Rosemount Manual: Rosemount 2160 Wireless Vibrating Fork Liquid Level Switch Manuals & Guides
Reference Manual
00809-0100-4160, Rev AE
Rosemount™ 2160 Wireless Level Detector
Vibrating Fork
May 2022
Safety messages
NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum product performance,
ensure 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
North American Response Center
Equipment service needs.
• 1-800-654-7768 (24 hours a day — includes Canada)
• Outside of these areas, contact your local Emerson representative.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or serious injury.
Ensure the level detector is installed by qualified personnel and in accordance with applicable code of practice.
Use the level detector only as specified in this manual. Failure to do so may impair the protection provided by the level detector.
The weight of a level detector with a heavy flange and extended fork length may exceed 37 lb. (18 kg). A risk assessment is
required before carrying, lifting, and installing the level detector.
WARNING
Explosions could result in death or serious injury.
Installation of device in an explosive environment must be in accordance with appropriate local, national, and international
standards, codes, and practices.
Verify that the operating atmosphere of the level detector is consistent with the appropriate hazardous locations certifications.
Before connecting a handheld communicator in an explosive atmosphere, ensure that the instruments in the loop are installed in
accordance with intrinsically safe or non-incendive field wiring practices.
WARNING
Process leaks could result in death or serious injury.
Ensure the level detector is handled carefully. If the process seal is damaged, gas might escape from the vessel (tank) or pipe.
WARNING
Any substitution of non-recognized parts may jeopardize safety. Repair (e.g. substitution of components) may also
jeopardize safety and is not allowed under any circumstances.
Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and
jeopardize safety. Unauthorized changes that interfere with the integrity of the welds or flanges, such as making additional
perforations, compromise product integrity and safety. Equipment ratings and certifications are no longer valid on any products
that have been damaged or modified without the prior written permission of Emerson. Any continued use of product that has
been damaged or modified without the written authorization is at the customer’s sole risk and expense.
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WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
CAUTION
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate
readings.
For information on Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.
CAUTION
Hot surfaces
The flange and process seal may be hot at high process temperatures. Allow to cool before servicing.
NOTICE
Power module considerations.
Each power module contains primary lithium/thionyl chloride batteries. Under normal conditions, the battery materials are selfcontained 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.
Use caution when handling the power module. The Power Module may be damaged if dropped from heights in excess of 20 ft. (6
m).
Power modules should be stored in a clean and dry area. For maximum battery life, storage temperature should not exceed 86 °F
(30 °C).
The power module may be replaced in a hazardous area. The power module has surface resistivity greater than one gigaohm and
must be properly installed in the wireless device enclosure. Care must be taken during transportation to and from the point of
installation to prevent electrostatic charge build-up.
NOTICE
Shipping considerations for wireless products.
The unit was shipped to you without the power module installed. Remove the power module prior to any re-shipping.
Each Black Power Module (model number 701PBKKF) contains two “C” size primary lithium batteries. Primary lithium batteries
(charged or discharged) 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. Consult current regulations and requirements before shipping.
Each Blue Power Module (A0701PBU) contains two "D" size primary lithium batteries. Primary lithium batteries (charged or
discharged) 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.
