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00809-0100-4741 English Rev. AA Model 3095 ™ Multivariable Level Controller P r o d u c t D i s c o n t i n u e d...
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Within the United States, Rosemount Inc. has two toll-free assistance numbers. Customer Central: 1-800-999-9307 ( 7:00 a.m. to 7:00 p.m. CST) Technical support, quoting, and order-related questions.
Table of Contents IMPORTANT Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.
Section Introduction USING THIS MANUAL This manual provides installation, configuration, troubleshooting, and ® maintenance instructions for the Rosemount Model 3095 ™ Multivariable Level Controller and for its operation with the Model ® 275 HART Communicator. The rest of this manual consists of the following sections: Section 2: Level Controller Overview and Installation introduces the Level Controller and explains how to install it.
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™ Rosemount Model 3095 Multivariable Level Controller...
Section Level Controller Overview and Installation This section contains overview information about the Model 3095 Multivariable Level Controller system, an installation flowchart showing the sequence of Level Controller installation and wiring, installation considerations, and the field installation procedure. SAFETY MESSAGES...
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High voltage that may be present on leads could cause electrical shock: • Avoid contact with leads and terminals. LEVEL CONTROLLER The Model 3095 Multivariable Level Controller is a multivariable, microprocessor-based, analog and digital output device for use in single OVERVIEW loop, level process applications.
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Level Controller Overview and Installation Figure 2-1 illustrates a single loop level control system. The single control loop consists of: • A level process. • A Level Controller with a 4–20 mA control output signal. • An electrical-to-pneumatic converting device such as a 3311 I/P. •...
™ Rosemount Model 3095 Multivariable Level Controller Review the flowchart shown in Figure 2-3 before you begin installing BEFORE YOU BEGIN the Level Controller. This flowchart summarizes the tasks you should complete to ensure a successful installation. FIGURE 2-3. Level Controller Installation Flowchart.
BECOMING FAMILIAR Figure 2-1 on page 2-2 illustrates a typical Level Controller installation site; Figure 2-4 shows the exploded view of the Model 3095 Level WITH THE LEVEL Controller. Major components of the Level Controller system and the CONTROLLER...
Level Controller Overview and Installation BENCH CONFIGURATION Before mounting the Level Controller in the field, the controller can be configured on the bench using a Model 275 HART Communicator. NOTE For bench configuration, a jumper must be installed across the output terminals.
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™ Rosemount Model 3095 Multivariable Level Controller Use the following steps to change the jumper settings: 1. If the controller is installed, secure the loop and remove power. 2. Remove the housing cover opposite the field terminal side. Do not remove the instrument cover in explosive atmospheres when the circuit is alive.
Level Controller Overview and Installation GENERAL INSTALLATION The accuracy of a level control measurement depends upon proper installation of the controller and impulse piping. The piping between CONSIDERATIONS the process and the controller must accurately transfer the pressure in order to obtain accurate measurements. Mount the controller close to the process and use a minimum of impulse piping to achieve best accuracy.
The following guidelines have been established to ensure a tight flange, adapter, or manifold seal. Use only bolts supplied with the controller or sold by Rosemount Inc. as a spare part to the Level Controller. Unauthorized parts can affect product performance and may impair the protection provided by the equipment.
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Level Controller Overview and Installation FIGURE 2-7. Mounting Configurations and Optional Mounting Accessories. 3.54 6.25 LEVEL FLANGE (90) (159) PIPE MOUNTED WITH OPTIONAL BRACKET ONE DIAPHRAGM SEAL INTEGRAL MOUNT MANIFOLD TWO DIAPHRAGM SEALS NOTE Dimensions are in inches (millimeters). 2-11...
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™ Rosemount Model 3095 Multivariable Level Controller FIGURE 2-8. Coplanar Mounting Bolts and Bolting Configurations for Coplanar Flange. Size in. Description Qty. (mm) Flange bolts 1.75 (44) Flange/adapter bolts 2.88 (73) Manifold/flange bolts 2.25 (57) 1.75 (44) x 4 CONTROLLER WITH FLANGE BOLTS 2.25 (57) x 4...
