and 1199 Diaphragm Seal Systems Manuals & Guides

Reference Manual

00809-0100-4002, Rev FA

Rosemount™ DP Level Transmitters and
Diaphragm Seal Systems

April 2022

Safety Messages

NOTICE

For technical assistance. contacts are listed below:

Customer Central

Technical support, quoting, and order related questions.

United States:

Asia Pacific:

Europe/Middle East/Africa:

North American Response Center

Equipment service needs

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

Outside of these areas, contact your local Emerson representative.

1-800-999-9307 (7:00 a.m. to 7:00 p.m. CST)

65 777 8211

49 (8153) 9390

WARNING

Follow instructions

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

Ensure only qualified personnel perform the installation.

Explosion

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 handheld communicator in an explosive atmosphere, ensure that 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.

Electical hazard

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
transmitter leads and terminals.

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

Process leaks

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.

Manifold installation

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
sensor module housing.

2

WARNING

Sensor module and electronics 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.)

Physical access

Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.

Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.

CAUTION

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.

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.

3

4

Reference Manual Contents

00809-0100-4002 April 2022

Contents

Chapter 1 Introduction.............................................................................................................. 7

1.1 Using this manual........................................................................................................................ 7

1.2 Product recycling/disposal...........................................................................................................7

Chapter 2 Remote Seal Systems................................................................................................. 9

2.1 DP Level and remote seal system measurement.......................................................................... 9

2.2 Terminology of system components............................................................................................9

2.3 Seal system performance...........................................................................................................10

2.4 Balanced vs. Tuned-System assemblies......................................................................................12

2.5 Specifying the right solution for vacuum applications................................................................14

2.6 Diaphragm weld types...............................................................................................................15

2.7 Differences between electronic remote sensors and capillary systems.......................................17

2.8 Instrument Toolkit: seal ordering and application process......................................................... 17

2.9 Rosemount Thermal Range Expander: proper use and applications........................................... 18

2.10 Thermal optimizer: proper use and applications...................................................................... 20

Chapter 3 Installation...............................................................................................................23

3.1 Seal handling and installation.................................................................................................... 23

3.2 Gaskets......................................................................................................................................25

3.3 Tagging..................................................................................................................................... 26

3.4 Torque sequence....................................................................................................................... 27

3.5 FFW flush flanged seal................................................................................................................28

3.6 Offline (RFW) remote flanged seal............................................................................................. 31

3.7 EFW extended flanged seal........................................................................................................ 35

3.8 PFW pancake seal...................................................................................................................... 36

3.9 FCW flush flanged seal—ring type joint (RTJ) gasket surface....................................................... 39

3.10 RCW remote flanged seal - ring type joint (RTJ) gasket surface.................................................41

3.11 FUW flush flanged groove type seals........................................................................................43

3.12 FVW flush flanged tongue type seals........................................................................................45

3.13 RTW remote threaded type seals............................................................................................. 47

3.14 HTS male threaded seal........................................................................................................... 50

3.15 SCW hygienic Tri-Clover Tri Clamp seals...................................................................................51

3.16 SSW hygienic tank spud seal.................................................................................................... 54

3.17 STW hygienic thin wall tank spud seal......................................................................................58

3.18 EES hygienic flanged tank spud extended seal..........................................................................59

3.19 VCS Tri Clamp in-line seal.........................................................................................................60

3.20 SVS VARIVENT® compatible hygienic connection seal..............................................................62

3.21 SHP hygienic Cherry-Burrell® “I” line seal................................................................................. 63

Rosemount DP Level 5

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3.22 SLS dairy process connection–female thread seal per DIN 11851.............................................64

3.23 WSP saddle seal....................................................................................................................... 65

3.24 UCP union connection pipe mount seal....................................................................................67

3.25 PMW paper mill sleeve seal......................................................................................................70

3.26 CTW chemical tee seal.............................................................................................................72

3.27 TFS wafer style In-line seal........................................................................................................73

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

Chapter 4 Configuration...........................................................................................................77

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

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

Chapter 5 Fill Fluids..................................................................................................................91

5.1 Quality.......................................................................................................................................91

5.2 Fill fluid selection....................................................................................................................... 91

5.3 Fill fluid vapor pressure curves................................................................................................... 92

Chapter 6 Maintenance and Troubleshooting...........................................................................95

6.1 Cleaning.................................................................................................................................... 95

6.2 Troubleshooting........................................................................................................................95

6.3 Return of materials.................................................................................................................... 97

6.4 Service support..........................................................................................................................97

Chapter 7 Reference data......................................................................................................... 99

7.1 Product certifications.................................................................................................................99

7.2 Ordering information, specifications, and drawings...................................................................99

7.3 Spare parts................................................................................................................................ 99

6 Emerson.com/Rosemount

Reference Manual Introduction

00809-0100-4002 April 2022

1 Introduction

1.1 Using this manual

This manual is designed to assist in installing, operating, and maintaining the Rosemount
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:

• Remote Seal Systems provides an overview of Remote Seal Systems.

• Installation contains mechanical and electrical installation instructions.

• Configuration outlines how to range a DP Level Remote Seal System.

• Fill Fluids describes the offering of fill fluids available with Remote Seal Systems.

• Maintenance and Troubleshooting provides techniques for cleaning and maintaining

the system as well as addressing the most common operating problems.

• Reference data provides resources for product certifications, ordering information,

specifications, drawings, and spare parts.

See Rosemount DP Level Transmitters and 1199 Seal Systems Product Data Sheet or 1299
Seal System Product Data Sheet for more detailed 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.

Rosemount uses both the 1199 and 1299 models for specifying remote seals. This manual
includes information for both.

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.

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8 Emerson.com/Rosemount

A

B

C D

E

B

C

F

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2 Remote Seal Systems

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

A. Pressure, differential pressure, or multivariable transmitter

B. Process flange
C. Remote diaphragm
D. Capillary

E. Flushing ring (optional)

F. Direct mount

Single-seal assembly

Rosemount DP Level 9

A

B

C

D

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Figure 2-2: Flushed Flanged (FFW) Seal and Components

A. Process flange

B. Diaphragm
C. Gasket
D. Flushing ring (optional)

2.3 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 shows how diaphragm size can affect the measurement reading at the

transmitter. For smaller seal sizes, such as the 1½-in. size, the amount of back pressure on
the transmitter causes an additional 12.1 inH2O (307 mmH2O)error. Moving to the 2-in.
size gives 1.7 inH2O (43 mmH2O)and the largest 3-in. size shown only has 0.5 inH2O (13
mmH2O)error. Using a larger diaphragm can drastically improve performance and
provides a more stable reading.

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Note

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

Figure 2-3: Back Pressure on Diaphragm Causing Error

2.3.2

2.3.3

Note

Diaphragm temperature effects decrease as seal size increases.

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

Tuned-System™ Assemblies and Balanced System Assemblies and will have the same
impact on the transmitter regardless of where the transmitter is mounted.

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

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.

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.

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Figure 2-5: Balanced System

+3.6 inH2O
(9.0 mbar)

No error
(Cancels out)

+3.6 inH2O
(9.0 mbar)

Head temperature
effect

Seal 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

+3.6 inH2O
(9.0 mbar)

-1.7 inH2O
(4.2 mbar)

+1.9 inH2O
(4.7 mbar)

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.

Rosemount DP Level 13

Remote Seal Systems Reference Manual

April 2022 00809-0100-4002

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

2.5.3

2.5.4

• Fill fluid selection

• Transmitter mounting position

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).

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.

14 Emerson.com/Rosemount

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B

A C

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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.

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
Fill Fluid Specifications Technical Note.

2.6 Diaphragm weld types

Weld-type is factory-determined as best for the seal typed specified. Pancake Flanged
(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

Rosemount DP Level 15

A

B D

C

E

F

A

B

C

D

E

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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
D. Diaphragm

E. TIG weld point

F. Seam weld point

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.

A. Material A

B. Tantalum
C. Upper housing
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

A. Non-proprietary electrical cable

B. Oil-filled capillary system

Traditional 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

Rosemount DP Level 17

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

A. Intermediate diaphragm

B. High temperature fill fluid (viscous)

C. Ambient temperature fill fluid

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 –103 °F (–75 °C), and process temperatures up to 770 °F
(410 °C) and 850 °F (454 °C) design temperature
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.

(1)

. This improves response time up to 46

UltraTherm 805 supports maximum design temperature of 850 °F (454 °C). Design temperature rating is for non-

(1)

continuous use with a cumulative exposure time less of than 12 hours. Continuous use temperature is rated to 770 °F (410
°C).

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Figure 2-9: Rosemount Thermal Range Expander Temperature Operating Range

Rosemount DP Level 19

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)

662 °F (350 °C)

842 °F (450 °C)

401 °F (205 °C)

185 °F (85 °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)

Ambient temperature °F (°C)

Process temperature °F (°C)

122 °F (50 °C)

302 °F (150 °C)

482 °F (250 °C)

662 °F (350 °C)

842 °F (450 °C)

185 °F (85 °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)

698 °F (370 °C)

68 °F (20 °C)

68 °F (20 °C)

77 °F (25 °C)

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2.10 Thermal optimizer: proper use and applications

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).

Figure 2-10: Fill Fluid Temperature Limits

Thermal optimizer with Silicone 704

Thermal optimizer with Silicone 705

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2.10.1 Thermal optimizer limitations

Figure 2-10 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 122 °F (50 °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.

Rosemount DP Level 21

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3 Installation

3.1 Seal 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.

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

3.1.3

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).

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.

Rosemount DP Level 23

Rosemount 3051SAL with Thermal Range Expander

Marking:
“Do Not Insulate
Above this Line”

Ok to

Insulate

Do Not
Insulate

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

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.

CAUTION

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.

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3.2 Gaskets

WARNING

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.

The intermediate gasket between the seal and lower housing is supplied when the lower
housing or flushing connection is provided when ordered on an 1199. The default gaskets
are listed in Table 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.

When ordering a 1299 seal system, the gasket option must be selected in the model
number, there will not be a default gasket shipped.

Table 3-1: Gasket Materials for 1199

Seal type Gaskets

Flanged seals assemblies

FFW Klingersil® C-4401

RFW Klingersil C-4401

EFW No gasket is supplied

PFW Klingersil C-4401

FCW No gasket is supplied

RCW Klingersil C-4401

FUW/FVW No gasket is supplied

Threaded seal assemblies

RTW Klingersil C-4401

HTS No gasket is supplied

Hygienic seal assemblies

(1)

SCW

No gasket is supplied

SSW Ethylene propylene O-ring

STW Ethylene propylene O-ring

EES No gasket is supplied

Rosemount DP Level 25

Installation Reference Manual

April 2022 00809-0100-4002

Table 3-1: Gasket Materials for 1199 (continued)

Seal type Gaskets

(1)

VCS

(1)

SVS

SHP No gasket is supplied

(1)

SLS

Specialty seals

WSP Klingersil C-4401

UCP Barium-Sulfate filled PTFE O-ring

CTW No gasket is supplied

TFW No gasket is supplied

WFW Klingersil C-4401

(1) Use EHEDG approved gasket for EHEDG conformity.