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Reference Manual Contents
00809-0100-4160 May 2022
Contents
Chapter 1 Introduction.............................................................................................................. 7
1.1 Using this manual........................................................................................................................ 7
1.2 Product certifications...................................................................................................................7
1.3 Product recycling/disposal...........................................................................................................7
Chapter 2 Level detector overview.............................................................................................9
2.1 Measurement principle................................................................................................................9
2.2 Process characteristics.................................................................................................................9
2.3 Vessel characteristics...................................................................................................................9
2.4 Application examples.................................................................................................................10
2.5 Components of the level detector..............................................................................................12
2.6 Emerson Wireless...................................................................................................................... 14
Chapter 3 Installation...............................................................................................................15
3.1 Safety messages........................................................................................................................ 15
3.2 Installation considerations.........................................................................................................15
3.3 Installation procedures.............................................................................................................. 22
Chapter 4 Configuration...........................................................................................................33
4.1 Safety messages........................................................................................................................ 33
4.2 Configuration procedure........................................................................................................... 34
4.3 Get started with your preferred configuration tool.....................................................................34
4.4 Join device to wireless network.................................................................................................. 37
4.5 Configure device using guided setup......................................................................................... 46
Chapter 5 Operation................................................................................................................ 47
5.1 Device display screen messages.................................................................................................47
5.2 View diagnostic screens.............................................................................................................48
5.3 View measurement data............................................................................................................50
5.4 Check device status................................................................................................................... 50
Chapter 6 Service and troubleshooting.................................................................................... 53
6.1 Safety messages........................................................................................................................ 53
6.2 Device display alerts.................................................................................................................. 53
6.3 Troubleshooting........................................................................................................................57
6.4 Service and troubleshooting tools..............................................................................................59
6.5 Replace power module.............................................................................................................. 66
6.6 Opening the lid (cover).............................................................................................................. 68
6.7 Service support..........................................................................................................................69
Appendix A Specifications and reference data............................................................................. 71
A.1 General......................................................................................................................................71
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A.2 Physical specifications............................................................................................................... 71
A.3 Performance specifications........................................................................................................72
A.4 Electrical specifications..............................................................................................................73
A.5 Functional specifications........................................................................................................... 74
A.6 Environmental specifications.....................................................................................................75
A.7 Dimensional drawings............................................................................................................... 77
Appendix B Configuration parameters........................................................................................ 85
B.1 Manual setup.............................................................................................................................85
B.2 Alert setup.................................................................................................................................90
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Reference Manual Introduction
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1 Introduction
1.1 Using this manual
The sections in this manual provide detailed information on installing, operating, and
maintaining the Rosemount 2160 Wireless Level Detector - Vibrating Fork.
The sections are organized as follows:
Level detector overview provides a description of the Rosemount 2160 and its basic
principles.
Installation contains mechanical installation instructions.
Configuration provides instructions on how to configure the level detector.
Operation contains operation and maintenance techniques.
Service and troubleshooting provides troubleshooting techniques for the most common
operating problems.
Specifications and reference data supplies reference and specification data.
Configuration parameters provides extended information about the configuration
parameters.
1.2 Product certifications
See the Rosemount 2160 Product Certifications document for detailed information on the
existing approvals and certifications.
1.3 Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of
in accordance with local and national legislation or regulations.
Related information
Service support
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2 Level detector overview
2.1 Measurement principle
The Rosemount 2160 is the world’s first WirelessHART® level detector using Emerson's
vibrating fork technology.
Using the principle of a tuning fork, a piezo-electric crystal oscillates the forks at their
natural frequency. Changes to the oscillation frequency are continuously monitored by
electronics as it varies depending on the liquid medium in which the forks are immersed.
The denser the liquid, the lower the oscillation frequency.
Whenever a liquid medium in a vessel (tank) or pipe drains down past the forks, it causes a
distinct frequency change. This change is detected by the electronics and a dry condition
is indicated.
Whenever a liquid medium in a vessel (tank) or pipe rises and contacts the forks, again a
distinct frequency change is detected. This time, the electronics will indicate a wet
condition.
The wet and dry conditions, along with other parameters, are regularly transmitted over a
secure wireless connection to a wireless gateway.
2.2 Process characteristics
Emerson's vibrating fork technology is virtually unaffected by turbulence, foam, solids
content, coating products, and liquid properties. The natural frequency (1400 Hz) of the
fork avoids interference from plant vibration that may cause false detection. This allows
for minimum intrusion into the tank or pipe using a short fork.
2.3 Vessel characteristics
The level detector should be mounted using its process connection, and in a horizontal or
vertical orientation so that the liquid medium can flow freely in the gap between the forks.
A vessel (tank) or pipe can be almost any shape or type, but check that the process
conditions are within the operating limits of the level detector.
Avoid installing near agitators and inlet pipes where the forks are likely to be splashed and
cause a false detection of a wet condition. False detection events can be minimized by a
programmable delay that allows time for the fork to dry.
Never force the level detector into a vessel (tank) or pipe space. Any contact with the
opposite wall, or in-tank objects, could damage the forks and other wetted-process parts.
Extended length versions require supports at regular spaced intervals.
Related information
Required supports for extended fork
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2.4 Application examples
Overfill prevention
Spillage caused by overfilling can be hazardous to people and the environment, resulting
in lost product and potentially high clean-up costs. The Rosemount 2160 is an overfill
prevention product from Emerson that can be used as one of multiple layers of protection.