Level Controller Overview and Installation EXAMPLE Figure 2-9 illustrates example installations for the Model 3095 Level Controller. “H” and “L” in the examples correspond to the H and L INSTALLATIONS stamped on the Level Controller sensor module and indicate which way the controller is to be installed.
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™ Rosemount Model 3095 Multivariable Level Controller FIGURE 2-9. Example Installations. Controller Height = C Controller Height = A Controller Height = -B OPEN TANK OPEN TANK WITH BUBBLER Controller Height = A Controller Height = E + D Controller Height = -B...
Level Controller Overview and Installation ™ TAP CONSIDERATIONS When the Level Controller is oriented on its side, the Coplanar flange may be mounted to ensure proper venting or draining. Mount the flange so that the drain/vent connections are on the top half of the flange for liquid service.
Mount the Level Controller to minimize ambient temperature changes. ENVIRONMENTAL Section 6: Level Controller Specifications and Reference Data CONSIDERATIONS lists the Model 3095 temperature operating limits. Mount the Level Controller to avoid vibration and mechanical shock, and to avoid external contact with corrosive materials. Access Requirements When choosing an installation location and position, take into account the need for access to the controller.
, or 2¼ inches (51, 54, or 57 mm) may be obtained. There are two styles of Rosemount flange adapters, each requiring a unique O-ring, as shown below. Each flange adapter is distinguished by its unique groove. Use only the O-ring designed to seal with the corresponding flange adapter.
™ Rosemount Model 3095 Multivariable Level Controller The signal terminals are located in a compartment of the electronics ELECTRICAL housing separate from the controller electronics. Figure 2-11 illustrates CONSIDERATIONS power supply load limitations for the controller. The dc power supply should provide power with less than 2% ripple.
Only use bolts supplied with the Level Controller Install Bolts or sold by Rosemount Inc. as a spare part to the Level Controller. Unauthorized parts can affect product performance and may impair the protection provided by the equipment.
™ Rosemount Model 3095 Multivariable Level Controller The external RTD assembly is optional and not required for Level Install RTD Assembly Controller operation. The RTD Assembly allows you to read temperatures as a HART variable only. To install the Series 68 or Series 78 RTD Assembly: 1.
Rubber Bushing and Connector ¾ to ½–in. NPT Adapter (Slide stop to edge (Connects to Model 3095 MV) (Screws into RTD Connection Head) of armored cable) Check for Leaks Check all process penetrations for leaks. Process leaks can cause death or serious injury.
™ Rosemount Model 3095 Multivariable Level Controller 5. Plug and seal unused conduit connections on the Level Controller housing to avoid moisture accumulation in the terminal side of the housing. The unused conduit opening on the controller housing must be plugged and sealed to meet explosion-proof requirements.
This section explains the operation, design, functionality and options of the Level Controller. LEVEL VARIABLES The 3095 Level Controller measures differential pressure (DP) and uses that measurement to calculate process level. The level calculation is AND VALUES completed by the sensor microprocessor using the following equation: ÷...
±0.075% accuracy for the DP sensor. There is no need to calibrate the DP sensor. All Model 3095 Level Controllers are factory-calibrated from –LRL to +URL. The Level Controller uses the DP input to calculate the Primary Variable, which is Level.
Level Controller Configuration PID CONTROLLER The Model 3095 Multivariable Level Controller features a series-type controller for Proportional (P), Proportional and Derivative (PD), DESCRIPTION Proportional and Integral (PI), and Proportional-Integral-Derivative AND DETAILS (PID) control modes. The controller algorithm: • Sets the control type (PID) •...
AUTO = Automatic Mode ALL = All Modes AUTOTUNING The Model 3095 Level Controller is available with Rosemount’s Autotuning algorithm, which accurately determines the optimal tuning parameters for a level control loop without operator interaction. The Autotuner algorithm is specified by the “CC” option code in the level controller ordering table.
