WirelessHART Rosemount 2160 WirelessHART User manual

www.rosemount.com
Reference Manual
00809-0100-4160, Rev AB
March 2010
Rosemount 2160 WirelessHART™
Vibrating Fork Liquid Level Switch
2160***E
2160***S

Reference Manual
00809-0100-4160, Rev AB
March 2010 Rosemount 2160
www.rosemount.com
Rosemount 2160 WirelessHART
Vibrating Fork Liquid Level Switch
Rosemount 2160 Hardware Revision 1
HART®Device Revision 1
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 AB
March 2010
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 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 AB
March 2010
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Required Bench Top Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Device Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Join Device to Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Configure Update Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Remove Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Review Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Review Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Review Device Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Review Radio Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Review Device Temperature Information . . . . . . . . . . . . . . . . . . . . . . .2-6
Field Communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Check Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Sensor Output Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Media Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Write Protect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Measurement and Status Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
LCD Display Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Detailed Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Process Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Sensor Stabilization Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Measurement Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Allowable Change In Dry Fork Frequency. . . . . . . . . . . . . . . . . . . . . .2-12
Table of Contents

Reference Manual
00809-0100-4160, Rev AB
March 2010
IV
Rosemount 2160
Sensor Fault Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Update Rate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Diagnostics and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Master Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Join Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Communication Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Join Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Number Of Available Neighbors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Number of Advertisements Heard. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Number of Join Attempts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Sensor Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Uncompensated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Sensor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Dry Fork Frequency / Switch Points . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Dry Fork Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Sensor Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Calibrate Dry Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Sensor Calibration Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Calibration Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Reset Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Sensor Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Fork Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Advanced Functions for HART Protocol . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Saving, Recalling, and Cloning Configuration Data . . . . . . . . . . . . . .2-23
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 AB
March 2010
V
Rosemount 2160
SECTION 4
Commissioning Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Verify Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
AMS Wireless Configurator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
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
SECTION 6
Troubleshooting Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Disassembly Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Remove from Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Remove Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Remove Feature Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Remove the Sensor from the Housing . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Re-assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Attach the Sensor to the Wireless Housing. . . . . . . . . . . . . . . . . . . . . .6-5
Install the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Re-assemble to the Process Flange. . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
SECTION 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

Reference Manual
00809-0100-4160, Rev AB
March 2010
VI
Rosemount 2160
SECTION B
Product Certifications Rosemount 2160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Approved Manufacturing Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
European Directive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Telecommunication Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
FCC and IC Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Canadian Registration Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Hazardous Locations Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Reference Manual
00809-0100-4160, Rev AB
March 2010 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
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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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March 2010
Rosemount 2160
1-2
USING THIS MANUAL This manual provides information on installing, operating, and maintaining the
Rosemount 2160 WirelessHART liquid level switch.
• Section 2: Configuration provides instruction on commissioning and
operating the and 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.
•Section 6: Troubleshooting provides troubleshooting techniques for
the most common operating problems.
•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 WirelessHART 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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March 2010
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Rosemount 2160
ABOUT THE 2160
Switch Overview The Rosemount 2160 WirelessHART 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, and
IECEx Intrinsically Safe
Antenna
Optional LCD
Display

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March 2010
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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 (~1300Hz) 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 2-8 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 2-9 for further information.

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March 2010
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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/ft3(500 kg/m3)
(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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March 2010
Rosemount 2160
1-6
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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March 2010
1-7
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 (H20)
HY = Switching Hysteresis
±0.039 in.
(1 mm)
±0.5 in.
(13 mm)
±0.5 in.
(13 mm)

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Rosemount 2160
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 the United States, contact the
nearest Emerson Process Management representative.
Within the United States, call the Emerson Process Management Instrument
and Valves Response Center using the 1 800 654 7768 toll-free number. 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.
The battery pack 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.
PRODUCT
RECYCLING/DISPOSAL Recycling of equipment and packaging should be taken into consideration.
The product and packaging should be disposed of in accordance with local
and national legislation.
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:
The unit was shipped to you without the 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.

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Reference Manual
00809-0100-4160, Rev AB
March 2010 Rosemount 2160
www.rosemount.com
Section 2 Configuration
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-3
Required Bench Top Configuration . . . . . . . . . . . . . . . . .page 2-3
Device Network Configuration . . . . . . . . . . . . . . . . . . . . .page 2-4
Review Configuration Data . . . . . . . . . . . . . . . . . . . . . . . .page 2-5
Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-7
Check Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-8
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-8
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-10
Detailed Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-11
Diagnostics and Service . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-15
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-21
Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-22
Advanced Functions for HART Protocol . . . . . . . . . . . . .page 2-23
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 AB
March 2010
Rosemount 2160
2-2
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