Rosemount 2160 Wireless Vibrating Fork Liquid Level Switch Owner's manual

Brand: Rosemount

Model: 2160 Wireless Vibrating Fork Liquid Level Switch

Category: Networking

Type: Owner's manual

www.rosemount.com

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160 Wireless

Vibrating Fork Liquid Level Switch

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

www.rosemount.com

Rosemount 2160 Wireless

Vibrating Fork Liquid Level Switch

Rosemount 2160 Hardware Revision 2

HART

Device Revision 2

Field Communicator Field Device Dev v1, DD v2

NOTICE

Read this manual before working with the product. For personal and system safety, and for

optimum product performance, make sure you thoroughly understand the contents before

installing, using, or maintaining this product.

For technical assistance, contacts are listed below:

Customer Central

Technical support, quoting, and order-related questions.

United States: 1 800 999 9307 (7:00 am to 7:00 pm CST)

Asia Pacific: 65 777 8211

Europe/ Middle East/ Africa: 49 (8153) 9390

North American Response Center

Equipment service needs.

1 800 654 7768 (24 hours—includes Canada)

Outside of these areas, contact your local Emerson Process Management representative.

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.

For information on Rosemount nuclear-qualified products, contact an Emerson Process

Management Sales Representative.

Replacement equipment or spare parts not approved by Emerson for use as spare

parts could reduce the capabilities of the 2160, and may render the instrument

dangerous.

• Use spare parts supplied or sold by Emerson

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

The power module with the wireless unit contains two “C” size primary lithium/thionyl chloride

batteries. Each battery contains approximately 2.5 grams of lithium, for a total of 5 grams in each

pack. Under normal conditions, the battery materials are self-contained and are not reactive as

long as the batteries and the pack integrity are maintained. Care should be taken to prevent

thermal, electrical or mechanical damage. Contacts should be protected to prevent premature

discharge.

Battery hazards remain when cells are discharged.

Batteries should be stored in a clean and dry area. For maximum battery life, storage temperature

should not exceed 86 °F (30 °C).

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

• The Rosemount 2160 is a wireless liquid level switch. It must be installed, connected,

commissioned, operated, and maintained by suitably qualified personnel only, observing

any national and local requirements that may apply

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

protection provided by the equipment

Explosions could result in death or serious injury

• Installation of the 2160 in a hazardous environment must be in accordance with the

appropriate local, national, and international standards, codes, and practices.

Please review the approvals section of the 2160 Reference Manual for any restrictions

associated with an installation

• Before connecting a Field Communicator in an explosive atmosphere, ensure the

installation is in accordance with intrinsically safe or non-incendive field wiring practices

• Verify that the operating atmosphere of the level switch is consistent with the

appropriate hazardous locations certifications

External Surface may be hot

• Care must be taken to avoid possible burns

Process leaks could result in death or serious injury

• Install and tighten process connectors before applying pressure

• Do not attempt to loosen or remove process connectors while the 2160 is in service

Electrical shock could cause death or serious injury

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

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

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

• Make sure that power to the 2160 is off while making connections

Operation is subject to the following two conditions: (1) This device may not cause

harmful interference, and (2) this device must accept any interference received,

including interference that may cause undesired operation.

NOTICE

Shipping considerations for wireless products:

The unit was shipped to you without the Black Power Module installed. Please remove the

power module prior to shipping.

Each power module contains two “C” size primary lithium batteries. These batteries are

regulated in transportation by the U. S. Department of Transportation, and are also covered

by IATA (International Air Transport Association), ICAO (International Civil Aviation

Organization), and ARD (European Ground Transportation of Dangerous Goods). It is the

responsibility of the shipper to ensure compliance with these or any other local requirements.

Please consult current regulations and requirements before shipping.

Reference Manual

00809-0100-4160, Rev AD

January 2013

III

Rosemount 2160

SECTION 1

OVERVIEW

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

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Definitions And Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

About the 2160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Measurement Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Short Fork Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Rosemount 2160 Application Examples . . . . . . . . . . . . . . . . . . . . . . . .1-5

Extended Fork Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Switchpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Service Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Product Recycling/Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

SECTION 2

CONFIGURATION

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

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Required Bench Top Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Squawk Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

AMS Wireless Configurator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Field Communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Device Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Join to Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Configure Update Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Remove Black Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Review Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Review Device Identification Information . . . . . . . . . . . . . . . . . . . . . . .2-8

Review Radio Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Check Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Sensor Output Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Media Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Write Protect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Data Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

LCD Display Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Detailed Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Configure Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Sensor Stabilization Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Measurement Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Allowable Change In Dry Fork Frequency. . . . . . . . . . . . . . . . . . . . . .2-13