Level Controller Configuration Why Autotune? A poorly tuned loop results in poor process level control and excess stress on the control element. Figure 3-3 illustrates the relationship between the Control Signal percentage and the Level (or, percent of tank height) of a poorly tuned loop. FIGURE 3-3.
™ Rosemount Model 3095 Multivariable Level Controller The Level Controller Autotuner works without any pre-tuning of the Autotuner Operation control loop. The Autotuner functions under any condition, and does not require a steady-state process. Use the Model 275 HART Communicator or Asset Management...
Level Controller Configuration ADAPTIVE BIAS CONTROL Rosemount’s Adaptive Bias Control algorithm is a standard offering with the Model 3095 Level Controller. The Adaptive Bias Control (ABC) algorithm is used when operating in Proportional (P) or Proportional-Derivative (PD) modes. Adaptive Bias Control eliminates limit cycling caused by the control element’s attempts to adjust the...
™ Rosemount Model 3095 Multivariable Level Controller The Model 3095 Level Controller is available with an optional Local LOCAL OPERATOR Operator Interface (LOI), which acts as a local indicator and operator INTERFACE interface. The LOI can be configured with the Model 275 HART communicator, AMS, or locally through a set series of adjustments to the Z and S buttons located at the top of the Level Controller housing.
The Mode Shed option allows the Level Controller to maintain control of the process loop in the event of measuring sensor failure. The Model 3095 Level Controller continuously completes diagnostics of the multi-variable sensor and the controller. If the diagnostics determines that the level measurement is in a failed condition, the controller allows the user to select a “mode shed,”...
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™ Rosemount Model 3095 Multivariable Level Controller 3-10...
Section Level Controller Configuration This section describes the tasks involved in configuring the Model 3095 Level Controller. CONFIGURATION Configuring the Level Controller consists of four major tasks: OVERVIEW 1. Set Up the Level Calculation: These tasks set up the Level Controller for the specific process, and include setting process density, level units, controller height, and damping.
The control signal remains fixed at the value when OOS mode was entered until the OOS mode is exited. The Model 3095 Level Controller is shipped in OOS mode. Before configuring the controller, ensure that the controller is in the OOS mode (Out-of-Service).
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Level Controller Configuration FIGURE 4-1. Guidelines for Determining Controller Height. Controller Height = C Controller Height = A Controller Height = -B OPEN TANK OPEN TANK WITH BUBBLER Controller Height = A Controller Height = E + D Controller Height = -B CLOSED TANK WITH DRY LEG CLOSED TANK WITH WET LEG,...
™ Rosemount Model 3095 Multivariable Level Controller Determining the controller height varies according to the installation Set Controller Height type and controller location (see Figure 3-3). Note that the controller height units are determined by the units selected for the level units.
Level Controller Configuration CONFIGURE THE These tasks configure how you want to control the liquid level process. CONTROLLER Set Range Values The Level Controller range is determined by user-entered range points: Lower Range Value (LRV) and Upper Range Value (URV). The level measurement span (URV –...
™ Rosemount Model 3095 Multivariable Level Controller Adaptive Bias Control (ABC) provides a method to create a steady state Adaptive Bias Control deadband for the level controller. Once the desired level is obtained, the (ABC) Settings controller could repeatedly open and close the valve for very small differences between the setpoint and the actual tank level.
Level Controller Configuration Set Mode Shed Options See page 3-9 for details about Mode Shed. (Failure Condition) Shed Action Shed Action selects whether the controller remains at its present value (hold output) or goes to the shed output value if the Level Controller HART Comm.
™ Rosemount Model 3095 Multivariable Level Controller Output limits determine the allowable minimum and maximum control Set Auto Output Limits output values when the controller is in automatic mode. Output Hi Limit For example, the minimum allowable control output may be 7.2 mA (20% of valve stroke) and the maximum allowable control output may HART Comm.
Level Controller Configuration Additional Options The following options are not required for Level Controller operation. Setpoint Tracking When enabled and in manual mode, setpoint tracking automatically changes the setpoint to the measured level value. This option is valid in HART Comm. 6, 2, 2, 6 manual (MAN) mode only.
