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Rosemount 5402
Reference Manual
314 pgs5.49 Mb0

Emerson Rosemount 5400 Series, Rosemount 5402, Rosemount 5401 Reference Manual

Reference Manual
00809-0100-4026, Rev HA
November 2014
Rosemount 5400 Series
Superior Performance Two-Wire Non-Contacting Radar Level Transmitter
Reference Manual
00809-0100-4026, Rev HA
November 2014
Rosemount 5400 Series
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.
Within the United States, Emerson Process Management has two toll-free assistance numbers.
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 a day — includes Canada) For equipment service or support needs outside the United States, contact your local
Emerson Process Management representative.
There are no health hazards from the Rosemount 5400 Series transmitter. The microwave power density in the tank is only a small fraction of the allowed power density according to international standards.
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 Process Management Sales Representative.
This product is designed to meet FCC and R&TTE requirements. This device complies with part 15 of the FCC rules. Operation is subjec t to the following t wo
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.
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Contents
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Contents
1Section 1: Introduction
1.1 Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Service support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Product recycling/ disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2Section 2: Transmitter Overview
2.1 Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3 System architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.4 Process characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5 Components of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.6 Antenna selection guide/measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3Section 3: Mechanical Installation
3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.2 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Mounting considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.2 Special considerations in solids applications . . . . . . . . . . . . . . . . . . . . . . . . .24
3.3.3 Mounting in pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.3.4 Installation considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3.5 Nozzle considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.3.6 Nozzle recommendations and requirements . . . . . . . . . . . . . . . . . . . . . . . .30
3.3.7 Service space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.3.8 Beamwidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3.9 Vessel characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.3.10Disturbing objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.3.11Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.4.1 Cone antenna flange connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.4.2 Process seal antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.4.3 Rod antenna threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.4.4 Rod antenna flanged connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.4.5 Tri-Clamp™ tank connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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3.4.6 Bracket mounting on wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
3.4.7 Bracket mounting on pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4Section 4: Electrical Installation
4.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.2 Wiring and power supply requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.3 Cable/conduit entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
4.3.1 Conduit electrical connector wiring (using minifast
®
). . . . . . . . . . . . . . . . .45
4.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.5 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.6 Hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.7 External circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.7.1 Connecting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.8 HART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.8.1 Power requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.8.2 Load limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.8.3 Non-intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4.8.4 Intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.8.5 Type N approvals: non-sparking / energy-limited power supply . . . . . . . .53
4.8.6 Transient protection terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
4.9 F
OUNDATION fieldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.9.1 Power requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.9.2 Non-intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.9.3 Intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
4.9.4 Type N approvals: non-sparking / energy-limited power supply . . . . . . . .59
4.10HART to Modbus Converter (HMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
4.10.1Connecting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
4.10.2Connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
4.10.3RS-485 bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.10.4Installation cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.10.5External HART devices (slaves). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
4.11Establish HART communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
4.11.1Connect to the MA/MB terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
4.11.2Connect to the HART terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
4.12Optional devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
4.12.1Tri-Loop™ HART to analog converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
4.12.2751 Field Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
4.12.3Smart Wireless THUM
™
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
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5Section 5: Basic Configuration/Start-up
5.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
5.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
5.2.1 Basic configuration parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
5.2.2 Configuration tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
5.3 Basic configuration parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.3.1 Measurement units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.3.2 Tank geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.3.3 Process conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
5.3.4 Volume configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
5.3.5 Analog output (HART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
5.3.6 Level and distance calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
5.3.7 Echo tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
5.3.8 ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5.4 Basic configuration using RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5.4.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5.4.2 Help in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
5.4.3 Installing the RRM software for HART communication . . . . . . . . . . . . . . . .85
5.4.4 Specifying the COM port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
5.4.5 To set the COM port buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.4.6 Specifying measurement units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.4.7 Installing the RRM software for F
OUNDATION fieldbus . . . . . . . . . . . . . . . . . .88