Table Of Contents

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

Sensor Fault Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Diagnostics and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Load User Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Join Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Communication Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Join Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Available Neighbors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Join Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Sensor Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Uncompensated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Sensor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Dry Fork Frequency / Switch Points . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Sensor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Dry Fork Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Sensor Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Calibrate Dry Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Sensor Calibration Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Calibration Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Reset Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Sensor Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Fork Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Advanced Functions for HART Protocol . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Saving, Recalling, and Cloning Configuration Data . . . . . . . . . . . . . .2-24

SECTION 3

INSTALLATION

Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Wireless Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Installing the LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Correct Fork Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Tightening the 2160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Insulation (2160***E Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

SECTION 4

COMMISSIONING

Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Verify Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Local Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Smart Wireless Gateway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

AMS Wireless Configurator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

How to Use Squawk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

SECTION 5

OPERATION AND

MAINTENANCE

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

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LCD Screen Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Startup Screen Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Diagnostic Button Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Network Diagnostic Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Device Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

APPENDIX A

SPECIFICATIONS AND

REFERENCE DATA

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Physical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Dimensional Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

2160 Thread Mounting (Standard Length) . . . . . . . . . . . . . . . . . . . . . .A-6

2160 Thread Mounting (Extended Length) . . . . . . . . . . . . . . . . . . . . . .A-7

2160 Flange Mounting (Standard Length) . . . . . . . . . . . . . . . . . . . . . .A-8

2160 Flange Mounting (Extended Length) . . . . . . . . . . . . . . . . . . . . . .A-9

2160 Hygienic Fitting (Standard Length). . . . . . . . . . . . . . . . . . . . . . .A-10

2160 Hygienic Fitting (Extended Length) . . . . . . . . . . . . . . . . . . . . . .A-12

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Spare Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-15

APPENDIX B PRODUCT

CERTIFICATIONS

European Directive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Telecommunication Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

FCC and IC Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Canadian Registration Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Hazardous Locations Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

American and Canadian Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

European Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Rest Of The World Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

www.rosemount.com

Section 1 Overview

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

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-2

Definitions And Abbreviations . . . . . . . . . . . . . . . . . . . . .page 1-2

Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-2

About the 2160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-3

Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-9

Product Recycling/Disposal . . . . . . . . . . . . . . . . . . . . . . .page 1-9

SAFETY MESSAGES 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 caution symbol ( ). The

external hot surface symbol ( ) is used when a surface is hot and care must

be taken to avoid possible burns. If there is a risk of an electrical shock the

( ) symbol is used. Refer to the safety messages listed at the beginning of

each section before performing an operation preceded by this symbol.

Warnings

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

• The Rosemount 2160 is a wireless liquid level switch. It must be installed, connected,

commissioned, operated, and maintained by suitably qualified personnel only, observing

any national and local requirements that may apply

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

protection provided by the equipment

Explosions could result in death or serious injury

• Installation of the 2160 in a hazardous environment must be in accordance with the

appropriate local, national, and international standards, codes, and practices.

Please review the approvals section of the 2160 Reference Manual for any restrictions

associated with an installation

• Before connecting a Field Communicator in an explosive atmosphere, ensure the

installation is in accordance with intrinsically safe or non-incendive field wiring practices

• Verify that the operating atmosphere of the level switch is consistent with the

appropriate hazardous locations certifications

External Surface may be hot

• Care must be taken to avoid possible burns

Process leaks could result in death or serious injury

• Install and tighten process connectors before applying pressure

• Do not attempt to loosen or remove process connectors while the 2160 is in service

Electrical shock could cause death or serious injury

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

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

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

• Make sure that power to the 2160 is off while making connections

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January 2013

Rosemount 2160

1-2

USING THIS MANUAL This manual provides information on installing, operating, and maintaining the

Rosemount 2160 Wireless liquid level switch.

• Section 2: Configuration provides instruction on commissioning and

operating the Rosemount 2160. Information on software functions,

configuration parameters, and online variables is also included.

• Section 3: Installation contains mechanical and electrical installation

instructions.

• Section 4: Commissioning contains techniques for properly

commissioning the device.

• Section 5: Operation and Maintenance contains operation and

maintenance techniques.

• Appendix A: Specifications and Reference Data supplies reference

and specification data, as well as ordering information.

• Appendix B: Product Certifications contains approval information.

