Rosemount 2120 Manual: A Comprehensive Guide
This manual details the Rosemount 2120 vibrating fork level switch, covering installation, operation, troubleshooting, and safety certifications like SIL 2 & SIL 3.
The Rosemount 2120 vibrating fork level switch is a robust and dependable solution for point level detection in diverse industrial applications. Designed for simplicity and reliability, this switch offers a cost-effective method for both high and low-level alarms, as well as pump control duties.
Its core functionality revolves around tuning fork technology, utilizing a piezo-electric crystal to maintain consistent oscillation. The 2120’s design eliminates the need for external switching relays when utilizing the available 12V DC DPDT relay option.
Furthermore, the device boasts functional safety certification, achieving SIL 2 compliance with capabilities extending to SIL 3, making it suitable for safety-critical processes. This introduction sets the stage for a comprehensive understanding of the Rosemount 2120.
What is the Rosemount 2120?
The Rosemount 2120 is a vibrating fork liquid level switch engineered for continuous level detection in a wide array of processes; It’s a point level switch, meaning it indicates whether a substance is present at a specific point, not a continuous measurement of level.
This device utilizes a tuning fork principle, where a piezo-electric crystal maintains the forks’ oscillation. When the liquid covers the forks, the oscillation dampens, triggering a switch output.
Available with a convenient 12V DC DPDT relay, it simplifies wiring and reduces component count. The 2120 is designed for temperatures ranging from 40 to 302°F (40 to 150°C) and is a key component in Rosemount tank gauging systems like the 5900S.
Key Features and Benefits
The Rosemount 2120 boasts exceptional reliability and simplicity, making it ideal for demanding applications. Its key benefit lies in its robust design and minimal maintenance requirements. The integrated 12V DC DPDT relay eliminates the need for external switching relays, streamlining installation and reducing costs.
Furthermore, the device’s functional safety certification – SIL 2 with SIL 3 capability – ensures suitability for safety-critical processes. A prominent heartbeat LED provides instant visual confirmation of operation.
The tuning fork technology offers superior performance even with viscous liquids or build-up, and its compatibility with PNP/PLC systems enhances integration into existing control architectures.
Reliability and Simplicity
The Rosemount 2120 level switch excels in reliability and simplicity, offering a robust solution for diverse industrial applications. Its design minimizes moving parts, reducing potential failure points and ensuring long-term performance. Installation is straightforward, facilitated by the optional integrated 12V DC DPDT relay, which negates the need for separate switching devices.
The device’s tuning fork technology is inherently resistant to process variations and build-up, contributing to consistent and dependable operation. The clear heartbeat LED indicator provides immediate operational status, simplifying diagnostics and maintenance.
This combination of features delivers a level switch that is both easy to use and exceptionally dependable.
Applications of the Rosemount 2120
The Rosemount 2120 vibrating fork level switch is a versatile solution widely utilized across numerous industries. It’s a popular choice for both high and low level alarm systems, providing critical safety and operational control. Furthermore, the 2120 is frequently employed in pump control duties, ensuring efficient and reliable fluid management.
Its robust design makes it suitable for challenging environments and diverse media, including liquids, solids, and slurries. Common applications include chemical processing, water and wastewater treatment, food and beverage production, and power generation.
The switch’s simplicity and reliability make it ideal for critical level detection needs.
High and Low Level Alarm Systems
The Rosemount 2120 excels in high and low level alarm systems, offering dependable protection against overfill, empty conditions, and potential process upsets. Its vibrating fork technology provides quick and accurate detection, triggering alarms upon level changes. This proactive approach minimizes risks and ensures operational safety.
The switch can be configured for either normally open or normally closed operation, adapting to diverse alarm logic requirements. When integrated with control systems, the 2120 facilitates automated responses, such as pump shutdown or valve activation.
Combined with Rosemount Tank Gauging Systems (5900S), it provides a comprehensive level monitoring solution.
Pump Control Duties
The Rosemount 2120 level switch is a popular and reliable choice for pump control duties, offering a simple yet effective solution for automating liquid transfer processes. Its robust design and accurate detection capabilities ensure efficient pump operation, preventing both dry running and overflow conditions.
By directly controlling pump start/stop cycles based on pre-defined level thresholds, the 2120 optimizes fluid management and minimizes operational costs. The availability of a 12V DC DPDT relay simplifies integration with existing control systems, eliminating the need for additional switching components.
This contributes to reduced wiring complexity and improved system reliability.
Technical Specifications
The Rosemount 2120 vibrating fork level switch boasts a wide range of technical specifications designed for diverse applications. It’s engineered for operation within a temperature range of 40 to 302°F (40 to 150°C), ensuring suitability for various process conditions.
Regarding power requirements, a 12V DC DPDT relay option is available, streamlining integration and reducing external component needs. The device’s functionality relies on tuning fork technology and piezo-electric crystal oscillation for precise level detection.
Furthermore, the 2120 achieves SIL 2 certification with SIL 3 capability, meeting stringent safety standards. Detailed specifications are available within the Product Data Sheet.