5.4.8 Specifying measurement units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.4.9 Using the Setup functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.4.10Guided setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.4.11Using the Setup functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5 Configuration using a Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.7 Basic configuration using AMS Suite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.8 Configuration using DeltaV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.8.1 Advanced configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.9 F
OUNDATION fieldbus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.9.1 Assigning device tag and node address . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.9.2 Foundation fieldbus block operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.10Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.10.1Radar level transmitter - level value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.10.2Radar level transmitter - level value in percent (%). . . . . . . . . . . . . . . . . . 116
5.11Tri-Loop™ HART to Analog Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.12HART multidrop configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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6Section 6: Operation
6.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.2 Viewing measurement data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2.1 Using the display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2.2 Specifying display panel variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2.3 Viewing measurement data in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2.4 Viewing measurement data in AMS Suite and DeltaV . . . . . . . . . . . . . . . 125
6.3 LCD display error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.4 LED error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7Section 7: Service and Troubleshooting
7.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.2 Troubleshooting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.3 Service overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.3.1 Analyzing the measurement signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.3.2 Surface pulse not found. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.3.3 Registration of false echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.3.4 Using the Echo Curve Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.5 Using the Echo Curve Analyzer with a Field Communicator . . . . . . . . . . 140
7.4 Analog Output calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.5 Logging measurement data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.6 Backing up the transmitter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.8 Configuration report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.9 Viewing input and holding registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.10Reset to factory settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.11Surface search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.12Using the Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.13Write protecting a transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.14Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.14.1Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.14.2Device status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.14.3Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.14.4Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.14.5Measurement status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.14.6Volume calculation status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.14.7Analog Output status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.14.8Application errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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7.15Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.15.1Resource block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.15.2Transducer block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.15.3Analog Input (AI) function block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8Section 8: Safety Instrumented Systems (4-20 mA Only)
8.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.2.1 Applicable models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.2.2 Skill level of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.3 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.1 Damping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.2 Alarm and saturation levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.3 Amplitude threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.5.4 Write protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.5.5 Site acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.6 Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.6.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.7 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.7.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.7.2 Failure rate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.7.3 Useful lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.8 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.9 Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
AAppendix A: Reference Data
A.1 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.1.2 4-20 mA HART
®
(output option code H) . . . . . . . . . . . . . . . . . . . . . . . . . . 178
A.1.3 Foundation™ fieldbus (output option code F) . . . . . . . . . . . . . . . . . . . . . 181
A.1.4 RS-485 with Modbus communication
(output option code M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
A.1.5 Display and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
A.1.6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
A.1.7 Temperature and pressure limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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A.2 Performance specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
A.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
A.2.2 Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
A.2.3 Beam angle and beam width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
A.2.4 Transition zone and near zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
A.2.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
A.3 Physical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
A.3.1 Material selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
A.3.2 Housing and closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
A.3.3 Engineered solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
A.3.4 Tank connection and antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
A.4 Dimensional drawings and mechanical properties . . . . . . . . . . . . . . . . . . . . . . . 200
A.4.1 Rosemount 5402 and 5401 with SST Cone Antenna
(Model Code: 2S-8S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
A.4.2 Rosemount 5402 and 5401 with Protective Plate Cone Antenna
(Model Code: 2H-8H, 2M-8M, and 2N-8N) . . . . . . . . . . . . . . . . . . . . . . . . 201
A.4.3 Rosemount 5401 with Rod Antenna (Model Code: 1R-4R). . . . . . . . . . . 202
A.4.4 Rosemount 5402 with Process Seal Antenna
(Model Code: 2P-4P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A.4.5 Bracket mounting (Model Code: BR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A.4.6 Process connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A.5 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
BAppendix B: Product Certifications
B.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