No gasket is supplied

No gasket is supplied

No gasket is supplied

WARNING

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,

Figure 3-3, and Figure 3-4.

Figure 3-2: Rosemount 3051S Sample Label

Figure 3-3: Rosemount 3051 Sample Label

26 Emerson.com/Rosemount

A

C

D

B

Reference Manual Installation

00809-0100-4002 April 2022

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.

3.4 Torque sequence

When tightening the assembly bolts, use a cross-pattern to ensure even installation. Best
practice is to tighten 20 to 30 percent, check the gap, tighten 50 to 70 percent, check
flange gap and uniformity, and continue to tighten in the appropriate pattern until you
reach 100 percent torque value. Time permitting, wait a minimum of four hours and
repeat the torque pattern to restore any short-term creep/relaxation in the connection.

Figure 3-5: Cross-Pattern Sequence

A. 4-bolt flange

B. 8-bolt flange
C. 12-bolt flange
D. 16-bolt flange

Rosemount DP Level 27

B

C

D

A

C

E

F

D

Installation Reference Manual

April 2022 00809-0100-4002

3.5 FFW flush flanged seal

Figure 3-6: FFW Two-Piece Design (Shown with Optional Flushing Ring)

A. Alignment clamp (option code SA)

B. Process flange
C. Diaphragm
D. Flushing ring (optional)

E. Connection to transmitter

F. Flushing connection

Standard expanded

Note

Two-piece design seal assembly and process flange are separate components and can be
rotated independent of each other. Alignment clamp (A) can be ordered using option
code SA on the 1199.

28 Emerson.com/Rosemount

B

D

E

C

Reference Manual Installation

00809-0100-4002 April 2022

Figure 3-7: FFW One-Piece Design (Shown with Optional Flushing Ring)

A. Process flange

B. Diaphragm
C. Flushing ring (optional)
D. Connection to transmitter

E. Flushing connection

3.5.1

Note

Alignment clamp (option code SA) not available for FFW one-piece design.

Parts required for installation

The parts required to install the FFW flush flanged seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Note

Flushing rings include an Emerson-supplied gasket. If an alignment clamp is used, a Phillips
or slotted screwdriver is required for installation

Verify the gasket materials are appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Rosemount DP Level 29

Installation Reference Manual

April 2022 00809-0100-4002

3.5.2 Installation steps

If a flushing ring is ordered and no alignment clamp is used, it is recommended that two
people install the FFW flush flanged seal to ensure proper alignment during installation.

Follow these steps to install the FFW flush flanged seal on an existing flanged process
connection:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. If installing a flushing ring, ensure flushing connections are sealed before

completing installation. Flushing rings may be ordered with or without, one or two
threaded flushing connections, factory supplied plugs, or drain vent valves. If no
flushing ring was purchased, proceed to Step 3. Assemble the flushing ring,
Emerson-supplied gasket, and remote seal together. If using an alignment clamp
(option code SA on the 1199) attach the flushing ring to the remote seal. Place the
alignment clamp in the machined groove on both the remote seal and the flushing
ring. Using the applicable screwdriver, tighten the screw on the clamp to hold the
flushing ring in place.

3. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

4. Place the appropriate end-user-supplied gasket on the remote seal or flushing ring

and align the gasket so that it is not inside the diaphragm weld as this will induce
errors.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Using the previously installed bolts, attach the remote seal and gasket to the

process connection. Secure with nuts and hand-tighten.

6. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (see Torque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

30 Emerson.com/Rosemount

B

D

E

Reference Manual

00809-0100-4002 April 2022

Installation

3.6 Offline (RFW) remote flanged seal

Figure 3-8: RFW Standard Design

A. Process flange

B. Diaphragm
C. Lower housing or flushing ring
D. Connection to transmitter

E. Flushing connection

Note

Lower housing always required for RFW remote flanged seal.

Figure 3-9: RFW Stud Bolt Design

A. Upper housing

B. Lower housing or flushing ring
C. Stud bolts
D. Diaphragm

E. Connection to transmitter

Rosemount DP Level 31

Installation

Reference Manual

April 2022 00809-0100-4002

Table 3-2: RFW Upper Housing Torque Values

Bolt thread size Material (nuts

and bolts)

⅜–24 NF SST 2.4 or 4.1 150/300 23

⅜–24 NF SST 2.4 600 23

⅜–24 NF CS 2.4 or 4.1 150/300/600 53

½–20 NF SST 4.1 600 50

½–20 NF CS 2.4 900/1500 105

½–20 NF SST 2.4 900 50

¾–16 NF

¾–16 NF

M10 x 1.50 SST 2.4 or 4.1 10K/20K/40K 23

M10 x 1.50 SST 2.4 or 4.1 PN10/PN40/PN63 23

M10 x 1.50 SST 2.4 PN100 23

M12 x 1.75 SST 4.1 PN100 50

M12 x 1.75 SST 2.4 PN160 50

(1) Thread lubricant required, e.g., antiseize, thread paste.

(1)

(1)

SST 2.4 1500 120

CS 2.4 2500 180

Diaphargm Size
(in.)

Class Torque (ft.-lb)

Note

This is the specification for connecting the remote seal to the lower housing, not the
torque specification for the lower housing onto the process flanged connection. The lower
housing bolts should be torqued to the applicable flange requirements.

3.6.1

4.1-in. (104 mm) diaphragm diameter option

The standard diaphragm size for the RFW remote flanged seal is 2.4-in. A larger, 4.1-in.
(104 mm), diaphragm size is offered for small spans to reduce temperature error when
taking process measurements.

3.6.2

Parts required for installation

The parts required to install the RFW remote flanged seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (lower housing to process flange) (end-user-supplied)

• Gasket (remote seal to lower housing) (Emerson-supplied on the 1199. 1299 requires a

gasket option to be selected.)

Note

Typically, the stud bolt design includes Emerson-supplied stud bolts.

32 Emerson.com/Rosemount

Reference Manual Installation

00809-0100-4002 April 2022

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.6.3 Standard design installation steps

It is recommended that two people install the standard design RFW remote flanged seal to
ensure proper alignment during installation.

Follow these steps to install the standard design RFW remote flanged seal on an existing
process flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. Ensure flushing connections are sealed before completing installation. Flushing

rings may be ordered with or without, one or two threaded flushing connections,
factory supplied plugs, or drain vent valves.

3. Assemble the flushing ring, Emerson-supplied gasket, and remote seal together.

Place the Emerson-supplied gasket inside the recessed cavity within the flushing
ring which is designed to hold the gasket in place.

4. Assemble to remote seal assembly to the process flange. Place the appropriate end-

user-supplied gasket between the flushing ring and process flange. Ensure that the
end-user-supplied gasket is centered on both the flushing ring and process flange.
Ensure the flange bolt holes between the remote seal and the process flange are
aligned.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Put the first end-user-supplied bolt through one of the holes on the bottom of the

seal and process flange. Secure with a nut and hand-tighten.

6. Install the remaining end-user-supplied bolts in a cross pattern, hand-tightening

each nut as the bolts are installed.

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (see Torque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

Rosemount DP Level 33

Installation Reference Manual

April 2022 00809-0100-4002

3.6.4 Stud bolt installation steps

Follow these steps to install the stud bolt design RFW remote flanged seal on an existing
process flange:

Procedure

1. Ensure flushing connections are sealed before completing installation. Lower

housing may be ordered with or without, one or two threaded flushing
connections, factory supplied plugs, or drain vent valves.

2. Install the stud bolts onto the lower housing.

3. Assemble the lower housing to the process flange. Place the appropriate end-user-

supplied gasket between the lower housing and process flange. Ensure that the
end-user-supplied gasket is centered on both the lower housing and process flange.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

4. Hand-tighten nuts onto the studs.

5. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (see Torque sequence). The nuts should be torqued to the
applicable flange requirements.

6. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

7. Assemble the remote seal, Emerson-supplied gasket, and lower housing. Place the

Emerson-supplied gasket inside the recessed cavity within the lower housing which
is designed to hold the gasket in place.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

8. Install the bolts in a cross pattern and hand-tighten.

9. Using a torque wrench on the bolt, tighten the assembly in a cross-pattern to

ensure even installation (see Torque sequence). The bolts should be torqued per

Offline (RFW) remote flanged seal based on size and bolt material. Consider leak

checking the installation to ensure a robust connection.

34 Emerson.com/Rosemount

A

B

C

C

D

Reference Manual

00809-0100-4002 April 2022

Installation

3.7 EFW extended flanged seal

Figure 3-10: EFW Extended Flanged Seal Assembly

3.7.1

3.7.2

A. Process flange

B. Extension
C. Diaphragm
D. Connection to transmitter

Note

Flushing ring/lower housing not available for EFW extended flanged seal.

Parts required for installation

The parts required to install the EFW extended flanged seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Installation steps

Rosemount DP Level 35

Follow these steps to install the EFW extended flanged seal on an existing process flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

B

C

D

A

E

C

D

F

E

Installation

April 2022 00809-0100-4002

2. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

3. Place the appropriate end-user-supplied gasket on the remote seal.

Reference Manual

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

4. Using the previously installed bolts, attach the remote seal and gasket to the

process flange. Secure with nuts and hand-tighten.

5. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

6. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The bolts should be torqued to the applicable
flange requirements. Required torque is a function of the gasket material and
surface treatment of the bolts and nuts which are end-user-supplied. Consider leak
checking the installation to ensure a robust connection.

3.8 PFW pancake seal

Figure 3-11: PFW Pancake Seal

A. Alignment clamp (option code SA)

B. Process flange
C. Flushing connection
D. Flushing ring (optional)

E. Diaphragm

F. Connection to transmitter

Note

Alignment clamp (A) can be ordered using option code SA on the 1199.

36 Emerson.com/Rosemount

Reference Manual Installation

00809-0100-4002 April 2022

3.8.1 Capillary support tube

A common option for the pancake type seal is the 4-in. capillary support tube. Due to the
side capillary-to-seal connection, the support tube provides a handle for aligning the
pancake seal during installation. The support tube should not be used for supporting any
weight.