High and low level point alarms
Maximum and minimum level detection in tanks containing different types of liquids are
ideal applications. It is common practice to have an independent high level alarm switch or
detector as a backup to an installed level device in case of primary failure.
Pump control or limit detection
Batch processing tanks often contain stirrers and agitators to ensure mixing and product
‘fluidity’. The Rosemount 2160 has a software-configurable time delay, from 0 to 3600
seconds, that virtually eliminates the risk of false detection from splashing.
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Pump protection or empty pipe detection
With the fork projecting only 2 in. (50 mm) (dependent on connection type), the
Rosemount 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 Rosemount 2160 is ideal for reliable pump control and can be used to
protect against pumps running dry.
High temperature applications
The high temperature version of the Rosemount 2160 is designed 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 Rosemount 2160 meets the most stringent hygienic requirements used in food and
beverage, and pharmaceutical applications.
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2.5 Components of the level detector
Figure 2-1 shows the components of a Rosemount 2160.
Figure 2-1: Rosemount 2160 Features
A. Removable cover (no LCD fitted)
B. Electronics housing
C.
LCD display (optional)
D. Removable cover (battery compartment)
E. Antenna
F. Threaded process connection (BSPT (R) or BSPP (G))
G. Flanged process connection
H. Tri Clamp process connection
I. Unused cable/conduit entry
J. ‘Fast drip’ forks
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K. Thermal tube (on high temperature version only)
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2.5.1 Short fork technology
Using short-fork technology, the device can be used in almost all liquid applications.
Extensive research has maximized the operational effectiveness of the fork design, making
it suitable for most liquid mediums including coating liquids, aerated liquids, and slurries.
2.5.2 Fork design
The “fast drip” design allows the liquid to be quickly drawn away from the fork tip, making
the Rosemount 2160 quicker and more responsive in high density or viscous liquid
applications.
Figure 2-2: “Fast drip” forks
2.5.3 Battery powered
The device is powered by an integral battery. The fork sensor requires very little power and
the battery life remains long even with fast update rates.
2.5.4 Instrument health monitor and continuous self-check
The Rosemount 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.
2.5.5 Adjustable time delay and update rate
There is a software-configurable output delay to virtually eliminate the risk of false
detections in turbulent or splashing applications. The 'fast drip' fork design also helps with
these types of application.
A software-configurable update rate allows a selection from one second up to 60 minutes.
A higher update rate will get more frequent updates to process variables at the expense of
draining the battery more quickly. A lower update rate can be used together with the
adjustable output delay, and prolong battery life.
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2.6 Emerson Wireless
Emerson Wireless is a self-organizing network solution. Wireless field instruments send
data to a Gateway, directly or routed through any of the wireless devices in the network, as
illustrated in Figure 2-3. Multiple communication paths are managed and analyzed in
parallel to assure optimal communication and sustained network reliability even if
obstructions are introduced.
Figure 2-3: Emerson Wireless Network
Gateways interface with existing host systems using industry standard protocols, and
native integration into DeltaV™ and Ovation™ is transparent and seamless.
Interference from other radios, Wi-Fi®, and EMC sources is avoided through Time
Synchronized Channel Hopping and Direct Sequence Spread Spectrum (DSSS). Also, a
layered security implementing industry standard Encryption, Authentication, Verification,
Anti-Jamming, and Key Management ensures that data transmissions are secure and
received only by the Gateway.
The Rosemount 2160 is a member of the Emerson Wireless portfolio, whose wireless
network experience totals billions of operating hours, hundreds of thousands of field
devices, and tens of thousands of networks around the world.
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3 Installation
3.1 Safety messages
Instructions and procedures in this section may require special precautions to ensure the
safety of the personnel performing the operations. Information that potentially raises
safety issues is indicated by a warning symbol ( ). Refer to the following safety messages
before performing an operation preceded by this symbol.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or
serious injury.
Ensure the level detector is installed by qualified personnel and in accordance with
applicable code of practice.
Use the level detector only as specified in this manual. Failure to do so may impair the
protection provided by the level detector.