B.2 European Directive information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B.3 FCC and ICC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B.4 Safety Instrumented Systems (SIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B.5 Hazardous locations certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
B.5.1 North-American certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
B.5.2 Canadian Standards Association (CSA) Approvals . . . . . . . . . . . . . . . . . . 221
B.5.3 European certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
B.5.4 IECEx Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
B.5.5 EAC certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
B.5.6 Brazilian certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
B.5.7 Chinese certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
B.5.8 Japanese certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
B.5.9 Other certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
B.5.10Canadian Registration Number (CRN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
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B.6 Approval drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
CAppendix C: Advanced Configuration
C.1 Tank geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
C.1.1 Distance offset (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
C.1.2 Minimum level offset (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
C.1.3 Hold off distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
C.1.4 Calibration distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
C.2 Advanced analog output settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
C.3 Advanced transmitter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
C.3.1 Antenna type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
C.3.2 Empty tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
C.3.3 Full tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
C.3.4 Double bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
C.3.5 Surface echo tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
C.3.6 Filter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
C.4 Advanced functions in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
C.4.1 Empty tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
C.4.2 Full tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
C.4.3 Double bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
C.4.4 Surface echo tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
C.4.5 Hold off setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
DAppendix D: Performing Proof Test
D.1 Performing proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
D.2 Field communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
D.3 RRM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
D.4 AMS Suite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
EAppendix E: Level Transducer Block
E.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
E.1.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
E.1.2 Channel definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
E.2 Parameters and descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
E.3 Supported units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
E.3.1 Unit codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
E.4 Diagnostics device errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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FAppendix F: Register Transducer Block
F. 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
F. 1 .1 Register access transducer block parameters . . . . . . . . . . . . . . . . . . . . . . 265
GAppendix G: Advanced Configuration Transducer Block
G.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
G.1.1 Advanced configuration transducer block parameters . . . . . . . . . . . . . . 269
HAppendix H: Resource Block
H.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
H.2 Parameters and descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
H.2.1 PlantWeb® alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
H.2.2 Alarm priority. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
H.2.3 Recommended actions for PlantWeb alerts . . . . . . . . . . . . . . . . . . . . . . . 282
IAppendix I: Analog-Input Block
I.1 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
I.2 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
I.3 Signal conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
I.4 Block errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
I.5 Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
I.6 Alarm detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
I.6.1 Status handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
I.7 Configure the AI block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
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Section 1 Introduction
Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1
Service support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Product recycling/ disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
1.1 Manual overview
The sections in this manual provide installation, configuration, and maintenance information for the Rosemount 5400 Series Radar Level Transmitter. The sections are organized as follows:
Section 2: Transmitter Overview
Theory of operation Description of the transmitter Process and vessel characteristics
Section 3: Mechanical Installation
Installation procedure Mounting considerations Mounting
Section 4: Electrical Installation
Cable/conduit entries Grounding Cable selection Hazardous areas External circuit breaker Power requirements Connecting the transmitter Non-intrinsically safe power supply Intrinsically safe power supply Optional devices
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Section 5: Basic Configuration/Start-up
Configuration instructions Configuration using the Rosemount Radar Master (RRM) software Configuration using a Field Communicator Configuration using AMS
®
Suite
Configuration using DeltaV™ FOUNDATION
TM
fieldbus overview
Section 6: Operation
Viewing measurement data with a display panel Viewing measurement data in RRM Viewing measurement data in AMS Suite and DeltaV
Section 7: Service and Troubleshooting
Tro ub le sh oo ti ng Error and warning codes Communication errors
Section 8: Safety Instrumented Systems (4-20 mA Only)
Functional specifications Installation Configuration Operation and maintenance Spare parts
Appendix A: Reference Data
Specifications Dimensional drawings and mechanical properties Process connections Ordering information
Appendix B: Product Certifications
Examples of labels European ATEX Directive information FM approvals CSA approvals IECEx approvals TIIS approval NEPSI approvals INMETRO approvals Approval drawings
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Appendix C: Advanced Configuration
Advanced tank geometry Advanced transmitter settings Advanced functions in RRM
Appendix D: Performing Proof Test
Describes the process of performing proof test
Appendix E: Level Transducer Block
Describes the operation and parameters of the Level Transducer Block
Appendix F: Register Transducer Block
Describes the operation and parameters of the Register Transducer Block
Appendix G: Advanced Configuration Transducer Block
Describes the operation and parameters of the Advanced Configurations Transducer
Block
Appendix H: Resource Block
Describes the operation and parameters of the Resource Block
Appendix I: Analog-Input Block
Describes the operation and parameters of the Analog-Input function block
1.2 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-RSMT (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.