3.8.2 Process flange

Emerson offers the option of supplying the process flange, otherwise the process flange is
furnished by the end-user. There is a 5/16–24 threaded connection on the back of the PFW
pancake seal. For certain pancake seal assemblies, the Emerson-supplied process flange
has a machined hole through the center of the flange that corresponds to the threaded
connection in the back of the pancake seal. This allows the flange to be connected to the
seal before installation to make handling easier. If the process flange is furnished by the
end-user, a 2 1/64-in. to ⅜-in. through hole could be drilled into the flange to support ease
of installation.

Rosemount DP Level 37

Installation

April 2022 00809-0100-4002

Reference Manual

3.8.3 Parts required for installation

The parts required to install the PFW pancake seal will be defined here. Prior to installation,
you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Note

Flushing rings include an Emerson-supplied gasket. If an alignment clamp is used, a Phillips
or slotted screwdriver is required for installation.

Verify the gasket materials are appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.8.4

Installation steps

If no alignment clamp is used on the flushing ring, it is recommended that two people
install the PFW pancake seal to ensure proper alignment during installation.

Follow these steps to install the PFW pancake seal on an existing process flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. If installing a flushing ring, ensure flushing connections are sealed before

completing installation. Flushing rings may be ordered with or without, one or two
threaded flushing connections, factory supplied plugs, or drain vent valves. If no
flushing ring was purchased, proceed to Step 3. Assemble the flushing ring,
Emerson-supplied gasket, and remote seal together. If using an alignment clamp
(option code SA) attach the flushing ring to the remote seal. Place the alignment
clamp in the machined groove on both the remote seal and the flushing ring. Using
the applicable screwdriver, tighten the screw on the clamp to hold the flushing ring
in place.

3. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

4. Place the appropriate end-user-supplied gasket on the remote seal or optional

flushing ring and align the gasket so that it is not inside the diaphragm weld as this
will induce errors.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Using the previously installed bolts, attach the remote seal and gasket to the

process flange. Secure with nuts and hand-tighten.

38 Emerson.com/Rosemount

A

C

D

B

C

Reference Manual

00809-0100-4002 April 2022

6. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The bolts should be torqued to the applicable
flange requirements. Required torque is a function of the gasket material and
surface treatment of the bolts and nuts which are end-user-supplied. Consider leak
checking the installation to ensure a robust connection.

Installation

3.9 FCW flush flanged seal—ring type joint (RTJ) gasket surface

Figure 3-12: FCW Two-Piece Design (Shown with Flushing Ring)

A. Process flange

B. Diaphragm
C. Flushing ring (optional)
D. Connection to transmitter

3.9.1

Parts required for installation

The parts required to install the FCW flush flanged seal with RTJ gasket surface will be
defined here. Prior to installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Verify the gasket materials are appropriate for the application.

Rosemount DP Level 39

Installation Reference Manual

April 2022 00809-0100-4002

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.9.2 Installation steps

Follow these steps to install the FCW flush flanged seal with RTJ gasket surface on an
existing process flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. If installing a flushing ring, ensure flushing connections are sealed before

completing installation. Flushing rings may be ordered with or without, one or two
threaded flushing connections, factory supplied plugs, or drain vent valves. If no
flushing ring was purchased, proceed to Step 3. Assemble the flushing ring,
appropriate end-user-supplied gasket, and remote seal together.

WARNING

Failure to properly install the gasket may cause process leaks, and measurement
errors which can result in death or serious injury.

3. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

4. Place the appropriate end-user-supplied gasket on the remote seal or optional

flushing ring.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Using the previously installed bolts, attach the remote seal and gasket to the

process flange. Secure with nuts and hand-tighten.

6. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The bolts should be torqued to the applicable
flange requirements. Required torque is a function of the gasket material and
surface treatment of the bolts and nuts which are end-user-supplied. Consider leak
checking the installation to ensure a robust connection.

40 Emerson.com/Rosemount

D

Reference Manual Installation

00809-0100-4002 April 2022

3.10 RCW remote flanged seal - ring type joint (RTJ) gasket surface

Figure 3-13: RCW Flanged Remote Seal RTJ and Flushing Connection Ring

A. Upper housing

B. Diaphragm
C. Lower housing or flushing ring
D. Stud bolts

Note

A lower housing is always required for the RCW type seal.

Table 3-3: RCW Upper Housing Torque Values

Bolt thread size Material (nuts

and bolts)

⅜–24 NF SST 2.4 or 4.1 150 23

⅜–24 NF SST 2.4 300/600 23

⅜–24 NF CS 2.4 or 4.1 150/300/600 53

½–20 NF SST 4.1 300/600 50

½–20 NF CS 2.4 900/1500 105

½–20 NF SST 2.4 900 50

¾–16 NF

¾–16 NF

(1) Thread lubricant required, e.g. antiseize, thread paste.

(1)

(1)

SST 2.4 1500 120

CS 2.4 2500 180

Diaphargm Size
(in.)

Class Torque (ft-lb)

Rosemount DP Level 41

Installation

April 2022 00809-0100-4002

Note

This is the specification for connecting the remote seal to the lower housing, not the
torque specification for the lower housing onto the process flanged connection. The lower
housing bolts should be torqued to the applicable flange requirements.

Reference Manual

3.10.1 4.1-in. (104 mm) diaphragm diameter option

The standard diaphragm size for the RCW remote flanged seal with RTJ gasket surface is

2.4-in. A larger, 4.1-in. (104 mm), diaphragm size is offered for small spans to reduce
temperature error when taking process measurements.

3.10.2 Parts required for installation

The parts required to install the RCW remote flanged seal with RTJ gasket surface will be
defined here. Prior to installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

3.10.3

• Gasket (lower housing to process connection) (end-user-supplied)

• Gasket (remote seal to lower housing) (Emerson-supplied on the 1199. 1299 requires a

gasket option to be selected.)

Note

Typically, Emerson-supplied stud bolts are included.

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Installation steps

Follow these steps to install the RCW remote flanged seal with RTJ gasket surface on an
existing process flange:

Procedure

1. Ensure flushing connections are sealed before completing installation. Lower

housing may be ordered with or without, one or two threaded flushing
connections, factory supplied plugs, or drain vent valves.

2. Install the stud bolts onto the lower housing.

3. Assemble the lower housing to the process flange. Place the appropriate end-user-

supplied gasket between the lower housing and process flange.

WARNING

Failure to properly install the gasket may cause process leaks, and measurement
errors which can result in death or serious injury.

4. Hand-tighten nuts onto the studs.

42 Emerson.com/Rosemount

C

B

Reference Manual

00809-0100-4002 April 2022

5. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The nuts should be torqued to the applicable
flange requirements.

6. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

7. Assemble the remote seal, Emerson-supplied gasket, and lower housing. Place the

Emerson-supplied gasket inside the recessed cavity within the lower housing which
is designed to hold the gasket in place.

Installation

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

8. Install the bolts in a cross pattern and hand-tighten.

9. Using a torque wrench on the bolt, tighten the assembly in a cross-pattern to

ensure even installation (Torque sequence). The bolts should be torqued per Table

3-3 based on size and bolt material. Consider leak checking the installation to

ensure a robust connection.

3.11 FUW flush flanged groove type seals

Figure 3-14: FUW Flush Flanged Type Seal—EN1092-1 Type D

A. Process flange

B. Diaphragm

C. Connection to transmitter

3.11.1

Parts required for installation

The parts required to install the FUW flush flanged groove type seal will be defined here.
Prior to installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

Rosemount DP Level 43

• Gasket (end-user-supplied)

Installation Reference Manual

April 2022 00809-0100-4002

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.11.2 Installation steps

Follow these steps to install the FUW flush flanged groove type seal on an existing process
flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

3. Place the appropriate end-user-supplied gasket on the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

4. Using the previously installed bolts, attach the remote seal and gasket to the

process flange. Secure with nuts and hand-tighten.

5. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

6. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The bolts should be torqued to the applicable
flange requirements. Required torque is a function of the gasket material and
surface treatment of the bolts and nuts which are end-user-supplied. Consider leak
checking the installation to ensure a robust connection.

44 Emerson.com/Rosemount

C

B

Reference Manual

00809-0100-4002 April 2022

Installation

3.12 FVW flush flanged tongue type seals

Figure 3-15: FVW Flush Flanged Type Seal—EN1092-1 Type C

A. Process flange

B. Diaphragm

C. Connection to transmitter

3.12.1

3.12.2

Parts required for installation

The parts required to install the FVW flush flanged tongue type seal will be defined here.
Prior to installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Installation steps

Follow these steps to install the FVW flush flanged tongue type seal on an existing process
flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

3. Place the appropriate end-user-supplied gasket on the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

Rosemount DP Level 45

Installation Reference Manual

April 2022 00809-0100-4002

4. Using the previously installed bolts, attach the remote seal and gasket to the

process flange. Secure with nuts and hand-tighten.

5. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

6. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (Torque sequence). The bolts should be torqued to the applicable
flange requirements. Required torque is a function of the gasket material and
surface treatment of the bolts and nuts which are end-user-supplied. Consider leak
checking the installation to ensure a robust connection.

46 Emerson.com/Rosemount

Reference Manual Installation

00809-0100-4002 April 2022

3.13 RTW remote threaded type seals

Figure 3-16: RTW Threaded Seal

A. Upper housing

B. Lower housing or flushing ring
C. Diaphragm
D. Connection to transmitter

Note

A lower housing is always required for the RTW type seal.

Table 3-4: RTW Upper Housing Torque Values

Bolt thread size Material (nuts and

bolts)

⅜–24 NF SST 1,500

⅜–24 NF CS 2,500 53

½–20 NF SST 1,500

½–20 NF SST 2,500 50

½–20 NF CS 5,000 105

¾–16 NF

¾–16 NF

M12 x 1.75 SST 1,500

M12 x 1.75 SST 2,500 50

(2)

(2)

SST 5,000 120

CS 10,000 180

MWP (psi) Torque (ft-lb)

(1)

(1)

(1)

23

50

50

M20 x 2.50 SST 5,000 120

(1) 1500 psi MWP RTW's are only available on 4.1-in diaphragm sizes.
(2) Thread lubricant required, e.g. antiseize, thread paste.

Rosemount DP Level 47

Installation Reference Manual

April 2022 00809-0100-4002

Note

This is the specification for connecting the remote seal to the lower housing, not the
torque specification for the lower housing onto the process threaded connection.
Standard NPT torque values for the size threads in the lower housing should be applied
here.