DEFINITIONS AND

ABBREVIATIONS

The following definitions are used in this manual:

The following abbreviations are used in this manual:

MODELS COVERED The following models of the Rosemount 2160 Wireless liquid level switch are

covered in this manual:

• The standard temperature 2160***S

• The extreme temperature 2160***E

Dry The 2160 fork (sensor) is submerged to a depth of less than 0.5 in. (13 mm)

Wet The 2160 fork (sensor) is submerged to a depth of greater than 0.5 in. (13 mm)

Fault The fork frequency is outside the normal frequency band

Normal

Mode

The operating mode in which the 2160 considers a 0 Hz fork frequency to

represent a Wet condition (and not a Fault)

Enhanced

Mode

The operating mode in which the 2160 considers a 0 Hz fork frequency to

represent a fault condition

DD Device Description

IS Intrinsically Safe

PV Primary Value or Process Value

SV Secondary Value

TV Tertiary Value (Third Value)

QV Quaternary Value (Fourth Value)

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January 2013

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Rosemount 2160

ABOUT THE 2160

Switch Overview The Rosemount 2160 Wireless is a wireless liquid point level switch.

Based on vibrating short fork technology, the 2160 is suitable for virtually all

liquid applications:

• Virtually unaffected by flow, bubbles, turbulence, foam, vibration, solids

content, coating, properties of the liquid, and product variations

• Operation in extreme temperatures of –94 to 500 °F (–70 to 260 °C)

• No need for calibration and requires minimum installation procedures

• No moving parts or crevices means virtually no maintenance

• Electronic self-checking and condition monitoring

• Programmable switching delay for turbulent or splashing applications

• Short fork length with extensions up to 118 in. (3 m)

• “Fast Drip” fork design gives quick response time

• General area and Intrinsically Safe options

This combination of features makes the 2160 an ideal choice for a wide

variety of challenging applications in the chemical, power generation, and oil

and gas industries.

Figure 1-1. Features of the 2160

Wetted Materials in 316/316L SST (1.4401/1.4404), or

Alloy C (UNS N10002) and Alloy C-276 (UNS N10276)

NEMA Type 4X (IP66)

Housing in Aluminum.

Removable Covers on

Both Sides

Short Fork Length

with Extensions

up to 118 in. (3 m)

Threaded,

Flanged, or

Hygienic

Connections

Thermal Tube

(2160***E Only)

Fast Drip Design

ATEX, FM, CSA, IECEx, and

NEPSI Intrinsically Safe

Antenna

Optional LCD

Display

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1-4

Measurement Principle The Rosemount 2160 is designed using the principle of a tuning fork.

A piezo-electric crystal oscillates the forks at their natural frequency. Changes

to this frequency are continuously monitored.

The frequency of the vibrating fork sensor changes depending on the medium

in which it is immersed. The denser the liquid, the lower the frequency.

When used as a low level alarm, the liquid in the tank or pipe drains down

past the fork, causing a change of natural frequency that is detected by the

electronics and switches the output state to a Dry condition.

When the 2160 switch is used as a high level alarm, the liquid rises in the

tank or pipe making contact with the fork, causing the output state to switch to

a Wet condition.

The output state, along with other parameters, are regularly transmitted over

a secure wireless connection to a Smart Wireless Gateway.

Short Fork Technology The natural frequency (~1400Hz) of the fork avoids interference from plant

vibration that may cause false switching. This allows for minimum intrusion

into the tank or pipe through the use of a short fork.

Using Short Fork Technology, the Rosemount 2160 can be used in almost all

liquid applications. Extensive research has maximized the operational

effectiveness of the fork design, making it suitable for most liquids including

coating liquids, aerated liquids, and slurries.

Special Features Instrument Health Monitor and Continuous Self-Check

The 2160 continuously performs instrument health diagnostics to self-check

the condition of the fork and sensor. These diagnostics can detect damage to

the forks including corrosion, internal or external damage to the forks, and

breakages to the internal wiring.

See “Operation Mode” on page 2-9 for further information.

Fork Design

The “fast drip” fork design draws liquid away from the fork tips, and together

with a short switching delay, allows the 2160 to react quickly and with greater

sensitivity to density variations.

Battery Powered

The 2160 is powered by an integral battery. The fork sensor requires very little

power and the battery life remains long even with fast update rates.

See “Battery Installation” on page 3-6 for further information.

Adjustable Time Delay

There is also a user-selectable time delay to virtually eliminate the risk of false

switching in turbulent or splashing applications.

See “Sensor Output Delay” on page 2-10 for further information.

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January 2013

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Rosemount 2160

Application Examples

For most liquids, including coating, aerated liquids and slurries, the function is

virtually unaffected by flow, turbulence, bubbles, foam, vibration, solid

particles, build-up, or properties of the liquid.

