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

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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
II
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
IV
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
V
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
VI
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
Reference Manual
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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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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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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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Rosemount 2160
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
3
(500 kg/m
3
)
(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
OK
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Extended Fork Supports
Figure 1-3. Supports Needed for
Extended Forks
OK
OK
OK
OK
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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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
HY
SP
SP = Switchpoint (H
2
0)
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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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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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.
/