48 Emerson.com/Rosemount

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Installation

3.13.1 Parts required for installation

The parts required to install the RTW remote threaded type seal will be defined here. Prior
to installation, you will need the following:

• Torque wrench

• Spanner wrench

• Mounting hardware (Emerson-supplied)

• Gasket (Emerson-supplied on the 1199. 1299 requires a gasket option to be selected.)

• Thread sealant

Thread sealant must meet the requirements of the application. An example thread sealant
is PTFE tape.

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.13.2

Installation steps

Follow these steps to install the RTW remote threaded type seal on an existing threaded
process connection:

Procedure

1. Apply thread sealant to the male threaded end of the connection. This will be the

process connection if using a female threaded lower housing, or the remote seal
itself if using a male threaded lower housing.

2. Thread the lower housing to the process connection. The lower housing includes a

small hole designed for a spanner wrench to facilitate installation and applying the
required torque. The applied torque should comply with ANSI B1.20.1 for NPT
connections or applicable torque requirements for pipe connections.

3. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

4. Place the Emerson-supplied gasket into the groove of the lower housing.

5. Place the remote seal on top of the gasket ensuring alignment with the lower

housing groove.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

6. Install the bolts and hand-tighten.

7. Using a torque wrench on the bolt, tighten the assembly in a cross-pattern to

ensure even installation (see Torque sequence). The bolts should be torqued per

Table 3-4 based on size and bolt material. Consider leak checking the installation to

ensure a robust connection.

Rosemount DP Level 49

A

B

Installation Reference Manual

April 2022 00809-0100-4002

Note

RTW remote threaded type seals with a 10,000 PSI pressure rating are supplied with
carbon steel bolts only.

3.14 HTS male threaded seal

Figure 3-17: HTS Male Threaded Seal

3.14.1

A. Connection to transmitter

B. Diaphragm

Parts required for installation

The parts required to install the HTS male threaded seal will be defined here. Prior to
installation, you will need the following:

• Thread sealant

Thread sealant must meet the requirements of the application. An example thread sealant
is PTFE tape.

50 Emerson.com/Rosemount

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B

A

B

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Reference Manual Installation

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3.14.2 Installation steps

Follow these steps to install the HTS remote threaded seal on an existing process flange:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. Apply the thread sealant to the male thread.

3. Thread the remote seal onto the process connection. The remote seal is designed

with a small hole to facilitate installation and applying torque. The applied torque
should comply with ANSI B1.20.1 for NPT connections or applicable torque
requirements for pipe connections.

3.15 SCW hygienic Tri-Clover Tri Clamp seals

Figure 3-18: SCW Tri Clamp Seal

2½-, 3-, and 4-in. size

2-in. size 1½-in. size

A. Connection to transmitter

B. Diaphragm

Rosemount DP Level 51

Installation Reference Manual

April 2022 00809-0100-4002

3.15.1 Clamp and gasket

The clamp is furnished by the end-user with the exception of an optional Emerson­supplied high pressure Ladish™ clamp. Maximum pressure rating of the system is
dependent upon the clamp pressure rating.

The gasket is furnished by the end-user with the exception of an optional Emerson­supplied Nitrile Butadiene (NBR) gasket.

Table 3-5: High Pressure Ladish Clamp Maximum Working Pressure

Process connection size 70 °F (21 °C) 250 °F (121 °C)

1½-in. 1,500 psi (103 bar) 1,200 psi (83 bar)

2-in. 1,000 psi (69 bar) 800 psi (55 bar)

2½-in. 1,000 psi (69 bar) 800 psi (55 bar)

3-in. 1,000 psi (69 bar) 800 psi (55 bar)

4-in. 600 psi (41 bar) 480 psi (34 bar)

3.15.2 Parts required for installation

The parts required to install the SCW hygienic Tri Clamp seal will be defined here. Prior to
installation, you will need the following:

• Clamp

• Gasket

• Wrench (optional, depending on clamp)

Verify the gasket material is appropriate for the application. Ensure to use an EHEDG
approved gasket if EHEDG conformance is needed.

52 Emerson.com/Rosemount

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3.15.3 Installation steps

Follow these steps to install the SCW hygienic Tri Clamp seal:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

2. Place the appropriate gasket for the application on the remote seal and align the

gasket so that it is not contacting the diaphragm as this will induce errors.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

3. Ensure that the SCW hygienic Tri Clamp seal is flush with the process connection.

4. Install clamp and tighten to manufacturer's specifications

Note

EHEDG requirement on T-stub installations: the length (L) divided by the diameter
(D) of the tee is to be less than 1 (i.e. L /D < 1).

Rosemount DP Level 53

A

B

C

D

Installation

April 2022 00809-0100-4002

Reference Manual

3.16 SSW hygienic tank spud seal

Figure 3-19: SSW Tank Spud Seal

A. Connection to transmitter

B. Extension lenght
C. Diaphragm
D. Tank spud

3.16.1

3.16.2

Parts required for installation

The parts required to install the SSW hygienic tank spud seal will be defined here. Prior to
installation, you will need the following:

• O-ring (Emerson-supplied)

• Clamp (Emerson-supplied)

Cutting and welding equipment required if installing a new tank spud.

Verify the O-ring material is appropriate for the application.

Installation steps

Follow these steps to install the SSW hygienic tank spud seal:

Procedure

1. Prepare the tank, see Tank preparation.

2. Weld the tank spud onto the tank per plant procedures, see Welding. Ensure the

tank spud is not assembled to the pressure transmitter and/or the remote seal prior
to welding.

3. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

54 Emerson.com/Rosemount

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4. Place the Emerson-supplied O-ring onto the groove.

Installation

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Insert the SSW hygienic tank spud seal into the tank spud.

6. Attach the Emerson-supplied clamp and hand-tighten the connection.

3.16.3 Tank preparation

When preparing the tank, ensure an area with a minimum diameter of 9¼-in. (235 mm) is
available to properly weld the tank spud. The center of the tank spud should be at least
1½-in. (38 mm) below the minimum measurement level. To get a proper process fluid
measurement, half of the remote seal diaphragm must be covered.

Figure 3-20: Tank Preparation

A. Tank spud

B. Hole cut
C. Center of the hole
D. Weld

Attempt to cut the hole as smoothly and as circular as possible. A torch cut is not
recommended. The tank spud O.D. is 5.98-in. ± 0.010-in. (152 mm ± 0.25 mm). When
cutting the hole for the tank spud, the gap between the hole diameter and spud O.D.
should be held to a minimum. It is recommended that the hole be no larger than 6.020-in.
(153 mm). Anything larger than 6.020-in. (153 mm) could increase the amount of tank
spud distortion.

If a bevel(s) is required, an angle no larger than 37.5° is recommended; see ASME B16.25
for more details. Bevels can be made on one or both sides of the tank. Do not grind or cut
the bevel to a sharp point. Attempt to leave a flat area.

Rosemount DP Level 55

A

B

C

A

Installation

April 2022 00809-0100-4002

Figure 3-21: Bevel Example

A. Tank spud

B. Bevel
C. Tank

The flat area should be large enough to minimize spud distortion but small enough so that
tank weld requirements can be met. Minimizing the bevel angle will decrease the amount
of fill required during weld and minimize the number of weld passes. These best practices
will decrease heat input and help mitigate distortion.

Reference Manual

3.16.4

Welding

CAUTION

Excessive heat will distort the tank spud. Allow adequate cooling time between passes.

Ensure spud is not assembled to transmitter and/or remote seal prior to welding. Do not
nick the sealing surfaces of the tank spud, the inner angled surfaces where the O-ring sits
shown in Figure 3-22, as any irregularities may cause leaks.

Figure 3-22: O-ring Sealing Surfaces

A. Sealing surfaces

With the spud centered in the tank hole, make sure the inner surface of the spud is flush
with the inner surface of the tank. The leak detection hole in the spud should be at the
bottom of the spud. With the spud properly located, tack weld it into place using four tack
welds, 90° from each other.

Begin welding on the inside of vessel. Weld in sections similar to the sequence in Figure

3-23.

56 Emerson.com/Rosemount

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Figure 3-23: Welding Sections

Allow time to cool between weld sections. Weld should be cooled to 350 °F (177 °C) or less
after each pass while being cool to the touch is preferred. Use of a damp cloth or
compressed air is allowed if rapid cooling is desired. Repeat procedure on the outside of
the tank.

Note

The number of weld passes should be kept to a minimum while maintaining tank weld
standards and sanitary requirements. Additional weld passes are a significant contributor
to spud distortion due to additional heat input and added filler material in beveled area of
hole. When fill passes are required, a 1/16-in. (1.58 mm) diameter weld rod is
recommended.

Note

For high pressure clamps up to 1,000 psi (69 bar), contact the factory.

Rosemount DP Level 57

A

B

Installation

April 2022 00809-0100-4002

Reference Manual

3.17 STW hygienic thin wall tank spud seal

Figure 3-24: STW Hygienic Thin Wall Tank Spud Seal

A. Connection to transmitter

B. Diaphragm

3.17.1

3.17.2

Parts required for installation

The parts required to install the STW hygienic thin wall tank spud seal will be defined here.
Prior to installation, you will need the following:

• O-ring (Emerson-supplied)

• Clamp (Emerson-supplied)

Cutting and welding equipment required if installing a new tank spud.

Verify the O-ring material is appropriate for the application.

Installation steps

Follow these steps to install the STW hygienic thin wall tank spud seal:

Procedure

1. Remove the plastic cover from the diaphragm of the remote seal.

2. Weld the tank spud onto the tank per plant procedures, see Welding.

WARNING

Ensure the tank spud is not assembled to the pressure transmitter and/or the
remote seal prior to welding.

3. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

4. Place the Emerson-supplied O-ring onto the groove. Failure to properly install the

gasket may cause process leaks, which can result in death or serious injury.

5. Insert the STW hygienic thin wall tank spud seal into the tank spud.

6. Attach the Emerson-supplied clamp and hand-tighten the connection.

58 Emerson.com/Rosemount

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Installation

3.18 EES hygienic flanged tank spud extended seal

Figure 3-25: EES Hygienic Flanged Tank Spud Extended Seal

A. Connection to transmitter

B. Diaphragm

3.18.1

3.18.2

Parts required for installation

The parts required to install the EES hygienic flanged tank spud extended seal will be
defined here. Prior to installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• O-ring (Emerson-supplied)

Cutting and welding equipment required if installing a new tank spud.

Verify the O-ring material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Installation steps

Follow these steps to install the EES hygienic flanged tank spud extended seal:

Procedure

1. Prepare the tank, see Tank preparation.

2. Weld the tank spud onto the tank per plant procedures, see Welding. Ensure the

tank spud is not assembled to the pressure transmitter and/or the remote seal prior
to welding.