See Figure 1-5 on page 1-8 for application examples.

The 2160 switch can be used in hazardous (IS) or non-hazardous (safe)

areas but supports higher process temperatures up to 500 °F (260 °C).

The switch can be mounted in almost any position in an open or closed tank

or pipe. There is a wide range of threaded, flanged, or hygienic connections.

Application Considerations:

• Ensure the process is operating within the instrument operating

temperature and pressure ranges (see “Specifications” on page A-1)

• Ensure the liquid viscosity is within the recommended viscosity range

(see “Specifications” on page A-1)

• Check that the liquid density is higher than 31.2 lb/ft

(500 kg/m

)

(see “Specifications” on page A-1)

• Check for risk of build-up on the forks

Avoid situations where drying and coating products may create

excessive build-up (see Figure 1-2)

• Ensure there is no risk of ‘bridging’ the forks

Examples of products that can create bridging of forks are dense paper

slurries and bitumen

• Check the solids content in the liquid

As a guideline, the maximum solid particle diameter in the liquid is

0.2 in. (5 mm). Extra consideration is needed when dealing with

particles bigger than 0.2 in. (5 mm). Consult the factory for advice.

• Problems may occur if product coats and dries causing caking.

• In almost all cases, the 2160 is insensitive to foams (i.e. does not see

the foam).

However in rare occasions, some very dense foams may be seen as

liquid; a known example of this is found in ice-cream and orange juice

manufacturing.

Figure 1-2.

Avoid Product Build-up

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January 2013

Rosemount 2160

1-6

Extended Fork Supports

Figure 1-3. Supports Needed for

Extended Forks

3.28 ft.

(1.0 m)

3.28 ft.

(1.0 m)

3.28 ft.

(1.0 m)

3.28 ft.

(1.0 m)

Maximum

3.28 ft.

(1.0 m)

Maximum

3.28 ft.

(1.0 m)

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January 2013

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Rosemount 2160

Switchpoint

Figure 1-4. Switchpoint

NOTE:

A lower density media will give a switchpoint closer to the connection.

A higher density media will give a switchpoint closer to the fork tip.

SP = Switchpoint (H

HY = Switching Hysteresis

±0.039 in.

(1 mm)

±0.5 in.

(13 mm)

±0.5 in.

(13 mm)

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1-8

Figure 1-5. Rosemount 2160

Application Examples

Overfill Protection

Spillage caused by overfilling can be hazardous to people and the environment, resulting in

lost product and potentially high clean up costs.

High and Low Level Alarm

Maximum and minimum level detection in tanks containing different types of liquids are ideal

applications. The Rosemount 2160 is robust and operates continuously across the

temperature range of –94 to 500 °F (–70 to 260 °C) and operating pressures of up to 1450 psig

(100 barg), making it perfect for use as a high or low level alarm. It is common practice to have

an independent high level alarm switch as a backup to an installed level device in case of

primary failure.

Pump Control (Limit Detection)

Batch processing tanks often contain stirrers and agitators to ensure mixing and product

‘fluidity’. The standard user-selectable time delay, from 0 to 3600 seconds, virtually eliminates

the risk of false switching from splashing.

Pump Protection or Empty Pipe Detection

With the fork projecting only 2 in. (50 mm) (dependant on connection type), the 2160 can be

installed in small diameter pipes. Short forks mean minimum intrusion on the wetside and

allow for simple, low cost installation at any angle into pipes or tanks. The 2160 is ideal for

reliable pump control and can be used to protect against pumps running dry.

Extreme Temperature Applications

The 2160***E is designed for extreme temperatures and is suitable for continuous operation

within the temperature range of –94 to 500 °F (–70 to 260 °C).

Hygienic Applications

With the highly polished forks option providing a surface finish (Ra) better than 0.4 µm, the

2160 meets the most stringent hygienic requirements used in food and beverage, and

pharmaceutical applications.

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January 2013

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Rosemount 2160

SERVICE SUPPORT To expedite the return process outside of North America, contact the nearest

Emerson Process Management representative.

Within the United States, call the Emerson Process Management Response

Center toll-free number 1 800 654 7768. 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.

PRODUCT

RECYCLING/DISPOSAL

Recycling of equipment and packaging should be taken into consideration

and disposed of in accordance with local and national legislation/regulations.

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.

NOTICE

Shipping considerations for wireless products (lithium batteries):

The unit was shipped to you without the power module installed. Please remove the power

module prior to shipping.

Primary lithium batteries (charged or discharged) are regulated in transportation by the U. S.