™ Rosemount Model 3095 Multivariable Level Controller Performing a level trim is recommended for all field installations. Level PERFORM A LEVEL TRIM trim can be done in OOS and MAN mode; it cannot be done in AUTO mode (see page 4-2).
Level Controller Configuration TUNE THE LOOP At this point, you should tune the loop according to industry accepted practices. See “Autotuner” on page 4-12 if you have purchased the Autotune feature (Option Code CC). If you do not have Autotune capabilities, follow the instructions in “Set Control Tuning.”...
™ Rosemount Model 3095 Multivariable Level Controller This selection sets the controller bias value. (This parameter is Manual Bias sometimes called manual bias or manual reset.) HART Comm. 6, 2, 1, 6 This value is only used if the Control Type is set to P or PD. This setting is used as the controller bias term for the P or PD algorithm equations.
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Level Controller Configuration Alpha is the loop performance factor used to adjust the loop response. Alpha A lower value results in more aggressive control while a higher value HART Comm. 6, 2, 4, 3, 3 results in more conservative control. Once the system has been autotuned, the Alpha parameter may be revised and new tuning parameters will be calculated.
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™ Rosemount Model 3095 Multivariable Level Controller This selection sets the maximum time allowed for the autotuning Time Limit procedure to complete. If tuning does not complete within this time HART Comm. 6, 2, 4, 3, 5 frame, tuning will cease and a message is displayed indicating that tuning failed.
Section Troubleshooting and Maintenance This section describes troubleshooting and maintenance tasks associated with the Model 3095 Level Controller. These include Level Controller device maintenance procedures and field replaceable part procedures. Use only the procedures and new parts specifically referenced in this manual.
™ Rosemount Model 3095 Multivariable Level Controller Process leaks could result in death or serious injury: • Install only the flange adapter O-ring designed to seal with the corresponding flange adapter. High voltage that may be present on leads could cause electrical shock: •...
Troubleshooting and Maintenance Interpreting Level If an alarm or error condition exists in the Level Controller, it will be displayed when the next Model 275 next communicates with the device. Controller Alarms and Error Conditions Table 5-2 explains critical alarms, Table 5-3 lists overrange conditions, and Table 5-4 identifies sensor limits.
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™ Rosemount Model 3095 Multivariable Level Controller Overrange conditions are typically caused by an error in which the Overrange Conditions sensor or level measurements have reached an overrange condition where substitute values are being used. TABLE 5-3. Corrective Action: Overrange Conditions.
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Troubleshooting and Maintenance Use a Model 275 HART Communicator to display the current process Unexpected Process Variable (PV) Readings variables. Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices.
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SENSING ELEMENT • The sensing element is not field repairable and must be replaced if found to be defective. Check for obvious defects, such as a punctured isolating diaphragm or fill fluid loss, and contact your nearest Rosemount Service Center.
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SENSING ELEMENT • The sensing element is not field repairable and must be replaced if found to be defective. Check for obvious defects, such as a punctured isolating diaphragm or fill fluid loss, and contact your nearest Rosemount Service Center.
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SENSING ELEMENT • The sensing element is not field repairable and must be replaced if found to be defective. Check for obvious defects, such as a punctured isolating diaphragm or fill fluid loss, and contact your nearest Rosemount Service Center.
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• The sensing element is not field repairable and must be replaced if found to be defective. Check for obvious defects, such as a punctured isolating diaphragm or fill fluid loss, and contact your nearest Rosemount Service Center. • Confirm that the electronics housing is properly sealed against moisture.
™ Rosemount Model 3095 Multivariable Level Controller Read the following information carefully before disassembling a device. DISASSEMBLY General information concerning the process sensor body and electrical PROCEDURES housing follow. Figure 2-4 on page 2-6 shows an exploded view of the Level Controller.