3. Remove the protective cover from the diaphragm of the remote seal. Use extreme

caution during installation to ensure the diaphragm is not damaged.

4. Insert end-user-supplied bolts in the bottom two bolt holes of the flange on the

remote seal.

5. Place the Emerson-supplied O-ring onto the groove.

Rosemount DP Level 59

Installation

April 2022 00809-0100-4002

Reference Manual

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

6. Insert the EES hygienic flanged tank spud extended seal into the tank spud.

7. Using the previously installed bolts, attach the remote seal and gasket to the

process connection. Secure with nuts and hand-tighten.

8. Insert end-user-supplied bolts in the top two bolt holes of the flange on the remote

seal. Secure with nuts and hand-tighten.

9. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure

even installation (see Torque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

3.19 VCS Tri Clamp in-line seal

Figure 3-26: VCS Tri Clamp In-line Seal

3.19.1 Parts required for installation

The parts required to install the VCS hygienic Tri Clamp seal will be defined here. Prior to
installation, you will need the following:

• Clamps (end-user-supplied)

• Gaskets (end-user-supplied)

• Wrench (optional, depending on clamp)

Verify the gasket material is appropriate for the application. Ensure to use an EHEDG
approved gasket if EHEDG conformance is needed.

60 Emerson.com/Rosemount

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3.19.2 Installation steps

Follow these steps to install the VCS hygienic Tri Clamp seal:

Procedure

1. Place the appropriate end-user-supplied gasket for the application on the remote

seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

2. Align one end of the VCS hygienic Tri Clamp seal flush with the process piping.

3. Attach the clamp and tighten to manufacturer's specifications (wrench might be

required depending on clamp style).

4. Place the second appropriate end-user-supplied gasket for the application on the

remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Align the other end of the VCS hygienic Tri Clamp seal with the process piping.

6. Attach the clamp and tighten to manufacturer's specifications (wrench might be

required depending on clamp style).

Note

EHEDG requirement on T-stub installations: the length (L) divided by the diameter
(D) of the tee is to be less than 1 (i.e. L /D < 1).

Rosemount DP Level 61

A

B

Installation

April 2022 00809-0100-4002

Reference Manual

3.20 SVS VARIVENT® compatible hygienic connection seal

Figure 3-27: SVS VARIVENT Compatible Connection Seal

A. Connection to transmitter

B. Diaphragm

3.20.1

3.20.2

Parts required for installation

The parts required to install the SVS VARIVENT seal will be defined here. Prior to
installation, you will need the following:

• Clamp (end-user-supplied)

• Gasket (end-user-supplied)

• Wrench (optional, depending on clamp)

Verify the gasket material is appropriate for the application. Ensure to use an EHEDG
approved gasket if EHEDG conformance is needed.

Installation steps

Follow these steps to install the SVS VARIVENT seal:

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

2. Place the appropriate gasket for the application on the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

3. Ensure that the SVS VARIVENT seal is flush with the process connection.

4. Install clamp and tighten to manufacturer's specifications.

62 Emerson.com/Rosemount

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Note

EHEDG requirement on T-stub installations: the length (L) divided by the diameter
(D) of the tee is to be less than 1 (i.e. L /D < 1).

Installation

3.21 SHP hygienic Cherry-Burrell® “I” line seal

Figure 3-28: SHP Cherry-Burrell “I” Line Seal

3.21.1

3.21.2

A. Connection to transmitter

B. Diaphragm

Parts required for installation

The parts required to install the SHP Cherry-Burrell seal will be defined here. Prior to
installation, you will need the following:

• Clamp (end-user-supplied)

• Gasket (end-user-supplied)

• Wrench (optional, depending on clamp)

Verify the gasket material is appropriate for the application.

Installation steps

Follow these steps to install the SHP Cherry-Burrell seal:

Rosemount DP Level 63

A

B

Installation

April 2022 00809-0100-4002

Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

2. Place the appropriate gasket for the application on the remote seal.

Reference Manual

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

3. Ensure that the SHP Cherry-Burrell seal is flush with the process connection.

4. Install clamp and tighten to manufacturer's specifications.

3.22 SLS dairy process connection–female thread seal per DIN 11851

3.22.1

Figure 3-29: SLS Hygienic Dairy Process Connection Female Thread Seal per DIN
11851

Parts required for installation

The parts required to install the SLS dairy process connection seal will be defined here.
Prior to installation, you will need the following:

• Gasket (end-user-supplied)

• Wrench (optional, depending on clamp)

Verify the gasket material is appropriate for the application. Ensure to use an EHEDG

3.22.2

64 Emerson.com/Rosemount

approved gasket if EHEDG conformance is needed.

Installation steps

Follow these steps to install the SLS dairy process connection seal:

D

L

A

A

B

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Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

2. Place the appropriate gasket for the application on the remote seal.

Installation

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

3. Ensure that the SLS dairy process connection seal is flush with the process
connection.

4. Tighten the nut onto the process connection per DIN 11851. Care should be taken
not to overtighten.

Note

EHEDG requirement on T-stub installations: the length (L) divided by the diameter
(D) of the tee is to be less than 1 (i.e. L /D < 1).

3.23 WSP saddle seal

Figure 3-30: WSP Saddle Seal

A. Connection to transmitter

B. Diaphragm

Parts required for installation

The parts required to install the WSP saddle seal will be defined here. Prior to installation,
you will need the following:

3.23.1

3-in. line size and smaller 4-in. line size and larger

Rosemount DP Level 65

Installation Reference Manual

April 2022 00809-0100-4002

• Torque wrench

• Mounting hardware (Emerson-supplied)

• Gasket (Emerson-supplied)

Cutting and welding equipment required if installing a new saddle lower.

Verify the gasket material is appropriate for the application.

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Installation

3.23.2 Installation steps

Follow these steps to install the WSP saddle seal:

Procedure

1. Prepare the tank and weld the saddle lower onto the tank per plant procedures.
Ensure the saddle lower is not assembled to the pressure transmitter and/or the
remote seal prior to welding.

CAUTION

Excessive heat will distort the saddle lower. Allow adequate cooling time between
passes.

2. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

3. Place the appropriate gasket for the application on the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

4. Insert the WSP saddle seal into the saddle lower.

5. Install the bolts in a cross pattern and hand-tighten.

6. Using a torque wrench on the bolt, tighten the assembly in a cross-pattern to
ensure even installation (see Torque sequence). The bolts should be torqued to 180
in-lb (20 N-m) with stainless or carbon steel bolts. Consider leak checking the
installation to ensure a robust connection.

3.24 UCP union connection pipe mount seal

Figure 3-31: UCP Threaded Pipe Mount Seal

A. Connection to transmitter

B. Diaphragm

Rosemount DP Level 67

Installation

April 2022 00809-0100-4002

Reference Manual

3.24.1 Parts required for installation

The parts required to install the UCP union connection seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Gasket (Emerson-supplied)

Cutting and welding equipment required if installing a new lower housing.

Verify the gasket material is appropriate for the application.

3.24.2 Installation steps

Follow these steps to install the UCP union connection seal:

Procedure

1. Using the appropriate size hole saw, cut a hole in the process vessel to accept the
lower housing. The diameter for a lower housing with a heat isolator groove is 2.37­in. (60 mm). The hole should produce a tight, uniform fit when coupled with the
lower housing.

2. Bevel the edge of the vessel hole to accept filler material (see Figure 3-32). An angle
no larger than 37.5° is recommended; see ASME B16.25 for more details. Bevels can
be made on one or both sides of the tank. Do not grind or cut the bevel to a sharp
point. Attempt to leave a flat area. The flat area should be large enough to minimize
spud distortion but small enough so that tank weld requirements can be met.
Minimizing the bevel angle will decrease the amount of fill required during weld and
minimize the number of weld passes. These best practices will decrease heat input
and help mitigate distortion.

3. Position the lower housing weld spud in the vessel hole, place heat sink and tack the
housing in place using the welding sequence shown in Figure 3-32. Cool each
section with a wet cloth before proceeding to the next section.

CAUTION

Do not place the seal in the lower housing prior to welding. Do not nick the sealing
surfaces of the weld spud, the inner angled surfaces where the gasket sits shown,
weld spud where the gasket sits, shown in Figure 3-32, as any irregularities may
cause leaks.

4. Weld the housing in place using 0.030- to 0.045-in. (0,762 to 1,143 mm) stainless
steel rod as filler in the beveled area. Using between 100 and 125 A, adjust the
amperage for 0.080-in. (2,032 mm) penetration. Allow time to cool between weld
sections. Weld should be cooled to 350 °F (177 °C) or less after each pass while
being cool to the touch is preferred. Use of a damp cloth or compressed air is
allowed if rapid cooling is desired. Repeat procedure on the outside of the tank.

Note

The number of weld passes should be kept to a minimum while maintaining tank
weld standards and process requirements. Additional weld passes are a significant

68 Emerson.com/Rosemount

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contributor to spud distortion due to additional heat input and added filler material
in beveled area of hole.

Figure 3-32: Installing the Weld Spud

Preparing the vessel hole Welding sequence

A. 100–125 A recommended
B. Heat isolation grooves
C. Weld spud

D. Bevelled edge

E. Process vessel

Dimensions are in inches (millimeters).

5. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

6. Place the gasket into the lower housing make sure the gasket is properly aligned on
the gasket sealing surface.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

7. Insert the UCP union connection seal into the lower housing and tighten the jam
nut.

CAUTION

Excessive heat will distort the weld spud. Allow adequate cooling time between
passes.

Rosemount DP Level 69

A

B

Installation

April 2022 00809-0100-4002

Reference Manual

3.25 PMW paper mill sleeve seal

Figure 3-33: PMW Threaded Pipe Mount Seal

3.25.1

3.25.2

A. Connection to transmitter

B. Diaphragm

Parts required for installation

The parts required to install the PMW paper mill seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Gasket (Emerson-supplied)

Cutting and welding equipment required if installing a new lower housing.

Verify the gasket material is appropriate for the application.

Installation steps

Follow these steps to install the PMW paper mill seal:

Procedure

1. Using the appropriate size hole saw, cut a hole in the process vessel to accept the
lower housing. The diameter for a lower housing with a heat isolator groove is 1.32­in. (33,4 mm). The hole should produce a tight, uniform fit when coupled with the
lower housing.

2. Bevel the edge of the vessel hole to accept filler material (see Figure 3-34). An angle
no larger than 37.5° is recommended; see ASME B16.25 for more details. Bevels can
be made on one or both sides of the tank. Do not grind or cut the bevel to a sharp
point. Attempt to leave a flat area. The flat area should be large enough to minimize
spud distortion but small enough so that tank weld requirements can be met.
Minimizing the bevel angle will decrease the amount of fill required during weld and

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minimize the number of weld passes. These best practices will decrease heat input
and help mitigate distortion.