Operating Temperature Range
The Rosemount 2120 level switch is specifically designed to function reliably across a broad spectrum of process temperatures. Its specified operating temperature range is 40 to 302°F (40 to 150°C), making it suitable for numerous industrial applications involving varying thermal conditions.
This wide range ensures consistent and accurate level detection whether dealing with moderately warm or relatively cool processes. Proper consideration of the process temperature within this range is crucial for optimal performance and longevity of the device.
Exceeding these limits may affect the accuracy or potentially damage the instrument; therefore, always consult the Product Data Sheet for detailed guidelines.
Power Requirements (Including 12V DC DPDT Relay)
The Rosemount 2120 level switch offers flexible power options to accommodate diverse installation needs. Notably, a key feature is the availability of a 12V DC DPDT relay version. This integrated relay eliminates the necessity for an external switching relay, simplifying wiring and reducing overall system costs.
This built-in relay provides convenient switching capabilities for direct connection to control systems or alarm circuits. Standard power requirements are typically within the 12V DC range, but it’s essential to verify the specific model’s requirements.
Always refer to the Product Data Sheet for precise voltage and current specifications to ensure proper and safe operation.
Functional Safety Certification (SIL 2 & SIL 3 Capability)
The Rosemount 2120 level switch is engineered for critical applications, boasting robust Functional Safety Certification. It is certified for SIL 2 compliance, demonstrating a high level of reliability and safety integrity. Furthermore, the device exhibits SIL 3 capability, enabling its use in even the most demanding safety instrumented systems (SIS).
This certification signifies that the 2120 meets stringent standards for hazard reduction and risk mitigation. Achieving SIL 3 capability expands the range of applications where the switch can be confidently deployed, particularly in industries where safety is paramount.
Detailed safety manuals and documentation are available for review.
Operating Principle
The Rosemount 2120 operates on a sophisticated principle utilizing a tuning fork design. At the heart of the device lies a piezo-electric crystal, which generates a consistent oscillation at the fork’s natural frequency. This continuous vibration is maintained as long as the forks are free from obstruction.
When process fluid contacts the forks, the oscillation is dampened, causing a change in the frequency. This alteration is immediately detected by the electronic module, triggering a switch output. This reliable detection method ensures accurate level sensing, even in challenging process conditions.
The system’s simplicity and lack of moving parts contribute to its exceptional reliability.
Tuning Fork Technology & Piezo-Electric Crystal Oscillation
The Rosemount 2120 leverages tuning fork technology for robust and dependable level detection. Two precisely tuned forks are constantly vibrating, driven by a piezo-electric crystal. This crystal generates a stable oscillation at the forks’ natural resonant frequency, ensuring consistent performance.
The piezo-electric effect converts electrical energy into mechanical vibration, and vice versa, allowing for sensitive detection of frequency changes. When the forks become immersed in process media, the vibration is dampened, altering the oscillation.
This frequency shift is instantly recognized by the instrument’s electronics, signaling a level change. This technology provides a highly accurate and reliable method for point level detection.
Installation Guidelines
Proper installation of the Rosemount 2120 is crucial for optimal performance. Ensure the mounting location is representative of the process and free from excessive vibration. Carefully review the wiring diagrams for correct electronic module connections, supporting both PNP and PLC configurations.
Prior to installation, verify compatibility with the process fluid and temperature range (40 to 302°F / 40 to 150°C). Tighten connections securely to prevent leaks and maintain a reliable seal.
Consider potential build-up on the forks and select a mounting orientation that minimizes accumulation. Always adhere to local safety regulations and consult the product data sheet for detailed instructions.
Wiring Diagrams & Electronic Module Connections (PNP/PLC)
The Rosemount 2120 offers flexible connectivity options, including PNP and PLC interfaces. Detailed wiring diagrams are essential for correct installation and operation. The 12V DC DPDT relay option eliminates the need for external switching relays, simplifying the wiring process.
For PNP connections, ensure proper sourcing and sinking configurations are observed. When interfacing with a PLC, verify compatibility with the PLC’s input requirements. Refer to the product documentation for specific voltage and current specifications.
Incorrect wiring can lead to malfunction or damage. Always double-check connections before applying power.
Material Safety Data Sheet (MSDS) Requirements for Hazardous Substances
Rosemount prioritizes safety; therefore, if a returned 2120 level switch has been exposed to hazardous substances as defined by OSHA, a Material Safety Data Sheet (MSDS) is mandatory. This documentation is crucial for handling, transportation, and disposal procedures, protecting personnel from potential risks.
A complete and current MSDS must accompany each returned unit that encountered hazardous materials. This sheet details the substance’s properties, hazards, safe handling practices, and emergency procedures. Failure to provide the required MSDS may result in the rejection of the returned product.
Ensure compliance with all relevant safety regulations.
Troubleshooting Common Issues
Rosemount 2120 troubleshooting often begins with the Heartbeat LED indicator. A steady light signifies normal operation, while a flashing light indicates a fault condition requiring investigation. Common issues include process buildup affecting fork vibration, leading to false readings or switch failure.