Troubleshooting and Maintenance Electrical Housing Electrical connections are located in a compartment identified as FIELD TERMINALS on the electronics housing. Unscrew the cover on the Field Terminal side to access the signal terminal block. Remove the signal terminal block by loosening the two small screws located at the 9 o'clock and 4 o'clock positions, then pulling the terminal block straight out to disconnect the block from the post connectors.
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™ Rosemount Model 3095 Multivariable Level Controller 4. Disconnect the sensor module ribbon cable to release the electronics board from the device. 5. Carefully tuck the cable connector completely inside the internal shroud. The shroud protects the cable from damage that might occur when the housing is rotated.
Troubleshooting and Maintenance Remove the Sensor Module from the Electronics Housing 6. Loosen the housing rotation set screw with a 5/64-inch hex wrench and back off one full turn. CAUTION Before removing the sensor module from the electronics housing, disconnect the electronics board power cable from the sensor module. This will prevent damage to the sensor module ribbon cable.
™ Rosemount Model 3095 Multivariable Level Controller Follow these procedures carefully to ensure proper reassembly: REASSEMBLY PROCEDURES Attach the Sensor Module 1. Inspect all cover and housing (non-process-wetted) O-rings and replace if necessary. Lightly lubricate with silicone to ensure a to the Electronics Housing good seal.
Troubleshooting and Maintenance Attach the Electronics Board 1. Remove the cable connector from its position inside the internal shroud, and attach the cable to the electronics board. 2. Align the post-receptacle connectors with the posts inside the electronics housing. 3. Insert the electronics board into the housing and tighten the captive mounting screws.
™ Rosemount Model 3095 Multivariable Level Controller 1. Visually inspect the Teflon sensor module O-rings. If the O-rings Reassemble the Process are undamaged, they can be re-used. If the O-rings show signs of Sensor Body damage, such as nicks or cuts, or if there is any doubt about their sealing ability, replace them with new O-rings.
To expedite the return process outside the United States, contact the nearest Rosemount representative. Within the United States, call the Rosemount National 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.
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™ Rosemount Model 3095 Multivariable Level Controller 5-18...
Section Level Controller Specifications and Reference Data FUNCTIONAL Service Liquid level measurement and control. SPECIFICATIONS Differential Sensor Ranges Code 2: 0–2.5 to 0–250 inH O (0–0.62 to 0–62.2 kPa). Code 3: 0–10 to 0–830 inH O (0–2.48 to 0–206 kPa). Limits Code 2: –250 to 250 inH O (–62.2 to 62.2 kPa).
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RTD connection for Class I, Division 2, Groups A, B, C, and D. Approved for Class I, Division 2, Groups A, B, C, and D. Install in accordance with Rosemount Drawing 03095-1024. Combination of Approval Code C and the following: Intrinsically Safe for Class I, Division 1, Groups A, B, C, and D when installed in accordance with Rosemount drawing 03095-1021.
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Specifications and Reference Data BASEEFA Type N Certification G Ex N IIC T5 (T = –45 °C to 40 °C). Ex N IIC T4 (T = –45 °C to 70 °C). 4-Pin Connector Connection Parameters. Output Voltage = 35 V. Output Current = 13 mA.
PT100 RTD conforming to IEC 751 Class B, which has a nominal resistance of 100 ohms at 0 °C and ∝ = 0.00385. Examples of compatible RTDs include the Rosemount Series 68 and 78 RTD Temperature Sensors.
™ Rosemount Model 3095 Multivariable Level Controller ORDERING INFORMATION Model Product Description 3095C Level Controller Code Output 4–20 mA with Digital Signal Based on HART Protocol Code Differential Pressure Range 0–2.5 to 0–250 inH O (0–0.62 to 0–62.2 kPa) 0–10 to 0–830 inH O (0–2.48 to 0–206 kPa)
The HART Tri-Loop accepts the Level Controller digital signal and converts it to three independent 4–20 mA analog signals. Any of the Model 3095 Level Controller process variables (DP, PT, level, or control output) can be provided via the Tri-Loop.