3. Position the weld spud in the vessel hole, place heat sink and tack the housing in
place using the welding sequence shown in Figure 3-34. Cool each section with a
wet cloth before proceeding to the next section.

WARNING

Do not place the seal in the lower housing prior to welding. Do not nick the inner
angled sealing surfaces of the weld spud where the gasket sits, shown in Figure

3-34, as any irregularities may cause leaks.

4. Weld the housing in place using 0.030- to 0.045-in. (0,762 to 1,143 mm) stainless
steel rod as filler in the beveled area. Using between 100 and 125 A, adjust the
amperage for 0.080-in. (2,032 mm) penetration. Allow time to cool between weld
sections. Weld should be cooled to 350 °F (177 °C) or less after each pass while
being cool to the touch is preferred. Use of a damp cloth or compressed air is
allowed if rapid cooling is desired. Repeat procedure on the outside of the tank.

Note

The number of weld passes should be kept to a minimum while maintaining tank
weld standards and process requirements. Additional weld passes are a significant
contributor to spud distortion due to additional heat input and added filler material
in beveled area of hole.

Figure 3-34: Installing the Weld Spud

Preparing the vessel hole

Welding sequence

A. 100 to 125 A recommended
B. Heat isolation grooves
C. Weld spud

D. Bevelled edge

E. Process vessel

Dimensions are in inches (millimeters).

CAUTION

Excessive heat will distort the weld spud. Allow adequate cooling time between
passes.

Rosemount DP Level 71

A

B

Installation

April 2022 00809-0100-4002

5. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

6. Place the O-rings onto the seal body.

Reference Manual

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

7. Insert the PMW paper mill seal into the lower housing.

8. Install capture bolt and torque to 7.5 ft-lb.

3.26 CTW chemical tee seal

Figure 3-35: CTW Chemical Tee Seal

3.26.1

3.26.2

A. Connection to transmitter

B. Diaphragm

Parts required for installation

The parts required to install the CTW chemical tee seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

Installation steps

Follow these steps to install the CTW chemical tee seal on an existing flanged process
connection:

72 Emerson.com/Rosemount

A

B

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Procedure

1. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

2. Place the appropriate end-user-supplied gasket on the remote seal.

Installation

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

3. Attach the remote seal and gasket to the process connection. Insert end-user­supplied bolts, secure with nuts, and hand-tighten.

4. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure
even installation (see Torque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

3.27 TFS wafer style In-line seal

Figure 3-36: TFS Wafer Style In-Line Seal

A. Connection to transmitter

B. Diaphragm

3.27.1

Parts required for installation

The parts required to install the TFS wafer style In-line seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (end-user-supplied)

Rosemount DP Level 73

Installation Reference Manual

April 2022 00809-0100-4002

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.27.2 Installation steps

Follow these steps to install the TFS wafer style In-line seal on an existing flanged process
connection:

Procedure

1. Place the appropriate end-user-supplied gasket for the application on one end of
the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

2. Align that end of the TFS wafer style In-line seal flush with the process flange.

3. Insert end-user-supplied bolts, secure with nuts, and hand-tighten

4. Place the second appropriate end-user-supplied gasket for the application on the
other end of the remote seal.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Align that end of the TFS wafer style In-line seal flush with the process flange.

6. Insert end-user-supplied bolts, secure with nuts, and hand-tighten.

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure
even installation (see Torque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

74 Emerson.com/Rosemount

A

B

A

B

Reference Manual

00809-0100-4002 April 2022

Installation

3.28 WFW flow-thru flanged seal

Figure 3-37: WFW Flow-Thru Flanged Seal

3.28.1

A. Connection to transmitter

B. Diaphragm

1- and 2-in. size

3-in. size

Parts required for installation

The parts required to install the WFW flow-thru flanged seal will be defined here. Prior to
installation, you will need the following:

• Torque wrench

• Mounting hardware (end-user-supplied)

• Gasket (lower housing to process flange) (end-user-supplied)

• Gasket (remote seal to lower housing) (Emerson-supplied)

Verify the gasket material is appropriate for the application.

Inspect bolts to ensure the material is compatible with industry standards per the
application such as ASME PCC-1.

3.28.2

Rosemount DP Level 75

Installation steps

Follow these steps to install the WFW flow-thru flanged seal on an existing process piping
system:

Procedure

1. Place the appropriate end-user-supplied gasket for the application on one end of
the lower housing flange.

Installation Reference Manual

April 2022 00809-0100-4002

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

2. Align that end of the WFW flow-thru flanged seal flush with the process flange.

3. Insert end-user-supplied bolts, secure with nuts, and hand-tighten.

4. Place the second appropriate end-user-supplied gasket for the application on the
other end of the lower housing flange.

WARNING

Failure to properly install the gasket may cause process leaks, which can result in
death or serious injury.

5. Align that end of the WFW flow-thru flanged seal flush with the process flange.

6. Insert end-user-supplied bolts, secure with nuts, and hand-tighten

7. Using a torque wrench on the nut, tighten the assembly in a cross-pattern to ensure
even installation (seeTorque sequence). The bolts should be torqued to the
applicable flange requirements. Required torque is a function of the gasket material
and surface treatment of the bolts and nuts which are end-user-supplied. Consider
leak checking the installation to ensure a robust connection.

8. Remove the protective cover from the diaphragm of the remote seal. Use extreme
caution during installation to ensure the diaphragm is not damaged.

9. Assemble the remote seal, Emerson-supplied gasket, and lower housing. Failure to
properly install the gasket may cause process leaks, which can result in death or
serious injury.

10. Install the bolts in a cross pattern and hand-tighten.

11. Using a torque wrench on the bolt, tighten the assembly in a cross-pattern to
ensure even installation (see Torque sequence). The bolts should be torqued to 180
in-lb (20 N-m) with stainless or carbon steel bolts. Consider leak checking the
installation to ensure a robust connection.

76 Emerson.com/Rosemount

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4 Configuration

4.1 Calculating range points

4.1.1 Remote seals

Calculating range points

• Open tank (zero based)

• Open tank (non-zero based)

• Closed tank (non-zero based)

Transmitters installation best practice

• Open tank (zero based)

• Closed tank (non-zero based)

(2)

(2)

• Zero trim via Field Communicator

• Re-range via zero button

• Re-range via Field Communicator

• Scale display

Figure 4-1: Remote Seals

ATM = open to atmosphere

Balanced (equal
capillary length and
size seal)

Tuned (unequal

capillary length)

Direct mount Remote capillary

(2) “Zero based” means 4 mA equals 0 inH2O.

Rosemount DP Level 77

Configuration Reference Manual

April 2022 00809-0100-4002

4.1.2 Zero-based lower range value

Figure 4-2: Remote Capillary and Direct Mount

ATM =

dH =

dL =

L

L

SGF =

SGP =

open to atmosphere

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20 mA lower

max

range value

=

the minimum level of process above the high pressure seal and typically the 4 mA lower

min

range value

specific gravity of fill fluid

specific gravity of process fluid

Tank span

4 mA

20 mA

Span

Remote capillary Direct mount

= L

× SGP – L

max

min

× SG

P

= (108 in. × 0.75) – (0 in. × 0.75) = 81 inH2O

= L

× SGP + dH × SG

min

F

= (0 in. × 0.75) + (0 in. × 0.934) = 0 inH2O

= L

× SGP + dH × SGF

max

= (108 in. × 0.75) + (0 in. × 0.934) = 81 inH2O

= 81 inH2O (81 to 0 inH2O)

Note

Both installations would have the same calculated range points.

Note

Silicone 200 has a specific gravity of 0.934.

78 Emerson.com/Rosemount

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4.1.3 Non-zero based lower range value

Figure 4-3: Remote Capillary

ATM =

dH =

dL =

L

open to atmosphere

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20

max

mA lower range value

L

=

the minimum level of process above the high pressure seal and typically the 4

min

mA lower range value

SGF =

SGP =

Tank span

specific gravity of fill fluid

specific gravity of process fluid

= L

× SGP – L

max

min

× SG

= (108 in. × 0.75) – (0 in. × 0.75) = 81 inH2O

4 mA

= L

× SGP + (dH × SGF)

min

= (0 in. × 0.75) + (60 in. × 0.934) = 56.04 inH2O

20 mA

= L

× SGP + (dH × SGF)

max

= (108 in. × 0.75) + (56.04 inH2O) = 137.04 inH2O

Span

= 81 inH2O (137.04 to 56.04 inH2O)

Note

Silicone 200 has a specific gravity of 0.934.

P

Rosemount DP Level 79

Configuration Reference Manual

April 2022 00809-0100-4002

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

Figure 4-4: Remote Capillary

ATM =

dH =

dL =

L

open to atmosphere

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20

max

mA lower range value

L

=

the minimum level of process above the high pressure seal and typically the 4

min

mA lower range value

SGF =

SGP =

Tank span

specific gravity of fill fluid

specific gravity of process fluid

= L

× SGP – L

max

min

× SG

P

= (108 in. × 0.75) = 81 inH2O

4 mA

= L

× SGP +(dH × SGF)

min

= (0 in. × 0.75) + (–120 in. × 0.934) = –112.08 inH2O

20 mA

= L

× SGP + (dH × SGF)

max

= (108 in. × 0.75) + (–120 in. × 0.934) = –31.08 inH2O

Span

= 81 inH2O (–112.08 to –31.08 inH2O)

Note

The height of the transmitter (Hd × Sg) should not be greater than approximately 394
inH2O (14.2 PSI) not to exceed the 0.5 PSIA sensor limits of a coplanar DP or GP.

Note

Silicone 200 has a specific gravity of 0.934.

80 Emerson.com/Rosemount

L

max

L

min

108 in.

0 in.

SG = 0.75

P

SG = 0.934

F

d = 120 in.

L

Reference Manual Configuration

00809-0100-4002 April 2022

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

Figure 4-5: Tuned-System

dH =

dL =

L

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20

max

mA lower range value

L

=

the minimum level of process above the high pressure seal and typically the 4 mA

min

lower range value

™

SGF =

SGP =

Tank span

specific gravity of fill fluid

specific gravity of process fluid

= L

× SGP – L

max

min

× SG

P

= (108 in. × 0.75) = 81 inH2O

4 mA

= L

× SGP – (dL × SGF)

min

= (0 in. × 0.75) – (120 in. × 0.934) = –112.08 inH2O

20 mA

= L

× SGP – (dL × SGF)

max

= (108 in. × 0.75) – (120 in. × 0.934) = –31.08 inH2O

Span

= 81 inH2O (–112.08 to –31.08 inH2O)

Note

Silicone 200 has a specific gravity of 0.934.