Verify proper wiring and power supply (including the 12V DC DPDT relay option). Check for obstructions or coating on the forks. If problems persist, consult the product data sheet for detailed diagnostics. Understanding build-up considerations is vital; ensure the application isn’t prone to excessive material accumulation.
Refer to the manual for specific error codes and solutions.
Heartbeat LED Indicator & Diagnostics
The Rosemount 2120 features a Heartbeat LED providing crucial operational status at a glance. A consistently lit LED confirms normal functionality and reliable oscillation of the tuning fork. However, a flashing LED signals a detected issue, prompting diagnostic investigation.
Diagnostic procedures involve verifying power supply integrity, checking wiring connections (especially with the 12V DC DPDT relay), and inspecting for process buildup on the forks. The manual details specific flash codes, each corresponding to a unique fault condition.
Understanding these codes allows for targeted troubleshooting, minimizing downtime and ensuring accurate level detection.
Build-Up Considerations & Examples
The Rosemount 2120’s performance can be affected by process material buildup on the vibrating forks. While designed for robust operation, excessive accumulation dampens oscillation, leading to false readings or switch failure. The manual emphasizes regular inspection for buildup, particularly in sticky or coating applications.
Examples illustrate acceptable versus problematic buildup scenarios. Minimal, evenly distributed coating is often tolerable, but significant, uneven deposits impede fork movement.
Preventative measures include selecting appropriate fork materials and considering process modifications to reduce adhesion. Proper installation and periodic cleaning, as outlined in the maintenance section, are crucial for sustained accuracy.
Product Data Sheet Information
The Rosemount 2120 Product Data Sheet is a vital resource providing comprehensive specifications and details beyond this manual. It contains critical information like detailed dimensions, process connection options, and enclosure types. Users can access it via the Rosemount website for the most current version.
Key data includes operating temperature ranges (40 to 302°F / 40 to 150°C), power requirements – including the 12V DC DPDT relay option – and material certifications. The sheet also outlines compatibility with Rosemount Tank Gauging Systems (5900S) for integrated level monitoring.
Always refer to the data sheet for precise specifications before installation or maintenance.
Accessing and Interpreting the Product Data Sheet
To access the Rosemount 2120 Product Data Sheet, navigate to the official Rosemount website (www.rosemount.com) and search for “2120 Product Data Sheet.” Download the latest revision for accurate specifications.
Interpreting the sheet requires attention to detail. Pay close attention to sections detailing process compatibility, ensuring materials suit your application. Understand the electrical specifications, particularly if utilizing the 12V DC DPDT relay.
Review the dimensional drawings for proper fitment. Note the operating temperature and pressure limits. The sheet also clarifies functional safety capabilities (SIL 2/3) and provides build-up considerations, aiding in optimal performance and reliable level detection.
Maintenance and Calibration
Rosemount 2120 level switches require minimal maintenance. Regularly inspect for process buildup, as this can affect performance. Observe the Heartbeat LED indicator; a consistent signal confirms proper oscillation.
Calibration is generally not required as the switch operates based on frequency detection. However, verify functionality after initial installation and following significant process changes.
If buildup occurs, clean the forks carefully, avoiding abrasive materials. Ensure wiring connections remain secure. Review the Product Data Sheet for specific material compatibility guidelines during cleaning. Proper maintenance ensures continued reliable operation and accurate level detection.
Recommended Maintenance Procedures
Regular visual inspections are key: check for physical damage, corrosion, and secure wiring connections. Monitor the Heartbeat LED – a flashing or absent signal indicates a potential issue.
Address process buildup promptly. Gentle cleaning with a compatible solvent is preferred; avoid abrasive cleaners. Document all maintenance activities.
Periodically verify switch functionality by simulating level changes. If hazardous substances are present, adhere to MSDS guidelines during maintenance. Consult the Product Data Sheet for specific material compatibility. Following these procedures ensures optimal performance and extends the lifespan of your Rosemount 2120 level switch.
Related Rosemount Products
For comprehensive tank management, explore the Rosemount Tank Gauging Systems, specifically the 5900S series. These systems offer advanced level, temperature, and interface measurement capabilities, complementing the point level detection provided by the 2120.
The 5900S integrates seamlessly with the 2120 for enhanced process control and inventory management. Rosemount offers a broad portfolio of instrumentation, including pressure, flow, and temperature transmitters, designed to optimize your entire process.
Visit rosemount.com to discover the full range of products and solutions. Utilizing these integrated systems maximizes efficiency and reliability within your operations.
Rosemount Tank Gauging Systems (5900S)
The Rosemount 5900S represents a significant advancement in tank inventory management and provides a complete solution beyond simple point level detection. It integrates level, temperature, and interface measurements for precise volume calculations and enhanced operational insights.
This system offers features like radar level measurement, multi-point temperature sensing, and sophisticated algorithms to compensate for changing conditions. The 5900S is often used in conjunction with the Rosemount 2120 for high and low-level alarms, creating a robust and reliable tank monitoring solution.
Access detailed product data sheets on rosemount.com to explore the full capabilities of the 5900S and its integration possibilities.