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 Occupational Safety and Health Administration (OSHA), a copy of the required Material Safety Data Sheet (MSDS) for each hazardous substance identified must be included with the returned goods.
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Emerson Process Management Instrument and Valves Response Center representatives will explain the additional information and procedures necessary to return goods exposed to hazardous substances.
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/regulations.
1.4 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 warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.
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Failure to follow safe installation and service guidelines could result in death or serious injury.
Make sure the transmitter is installed by qualified personnel and in accordance with
applicable code of practice.
Use the equipment only as specified in this manual. Failure to do so may impair the
protection provided by the equipment.
Do not perform any services other than those contained in this manual unless you are
qualified.
Any substitution of non-authorized parts or repair, other than exchanging the
complete transmitter head or antenna assembly, may jeopardize safety and is prohibited.
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 Process Management. Any continued use of product that has been damaged or modified without prior written authorization is at the customer's sole risk and expense.
Explosions could result in death or serious injury.
Verify that the operating environment of the transmitter is consistent with the
appropriate hazardous locations specifications. See “Product Certifications” on
page 217 in this manual.
To prevent ignition of flammable or combustible atmospheres, disconnect power
before servicing.
In an Explosion-proof/Flameproof installation, do not remove the transmitter cover
when power is applied to the unit.
Before connecting a HART
®
,
FOUNDATION™ fieldbus, or Modbus® based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices.
To avoid process leaks, only use O-rings designed to seal with the corresponding
flange adapter.
Electrical shock can result in death or serious injury.
Avoid contact with the leads and terminals. High voltage that may be present on leads
can cause electrical shock.
Make sure the main power to the Rosemount 5400 Series transmitter is off and the
lines to any other external power source are disconnected or not powered while wiring the transmitter.
Antennas with non-conducting surfaces.
Antennas with non-conducting surfaces (e.g. Rod antenna and Process Seal antenna)
may generate an ignition-capable level of electrostatic charge under extreme conditions. Therefore, when the antenna is used in a potentially explosive atmosphere, appropriate measures must be taken to prevent electrostatic discharge.
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Introduction
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Section 2 Transmitter Overview
Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Process characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Components of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
Antenna selection guide/measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
2.1 Theory of operation
The Rosemount 5400 Series Radar Transmitter is a smar t, two-wire continuous level transmitter. A 5400 transmitter is installed at the top of the tank and emits short microwave pulses towards the product surface in the tank. When a pulse reaches the surface, part of the energy is reflected back to the antenna for subsequent processing by the transmitter electronics. The time difference between the transmitted and reflected pulse is detected by a micro-processor and is converted into a distance, which calculates the level.