Rosemount DP Level 81

L

max

108 in.

SG = 0.75

P

SG = 0.934

F

d = -60 in.

H

L

min

0 in.

d = 60 in.

L

Configuration Reference Manual

April 2022 00809-0100-4002

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

Figure 4-6: Balanced System

dH =

dL =

L

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20

max

mA lower range value

L

=

the minimum level of process above the high pressure seal and typically the 4 mA

min

lower range value

SGF =

SGP =

Tank span

specific gravity of fill fluid

specific gravity of process fluid

= L

× SG

max

= 108 in. × 0.75 = 81 inH2O

4 mA

= L

× SGP – (dL × SGF) +(dH × SGF)

min

= (0 in. × 0.75) – (60 in. × 0.934) + (–60 in. × 0.934) = –112.08 inH2O

20 mA

= L

× SGP – (dL × SGF) +(dH × SGF)

max

= (108 in. × 0.75) – (60 in. × 0.934) + (–60 in. × 0.934) = –31.08 inH2O

Span

= 81 inH2O (–112.08 to –31.08 inH2O)

Note

Silicone 200 has a specific gravity of 0.934.

82 Emerson.com/Rosemount

L

max

108 in.

SG = 0.75

P

L

min

0 in.

d = 60 in.

H

d = 180 in.
(60 +120)

L

SG = 0.934

F

Reference Manual Configuration

00809-0100-4002 April 2022

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

Figure 4-7: Remote Capillary

dH =

dL =

L

vertical distance from transmitter to high pressure seal

vertical distance from transmitter to low pressure seal

=

the maximum level of process above the high pressure seal and typically the 20

max

mA lower range value

L

=

the minimum level of process above the high pressure seal and typically the 4 mA

min

lower range value

SGF =

SGP =

Tank span

specific gravity of fill fluid

specific gravity of process fluid

= L

× SG

max

= 108 in. × 0.75 = 81 inH2O

4 mA

= L

× SGP – (dL × SGF) +(dH × SGF)

min

= (0 in. × 0.75) – (180 in. × 0.934) + (60 in. × 0.934) = –112.08 inH2O

20 mA

= L

× SGP – (dL × SGF) +(dH × SGF)

max

= (108 in. × 0.75) – (180 in. × 0.934) + (60 in. × 0.934) = –31.08 inH2O

Span

= 81 inH2O (–112.08 to –31.08 inH2O)

Note

Silicone 200 has a specific gravity of 0.934.

Note

The transmitter location in a closed tank does not effect the 4 mA and 20 mA set points as
shown in example A, B, and C.

Rosemount DP Level 83

Configuration Reference Manual

April 2022 00809-0100-4002

4.2 DP Level transmitter installation best practices

Pressure transmitters have a sensor module with a primary fill fluid. Therefore, the
mounting position of a standard transmitter with silicon fill could read approx ±1.25 inH2O
worst case after installation. This is simply zeroed out using a Field Communicator after
installation so that it will read zero pressure. With a remote seal attached you have
additional components that will create additive pressure that would increase the amount
of potential shift. This would include the secondary fill fluid in the remote seal assembly
along with the potential of torqueing effects when the assembly is bolted to the process.
For these reasons, the transmitter’s digital output will most likely not match the exact
values calculated on paper. Even a redundant transmitter would most likely not read the
exact digital values after being installed. For these reasons, a re-range function is common
practice after all installations.

Figure 4-8: Installation Example

Pressure transmitter

A. Primary fill

B. Secondary fill

What is important is the calculated span (level height × specific gravity of the process).
After the transmitter is mounted, it is common and best practice to re-range the
transmitter so that the 4 mA point will be the installed digital value. The 20 mA point
would then be set based on the calculated span value setting it above the installed digital
value.

Pressure transmitter with remote seals

The procedure would be based on mounting configuration (zero based) 4 mA = 0 inH2O or
(non-zero based) 4 mA exceeds the ±3% of the upper sensor limit (USL).

4.2.1

84 Emerson.com/Rosemount

Open tank (zero based)

With open tank level applications this value can typically be zeroed out using a HART
device as long as it is < 3% USL. The maximum value that can be zeroed out is 3% of the USL
or 7.5 inH2O for a range 2 (250 inH2O) sensor.

Reference Manual Configuration

00809-0100-4002 April 2022

4.2.2 Closed tank (non-zero based)

For closed tank level applications, this value is most likely too high and cannot be zeroed
out due to the applied pressure of the secondary fill fluid. For this reason, the transmitter
would simply be re-ranged so that the 0% value (4 mA) would equal the installed value.
The 100 percent, (20 mA) would be adjusted to the required calculated span.

4.2.3 Open tank example (zero-based lower range value) with Field Communicator

Perform a zero trim via Field Communicator after installation for zero based lower range
values.

Figure 4-9: Open Tank

ATM: open to atmosphere.

Rosemount DP Level 85

Configuration Reference Manual

April 2022 00809-0100-4002

Figure 4-10: Before Zero Trim Using Field Communicator

Figure 4-11: After Zero Trim Using Field Communicator

86 Emerson.com/Rosemount

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

Note

For FOUNDATION™ Fieldbus, refer to the AI Function Blocks in reference manual.

Figure 4-12: Tuned-System

Procedure

1. Set seals at the same elevation for bench pressure verification, if required to range
transmitter. If the transmitter does not require bench pressure verification, proceed
to Step 2.

Bench pressure verification

Power and range the transmitter using a Field Communicator to the required tank
span. (Figure 4-12 example) With the required calibration fixture attached to the
seal assemble apply pressure.

4 mA = 0 inH2O

20 mA = 81 inH2O

2. Install the tuned system by assembling the seals to the process taps. Common
practice is to mount the high-pressure side seal to the low process tap and the low­pressure side seal to the high process tap.

3. Wire and apply power to the transmitter.

4. If the transmitter has a zero button, see Figure 4-13 and Figure 4-14, push the Zero
button. This will automatically re-range the transmitter so the LRV (4 mA) will equal
the current applied pressure value and the URV (20 mA) will be adjusted to the
required calculated span.

Example 1: Re-range using transmitter zero button

Transmitter is ranged per Figure 4-12:

Rosemount DP Level 87

A

A B

A B

Configuration Reference Manual

April 2022 00809-0100-4002

4 mA = 0 inH2O

20 mA = 81 inH2O

After installing and pushing the Zero button, the transmitter will now be ranged per
example from Figure 4-5:

4 mA = –112.08 inH2O

20 mA = –31.08 inH2O

Note

If you have a Field Communicator device connected when the Zero button is
pushed, you must re-boot the Field Communicator to see the change.

Figure 4-13: Zero and Span Buttons on Rosemount 2088, 2051, and 3051

A. Zero and span buttons

Figure 4-14: Zero and Span Buttons on Rosemount 3051S

Plantweb Junction box

A. Zero
B. Span

5. If the transmitter does not have a Zero button, use a Field Communicator to re­range the transmitter.

Example 2: Re-range using a Field Communicator

Transmitter is ranged per Figure 4-13:

88 Emerson.com/Rosemount

Reference Manual Configuration

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4 mA = 0 inH2O

20 mA = 81 inH2O

After mounting transmitter, the pressure reads –112.08 inH2O, see Figure 4-14.

Using a Field Communicator, re-range the transmitter, see Figure 4-14. The
transmitter will now be ranged per example from Figure 4-5:

4 mA = –112.08 inH2O

20 mA = –31.08 inH2O

Figure 4-15: Before Re-renge Using Field Conmmunicator

4.2.5

Figure 4-16: After Re-range Using Field Conmmunicator

6. If the device has a display and you want to configure the output to an engineering
unit other than the standard defaults, go to Scale display with Field Communicator.

Scale display with Field Communication

After the transmitter is installed, you can scale the display to match the DCS or PLC as
required but, often 0 to 100 percent is sufficient. As an example, in Figure Figure 4-12, the
display should be 0 to 81 inH2O. This can be done using a Field Communicator, example
shown below for the Rosemount 3051S. See the transmitter reference manual for steps to
configure the display.

Rosemount DP Level 89

Configuration Reference Manual

April 2022 00809-0100-4002

Note

Depending on the HART device (Field Communicator/AMS Wireless Configurator) DD the
following steps may be slightly different.

For the Rosemount 3051S, in the HART menu tree, go to the Scaled variable Config (under
guided set up). Follow the steps below: Bold text indicates entered value.

Procedure

1. Enter SV unit: (enter) inH2O

2. Select Scaled data option: (select) Linear

3. Enter Pressure value position 1: (enter) -112.08

4. Enter Scaled Variable position 1: (enter) 0

5. Enter Pressure value position 2: (enter) –31.08

6. Enter Scaled Variable position 2: (enter) 81

7. Enter Linear Offset: (enter) 0.00

8. Go to Display (under manual setup).

9. Pressure: OFF

10. Scaled Variable: ON

11. Module Temperature: OFF

12. Percent of range: OFF

Note

The transmitter is ranged –112.08 to –31.08 inH2O, but the display will show 0
inH2O at (4 mA) and 81 inH2O at (20 mA).

90 Emerson.com/Rosemount

Reference Manual

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Fill Fluids

5 Fill Fluids

This section discusses the process of selecting the appropriate fill fluid using vapor
pressure curves. To see the list of available Rosemount fill fluids, view the Rosemount DP
Level Fill Fluid Specifications Technical Note, or reference the Rosemount DP Level
Transmitters and 1199 Remote Seals Product Data Sheet or the 1299 Remote Seals
Product Data Sheet.

5.1 Quality

5.1.1 Specialized processing

Emerson has implemented proprietary processes to eliminate impurities and
contaminations in the fill fluid. This additional processing ensures stable measurement
and optimal performance under extreme temperatures and vacuum conditions. The
proprietary equipment and procedures used to build remote seal systems for high
temperature/high vacuum applications are continuously improved to deliver products
that meet ever increasing application demands. Tight quality control measures such as
helium leak checking of system welds ensures the reliability of every seal system.
Additional quality checks include continual station leak and health tests to confirm the fill
quality of the finished seal system.

5.1.2

Testing

Emerson’s vapor pressure curves are derived from empirical lab testing in real devices at
both vacuum conditions and at the maximum continuous temperature at one atmosphere
of pressure. The maximum continuous temperature at one atm of pressure correlates to
the thermal stability of the fill fluid, which is the maximum temperature the fill fluid will
remain in its original molecular form. Over time, exceeding the maximum recommended
temperature may result is the decomposition or vaporization of the fill fluid, resulting in
device failure.