INTRODUCTION This appendix provides an introduction to using the Model 275 HART Communicator with a Model 3095 Multivariable Level Controller. It describes the HART Communicator keypad, connections, menu structure, and Fast Key sequence features. It also includes a menu tree and a table of Fast Key sequences that apply specifically to the Level Controller.
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Rosemount Model 3095 Multivariable Level Controller FIGURE A-1. HART Communicator Menu Tree for the Level Controller. 1 Density Unit 1 MORE LEVEL SETUP 1 PROCESS 2 Density 2 Level 3 Gravity VARIABLES 1 LEVEL 3 Level Unit 4 Transmitter Height...
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HART Communicator TABLE A-1. HART Fast Key Sequences for the Level Controller. HART Communicator HART Communicator Function Function Fast Key Sequences Fast Key Sequences ABC Static Error 6, 2, 1, 9 LV Damping 6, 1, 1, 5 AO Alrm typ 6, 4, 3, 8 LV LRL 6, 1, 1, 4, 5...
Rosemount Model 3095 Multivariable Level Controller COMMUNICATOR KEYS The keys of the HART Commuincator include action, function, alphanumeric, and shift keys FIGURE A-4. The HART Communicator. Function Keys Action Keys Alphanumeric Keys Shift Keys Action Keys As shown in Figure A-4, the action keys are the six blue, white, and black keys located above the alphanumeric keys.
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HART Communicator Function Keys Use the four software-defined function keys, located below the LCD, to perform software functions. On any given menu, the label appearing above a function key indicates the function of that key for the current menu. As you move among menus, different function key labels appear over the four keys.
Rosemount Model 3095 Multivariable Level Controller MENUS AND FUNCTIONS The HART Communicator is a menu driven system. Each screen provides a menu of options that can be selected or provides direction for input of data, warnings, messages, or other instructions.
HART Communicator Online Menu The Online Menu can be selected from the Main Menu or it appears automatically if the HART Communicator is connected to an active loop and can detect an operating Level Controller. Online mode is used for direct evaluation of a particular meter, re- configuration, changing parameters, maintenance, and other functions.
Rosemount Model 3095 Multivariable Level Controller Diagnostic Messages The following pages contain a list of messages used by the Model 275 HART Communicator (HC) and their corresponding descriptions. Variable parameters within the text of a message are indicated with <variable parameter>.
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HART Communicator Message Description Mark as read only Asks whether the user should be allowed to edit the variable from variable on hotkey the hotkey menu if the item being added to the hotkey menu is a menu? variable. No device configuration There is no configuration saved in memory available to re- in configuration memory configure off-line or transfer to a device.
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Rosemount Model 3095 Multivariable Level Controller Message Description There is unsent data. Press YES to send unsent data and turn the HC off. Press NO to Send it before shutting turn the HC off and lose the unsent data. off?
Appendix Level Controller Accessories and Options Options and accessories available with the Model 3095 Level Controller can facilitate installation and enhance operation and ease of use. Instructions and procedures in this section may require special SAFETY MESSAGES precautions to ensure the safety of the personnel performing the operations.
Transient protection terminal blocks can be ordered factory-installed, or they can be ordered as a spare part to retrofit existing Model 3095 Level Controllers already in the field. The Rosemount spare part number for the transient protection terminal block is 03095-0964-0002.
External Ground Assembly. External Ground Assembly OPTIONS The Model 3095 Level Controller can be supplied with auto-tuning for Auto-Tuning level control. Auto-tuning determines the process parameters and (Option Code CC) applies tuning rules to determine the optimal tuning parameters (gain, reset, rate, and bias) for the PID equation.
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Rosemount Model 3095 Multivariable Level Controller...
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Appendix Approval Drawings Model 3095MV Explosion-Proof Installation Drawing, Factory Mutual (Drawing Number 03095-1025, Rev G) Page C-2 Index of I.S. F.M. for 3095 (Drawing Numbers 03095-1020, Rev AA) Page C-5 Model 3095MV Explosion-Proof Installation Drawing, Canadian Standards Association (Drawing Number 03095-1024, Rev D) Page C-11 Index of I.S.
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