Department of Transportation. They are also covered by IATA (International Air Transport

Association), ICAO (International Civil Aviation Organization), and ARD (European Ground

Transportation of Dangerous Goods). It is the responsibility of the shipper to ensure

compliance with these or any other local requirements. Please consult current regulations

and requirements before shipping.

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January 2013

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1-10

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

www.rosemount.com

Section 2 Configuration

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-2

Required Bench Top Configuration . . . . . . . . . . . . . . . . .page 2-2

Device Network Configuration . . . . . . . . . . . . . . . . . . . . .page 2-7

Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-4

Review Configuration Data . . . . . . . . . . . . . . . . . . . . . . . .page 2-8

Check Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-9

Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-9

LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-11

Detailed Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-12

Diagnostics and Service . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-15

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-21

Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-23

Advanced Functions for HART Protocol . . . . . . . . . . . . .page 2-24

SAFETY MESSAGES Procedures and instructions in this section may require special precautions to

ensure the safety of the personnel performing the operations. Information that

raises potential safety issues is indicated by a warning symbol ( ). Refer to

the following safety messages before performing an operation preceded by

this symbol.

Warnings

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

• The Rosemount 2160 is a wireless liquid level switch. It must be installed, connected,

commissioned, operated, and maintained by suitably qualified personnel only,

observing any national and local requirements that may apply

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

protection provided by the equipment

Explosions could result in death or serious injury

• Installation of the 2160 in a hazardous environment must be in accordance with the

appropriate local, national, and international standards, codes, and practices.

Please review the approvals section of the 2160 Reference Manual for any restrictions

associated with an installation

• Before connecting a Field Communicator in an explosive atmosphere, ensure the

installation is in accordance with intrinsically safe or non-incendive field wiring

practices

• Verify that the operating atmosphere of the level switch is consistent with the

appropriate hazardous locations certifications

External Surface may be hot

• Care must be taken to avoid possible burns

Process leaks could result in death or serious injury

• Install and tighten process connectors before applying pressure

• Do not attempt to loosen or remove process connectors while the 2160 is in service

Reference Manual

00809-0100-4160, Rev AD

January 2013

Rosemount 2160

2-2

OVERVIEW This section contains information on commissioning and verification that

should be performed prior to installation.

Field Communicator and AMS

instructions are given to perform configuration

functions. For convenience, Field Communicator fast key sequences are

labeled “Fast Keys” for each software function below the appropriate

headings.

Example Software Function

REQUIRED BENCH TOP

CONFIGURATION

Bench top configuration requires a Field Communicator, AMS, or any

Wireless Communicator.

Bench top configuration consists of testing the transmitter and verifying

transmitter configuration data. The 2160 can be configured before or after

installation (field hook-up). However, configuring the 2160 on the bench

before installation ensures that all network settings are working correctly.

When using a Field Communicator, any configuration changes made must be

sent to the 2160 by using the “Send” key (F2). AMS configuration changes are

implemented when the “Apply” button is clicked.

Squawk Feature The 2160 feature called “Squawk” can be used to visually identify an

individual 2160 in a wireless network. This can be a useful check during the

configuration and commissioning of multiple 2160 transmitters.

To find out more about this feature, see “How to Use Squawk” on page 4-4.

AMS Wireless

Configurator

AMS is capable of connecting to devices either directly using a HART

modem or wirelessly via the Smart Wireless Gateway.

When configuring on the bench with a HART modem, double click the device

icon, then choose the Configure/Setup tab (or right click and select

Configure/Setup).

When configuring with the Gateway, double click the device icon and then

choose the Configure/Setup tab (or right click and select Configure/Setup).

Field Communicator Remove the power module-side housing cover to expose the terminal block

and HART communication terminals, then connect the Black Power Module to

power the unit for configuration. Connect the Field Communicator leads to the

terminals labeled “COMM” on the terminal block. See Figure 2-1 on page 2-3.

Turn on the Field Communicator by pressing the ON/OFF key.

Electrical shock could cause death or serious injury

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

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

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

• Make sure that power to the 2160 is off while making connections

Fast Keys

1, 2, 3, etc.

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Rosemount 2160 Wireless Vibrating Fork Liquid Level Switch Owner's manual

Brand: Rosemount

Model: 2160 Wireless Vibrating Fork Liquid Level Switch

Category: Networking

Type: Owner's manual

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Rosemount 2160 Wireless Vibrating Fork Liquid Level Switch Owner's manual

Rosemount 2160 Wireless Vibrating Fork Liquid Level Switch Owner's manual

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