5.2 Fill fluid selection

Fill fluid selection is very important to the safety and reliability of your measurement
application.

5.2.1

Type of fill fluid

Different types of fill fluids exist to meet the needs of different applications. An all-purpose
fill fluid can be used in most applications. However, some processes might require a fill
fluid that is chemically inert to avoid reactions with oxygen. In the food and
pharmaceutical industries, a hygienic fill fluid may be needed that meets various industry
standards.

Rosemount DP Level 91

Fill Fluids

April 2022 00809-0100-4002

Reference Manual

5.2.2 Maximum and minimum temperatures

When selecting a fill fluid, the process and ambient temperatures must be within the
specified temperature range of the fill fluid. Too hot can cause the fill fluid to vaporize or
yield thermal stability issues. Too cold can cause the fill fluid to gel, which slows the time
response or can even render the system unresponsive.

5.2.3 Process pressure and temperature

When the process is under vacuum conditions (below 14.7 psia), the fill fluid will vaporize
at a lower temperature than when it is operating under normal atmospheric or greater
pressure. If the fill fluid vaporizes, the seal system is permanently damaged. Emerson
offers numerous types of fill fluids for remote seal systems, 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 vapor state. Safe and reliable system operation
requires the fill fluid to remain in a liquid state.

Figure 5-1: Liquid vs. Pressure State Under Vacuum

The thermal stability point of a fill fluid is equal to its maximum temperature at one
atmosphere. This point translates to the maximum continuous operating temperature of
the fill fluid.

5.3 Fill fluid vapor pressure curves

5.3.1 How to use vapor pressure curves

Take each temperature and pressure of your process cycle and find where each point falls
on the graph above (Figure 5-1). Whichever fill fluid that is farthest to the right containing
a point of your process cycle is most likely the correct fill fluid for your application.

92 Emerson.com/Rosemount

Reference Manual Fill Fluids

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Note

Fill fluids can operate at lower temperatures than their shaded section shown in Figure 5-2.
For exact minimum operating temperatures, consult the Rosemount DP Level Fill Fluid
Specifications Technical Note.

Figure 5-2: Vapor Pressure Curves of General Use Fill Fluids

5.3.2 Fill fluid selection example

In an application that has a maximum process temperature of 284 °F (140 °C) and a
maximum pressure of 700 Torr, SYLTHERM™ XLT would be recommended. However, say
the process pressure drops to 200 Torr and 284 °F (140 °C) at one point during the process
cycle, then Silicone 200 for vacuum applications would be recommended because it is the
fill fluid farthest to the right that the process falls into.

5.3.3

Fill fluid specifications

Rosemount fill fluid properties, vapor pressure curves, and specifications can be found in
the Rosemount DP Level Fill Fluid Specifications Technical Note.

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6 Maintenance and Troubleshooting

6.1 Cleaning

Avoid using abrasive agents or high pressure water jets when cleaning the remote seals.

6.2 Troubleshooting

Remote seal systems are factory filled systems that cannot be refilled in the field. Do not
attempt to disconnect the seals or capillaries from the transmitter. Doing so can damage
the seal system assembly and voids the product warranty. Listed below are the possible
problems, their potential causes, and, where applicable, a corrective action.

6.2.1

6.2.2

No output

Potential cause

Electrical problem

Recommended actions

1. See the troubleshooting section of the transmitter manual for more extensive
information.

2. Check for adequate voltage to the transmitter.

3. Check the milliampere rating of the power supply against the total current
being drawn for all transmitters being powered.

4. Check for shorts and multiple grounds.

5. Check for proper polarity at the transmitter terminal.

6. Check loop impedances.

CAUTION

Do not use higher than the specified voltage to check the loop, or the
transmitter electronics may be damaged.

Slow response

Potential cause

Damping too high

Recommended actions

See the “Damping Adjustment” information in the Calibration section of the
transmitter manual.

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Potential cause

Cold temperature

Recommended actions

Fill fluid viscosity is temperature dependent. Less viscous fill fluid enhances time
response. Heat traced capillaries can be added as an option to maintain constant
temperatures to fill fluid.

6.2.3 Drifting

Potential cause

Drifting

Recommended actions

If pressure measurement is changing, refer to Seal system performance for more
information. Running Instrument Toolkit will calculate the expected performance for
the seal system. Refer to Instrument Toolkit: seal ordering and application process for
more information.

6.2.4

6.2.5

6.2.6

Output reads negative pressure

Potential cause

Mounting effect

Recommended actions

The output will read negative as the remote fill fluid is applying pressure to the low
side. See Configuration.

No response to change in pressure

Potential cause

Damaged diaphragm

Recommended actions

Remove seal and inspect diaphragm.

Not responding to change in pressure

Potential cause

Multidrop mode

Recommended actions

See if the transmitter is in a multidrop mode.The multidrop mode locks the output at
4 mA.

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6.3 Return of materials

Within the United States, call the North American Response Center using the 1-800-654­RSMT (7768) toll-free number. This center, available 24 hours a day, will assist you with
any needed information or materials.

Outside of the United States, contact your local Emerson representative (support center
addresses and phone numbers are on the Title Page of this manual).

The center will ask for product model and serial numbers, and will provide a Return
Material Authorization (RMA) number. The center will also ask for the name of the process
material the product was last exposed to.

WARNING

Mishandling products exposed to a hazardous substance can cause death or serious injury.
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.

6.4 Service support

To expedite the return process outside of the United States, contact the nearest Emerson
representative.

Within the United States, call the Emerson Instrument and Valves Response Center using
the 1-800-654-RSMT (7768) toll-free number. This center, available 24 hours a day, will
assist you with any needed information or materials.

The center will ask for product model and serial numbers, and will provide a Return
Material Authorization (RMA) number. The center will also ask for the process material to
which the product was last exposed.

CAUTION

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.

Emerson Instrument and Valves Response Center representatives will explain the
additional information and procedures necessary to return goods exposed to hazardous
substances.

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7 Reference data

7.1 Product certifications

To view current product certification, follow these steps:

Procedure

1. Go to the product page on Emerson.com/Rosemount-1199. For 1299, use the
product page on this link.

2. Scroll as needed to the green menu bar and click Documents & Drawings.

3. Click Manuals & Guides.

4. Select the appropriate Quick Start Guide.

7.2 Ordering information, specifications, and drawings

To view current ordering information, specifications, and drawings, follow these steps:

Procedure

1. Go to the product page on Emerson.com/Rosemount-1199. For 1299, use the
product page on this link.

2. Scroll as needed to the green menu bar and click Documents & Drawings.

3. For installation drawings, click Drawings & Schematics and select the appropriate
document.

4. For ordering information, specifications, and dimensional drawings, click Data

Sheets & Bulletins and select the appropriate Product Data Sheet.

7.3 Spare parts

Table 7-1: Flush Flanged (FFW) and Pancake (PFW) Lower Housings

Material Size Part number

One ¼-in. Two ¼-in. One ½-in. Two ½-in.

316 SST 2-in. DP0002-2111-S6 DP0002-2121-S6 DP0002-2112-S6 DP0002-2122-S6

3-in. DP0002-3111-S6 DP0002-3121-S6 DP0002-3112-S6 DP0002-3122-S6

4-in./DN 100 DP0002-4111-S6 DP0002-4121-S6 DP0002-4112-S6 DP0002-4122-S6

DN 50 DP0002-5111-S6 DP0002-5121-S6 DP0002-5112-S6 DP0002-5122-S6

DN 80 DP0002-8111-S6 DP0002-8121-S6 DP0002-8112-S6 DP0002-8122-S6

Alloy C-276 2-in. DP0002-2111-HC DP0002-2121-HC DP0002-2112-HC DP0002-2122-HC

3-in. DP0002-3111-HC DP0002-3121-HC DP0002-3112-HC DP0002-3122-HC

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Table 7-1: Flush Flanged (FFW) and Pancake (PFW) Lower Housings (continued)

Material Size Part number

One ¼-in. Two ¼-in. One ½-in. Two ½-in.

4-in./DN 100 DP0002-4111-HC DP0002-4121-HC DP0002-4112-HC DP0002-4122-HC

DN 50 DP0002-5111-HC DP0002-5121-HC DP0002-5112-HC DP0002-5122-HC

DN 80 DP0002-8111-HC DP0002-8121-HC DP0002-8112-HC DP0002-8122-HC

Alloy 400 2-in. DP0002-2111-M4 DP0002-2121-M4 DP0002-2112-M4 DP0002-2122-M4

3-in. DP0002-3111-M4 DP0002-3121-M4 DP0002-3112-M4 DP0002-3122-M4

4-in./DN 100 DP0002-4111-M4 DP0002-4121-M4 DP0002-4112-M4 DP0002-4122-M4

DN 50 DP0002-5111-M4 DP0002-5121-M4 DP0002-5112-M4 DP0002-5122-M4

DN 80 DP0002-8111-M4 DP0002-8121-M4 DP0002-8112-M4 DP0002-8122-M4

Table 7-2: Gaskets for Flush Flanged (FFW) and Pancake (PFW) Lower Housings

Material Size Part number

Klinger C-4401 Virgin PTFE GHB GRAFOIL

®

Gylon 3510

316 SST 2-in. DP0007-0201-KF DP0007-0201-TF DP0007-0201-GF DP0007-0201-GY

3-in. DP0007-0301-KF DP0007-0301-TF DP0007-0301-GF DP0007-0301-GY

4-in./DN 100 DP0007-0401-KF DP0007-0401-TF DP0007-0401-GF DP0007-0401-GY

DN 50 DP0007-0601-KF DP0007-0601-TF DP0007-0601-GF DP0007-0601-GY

DN 80 DP0007-0801-KF DP0007-0801-TF DP0007-0801-GF DP0007-0801-GY

Table 7-3: Alignment Clamps for Flush Flanged (FFW) and Pancake (PFW) Lower Housings

Size Part number

ANSI/JIS 2-in. DP0127-2000-S1

3-in. DP0127-3000-S1

4-in. DP0127-4000-S1

DIN DN 50 DP0127-5000-S1

DN 80 DP0127-8000-S1

DN 100 DP0127-4000-S1

Table 7-4: Plugs for Flush Flanged (FFW) and Pancake (PFW) Lower Housings

Material ¼-in. ½-in.

SST 01199-7000-0502 01199-7000-0504

Alloy C-276 01199-7000-0602 01199-7000-0604

100 Emerson.com/Rosemount