The weight of a level detector with a heavy flange and extended fork length may exceed
37 lb. (18 kg). A risk assessment is required before carrying, lifting, and installing the level
detector.
Repair, e.g. substitution of components, etc. may jeopardize safety and is under no
circumstances allowed.
WARNING
Explosions could result in death or serious injury.
Verify that the operating atmosphere of the level detector is consistent with the
appropriate hazardous locations certifications.
Before connecting a handheld communicator in an explosive atmosphere, ensure that the
instruments in the loop are installed in accordance with intrinsically safe or non-incendive
field wiring practices.
WARNING
Process leaks could result in death or serious injury.
Ensure the level detector is handled carefully. If the process seal is damaged, gas might
escape from the vessel (tank) or pipe.
3.2 Installation considerations
Before installing the level detector, review the safety, environmental, application, and preinstallation sections.
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3.2.1 Environmental considerations
The Rosemount 2160 is weatherproof and protected against the ingress of dust, but must
be protected from flooding. Avoid installing the level detector near heat sources.
Figure 3-1: Environmental Considerations
3.2.2 Application considerations
The Rosemount 2160 is a wireless HART point level devices for use on open or closed
vessels (tanks) and in pipework containing liquid mediums.
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 medium.
Avoid process medium build-up on the forks
Avoid situations where a drying and coating process medium may create an excessive
build-up or implement preventative maintenance programs to ensure the build-up is not
enough to impair performance (see Figure 3-2).
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Always ensure:
• There is sufficient distance between build-up on the tank wall and the fork.
• There is no risk of ‘bridging’ the level switch forks.
Examples of products that can create ‘bridging’ of forks and impair performance are
dense paper slurries and bitumen.
Figure 3-2: Avoid Product Build-up
Operating temperature and pressure ranges
Ensure the process is operating within the instrument operating temperature and pressure
ranges.
Liquid density requirements
Minimum liquid density is 31.2 lb/ft3 (500 kg/m3.
Liquid viscosity range
0.2 to 10000 cP (centiPoise)
Solids content in the liquid medium
As a guideline, the maximum solid particle diameter in the liquid process medium is 0.2 in.
(5 mm). Extra consideration is needed when solid particles are bigger than 0.2 in. (5 mm)
and advice should be sought from Emerson.
Foams
In almost all cases, the Rosemount 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; known examples
of this are found in ice-cream and orange juice manufacturing.
Rosemount 2160 Wireless Level Detector 17
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Switching point
The switching point varies with different liquid densities. The switching point (SP) and
hysteresis (HY) for water are shown in Figure 3-3.
Figure 3-3: Switching Point in Inches (Millimeters)
Note
When mounted vertically, a low density medium has a switching point closer to the
process connection. A high density medium has a switching point closer to fork tip.
3.2.3 Pre-installation considerations
Measurement accuracy is dependent upon the proper installation of the device. Keep in
mind the need for easy access, personnel safety, practical field calibration, and a suitable
environment for the device.
Device identification
To identify a version of the level detector, see the label on the housing.
How to handle a level detector
Handle the level detector with great care.
The weight of the level detector with a heavy flange and extended fork length may exceed
37 lb. (18 kg). A risk assessment is required to be done before carrying, lifting, and
installing the level detector.
Use both hands to carry the extended length and high temperature versions, and do not
hold a level detector by the forks (see Figure 3-4).
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Figure 3-4: Handling
Make no alterations to the level detector
Never make any alterations to the mechanical or electrical features of the level detector
(see Figure 3-5).
Figure 3-5: Make No Alterations
Allow adequate space outside tank or pipe
Mount the Rosemount 2160 so that it is removable and allow easy access to the
replaceable battery. Ensure there is also enough room for replacing the battery.
Clearances:
• A clearance of 2⅜ in. (60 mm) for the standard battery-side cover to be removed.
• A clearance of 0.75 in. (19 mm) is required for a standard terminals-side cover to be
removed. If an LCD display is installed, 3 in. (76.2 mm) of clearance is required for
removal.
Note
The electronics housing and antenna can be rotated for optimal viewing position and
strongest wireless signal.
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Covers installation
Ensure a proper seal by installing the electronics housing covers so that metal contacts
metal. Always use Emerson's O-rings.
Mounting orientation
Mount the Rosemount 2160 at any angle that allows the level of the process medium to
rise, fall, or flow through the fork gap.
Related information
Correct fork alignment
Grounding the housing
Always ground the housing in accordance with national and local electrical codes. The
most effective grounding method for the housing is a direct connection to earth ground
with minimal impedance.
Pipe installation requirements
• The inside pipe diameter (D) must be 1.4 in. (35 mm) or larger.
• Ensure the fork tines intrude at least 0.9 in. (22 mm) into the pipe.
• Keep at least 0.3 in. (7 mm) of clearance between the fork tines and the pipe wall.
Figure 3-6: Pipe Installation
A. Minimum intrusion 0.9 in. (22 mm)
B. Minimum clearance 0.3 in. (7 mm)
Other recommendations
• Avoid:
— Installing near to liquid entering the tank at the filling-point.
— Heavy splashing on the forks.
Increasing the sensor output delay reduces accidental detection caused by splashing.
• Always ensure:
— The overall system is tested during commissioning.
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— The installation does not create tank crevices around the forks where a liquid
medium may collect. This event can happen with high-viscosity and high-density
liquids.
— The forks do not come into contact with the vessel (tank) or pipe wall, internal
fittings, or any other obstructions.
• Extra consideration is needed if the plant vibration is close to the 1400 Hz operating
frequency of the fork.
Required supports for extended fork
Supporting the extended fork avoids long fork length vibration.
Figure 3-7: Vertical Installation
A. Maximum 3.28 ft. (1.0 m)
B. 3.28 ft. (1.0 m)
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Figure 3-8: Horizontal Installation
A. Maximum 3.28 ft. (1.0 m)
B. 3.28 ft. (1.0 m)
3.3 Installation procedures
3.3.1 Process connection seals
Figure 3-9: Process Connection Seals
A. PTFE tape
B. NPT or BSPT (R) thread
Gasket
C.
D. BSPP (G) thread
E. Tri Clamp
F. The Tri Clamp seal is supplied in an accessory kit
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3.3.2 Correct fork alignment
Fork alignment in a pipe installation
The fork is correctly aligned by positioning the groove or notch as indicated (Figure 3-10).
Figure 3-10: Correct Fork Alignment for Pipe Installation
A. Tri Clamp process connections have a circular notch
B. Threaded process connections have a groove
Fork alignment in a vessel (tank) installation
The fork is correctly aligned by positioning the groove or notch as indicated (Figure 3-11).
Figure 3-11: Correct Fork Alignment for Vessel (Tank) Installation
A. Tri Clamp process connections have a circular notch
B. Threaded process connections have a groove
Flanged process connections have a circular notch
C.
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3.3.3 Mounting the threaded version
Threaded vessel (tank) or pipework connection
Procedure
1. Seal and protect the threads. Use anti-seize paste or PTFE tape according to site
procedures.
A gasket may be used as a sealant for BSPP (G) threaded connections.
2. Screw the level detector into the process connection.
Note
Tighten using the hexagon nut only.
Figure 3-12: Vertical Installation
A. Gasket for BSPP (G) threaded connection
Figure 3-13: Horizontal Installation
A. Gasket for BSPP (G) threaded connection
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Threaded flange connection
Procedure
1. Place the customer-supplied flange and gasket on the vessel (tank) nozzle.
A. Gasket (customer supplied)
2. Tighten the bolts and nuts with sufficient torque for the flange and gasket.
3. Seal and protect the threads. Use anti-seize paste or PTFE tape according to site
procedures.
A gasket may be used as a sealant for BSPP (G) threaded connections.
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4. Screw the level detector into the flange thread.
Note
Tighten using the hexagon nut only.
A. Gasket for BSPP (G) threaded connection
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3.3.4 Mounting the flanged version
Procedure
1. Lower the level detector into the nozzle.
A. Gasket (customer supplied)
2. Tighten the bolts and nuts with sufficient torque for the flange and gasket.
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3.3.5 Mounting the Tri Clamp version
Procedure
1. Lower the level detector into the flange face.
A. Seal (supplied with Tri Clamp)
2. Fit the Tri Clamp.
3.3.6 Install the power module
To install the battery that supplies all power to the Rosemount 2160:
Procedure
1. Remove the power module cover.
2.
Connect the power module.
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