The product level is related to the tank height and the measured distance by the following expression:
Level = Tank Height - Distance
Figure 2-1. Measurement Principle for the Rosemount 5400 Series
Time
Level
Distance
Tan k H eig ht
Signal Amplitude
Radar Pulse
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2.2 Application examples
Tanks, vessels, and containers with calm surfaces
Non-contacting radar can be used in less challenging applications, such as storage and buffer tanks:
It is easy to mount, maintenance-free, and highly accurateGives precise monitoring and control of the process
Overfill and underfill detection
The Rosemount 5400 Series can be advantageous in risk reduction systems:
Continuous measurement may reduce or simplify proof-testsMultiple 5400s can be used in the same tank
Corrosives
Radar measurement is ideal for most corrosive products, such as caustics, acids, solvents, and many other chemicals:
Does not contact the process productWide material offering such as PTFE, Alloy C-276 and Alloy 400Works well in non-metallic tanks also
Sticky, viscous, and crystallizing products
The best-in-class Rosemount 5400 Series provides an accurate and reliable level reading with difficult products, such as resins and adhesives:
Non-contacting is best practiceAlmost unaffected by coating and build-up because of the
uniquely designed condensation resistant antennas
Sludges and slurries
Applications like mud, pulp-stock, and lime slurries are ideal for non-contacting measurement:
Immune to splashing and solids contentUnaffected by density changesNo re-calibration, no or little maintenance
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Reactor vessels
The innovative design of the Rosemount 5400 Series makes it an excellent choice for the most difficult applications, such as reactor vessels:
Unique circular polarization provides greater mounting
flexibility – no tank wall clearance distance is needed
Direct measurement – independent of most variations in
process conditions, such as density, dielectric, vapor, temperature, and pressure
Can handle turbulent conditions created by agitation,
top-filling, or process reaction
Mounting flexibility
The versatile Rosemount 5400 Series can be used in mounting configurations other than standard nozzles:
Fits most existing pipes: 2-8 in. (50-200 mm)Easy to isolate from the process – use a ball-valve
Still-pipes reduce the influence of foam, turbulence, and tank obstructions. Ball-valves can be used on both still-pipes and nozzles.
Underground tanks
The mounting flexibility of the Rosemount 5400 Series makes it an excellent choice for many underground tanks:
Easy top-mountingCan handle long narrow nozzles up to 6 ft (2 m) as long as they
are clean and smooth, and pipes
Unaffected by dirty products with solids content
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2.3 System architecture
The Rosemount 5400 Series Radar Transmitter is loop-powered, and uses the same two wires for power supply and output signal. The output is a 4-20 mA analog signal superimposed with a
digital HART
®
, FOUNDATION™ fieldbus or Modbus® signal.
By using the optional HART Tri-Loop™, the HART signal can be converted up to three additional 4-20 mA analog signals.
With the HART protocol, multidrop configuration is possible. In this case, communication is restricted to digital, since current is fixed to the 4 mA minimum value.
The transmitter can be connected to a Rosemount 751 Field Signal Indicator, or it can be equipped with an integral display.
The transmitter can easily be configured using a Field Communicator or a PC with the Rosemount Radar Master (RRM) software. Rosemount 5400 Series transmitters can also be
configured with the AMS
®
Suite and DeltaV™ software, and other tools that support Electronic
Device Description Language (EDDL) functionality.
For HART communication, a minimum load resistance of 250 : within the loop is required.
Figure 2-2. HART System Architecture
Integral Display
Rosemount 5400 Series Radar Transmitter
Rosemount 751 Field Signal Indicator
Field Communicator
Tri -L oo p
3 x 4-20 mA
DCS
HART modem
RRM or AMS Suite
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Figure 2-3. FOUNDATION fieldbus System Architecture
The RS-485 Modbus version communicates by Modbus RTU, Modbus ASCII, and Level Master Protocols.
HART communication is used for configuration via HART terminals, or tunneling via the RS-485.
Figure 2-4. RS-485 with Modbus Communication
FOUNDATION fieldbus
Note
Intrinsically safe installations may allow fewer devices per I.S. barrier due to current limitations.
Host / DCS system (e.g. DeltaV)
Maintenance
Field Communicator
Rosemo unt 5401
Rosemount 5402
Rosemo unt 5601
Fieldbus Modem
H1 - Low Speed Field Bus
6200 ft (1900 m) max (depending upon cable characteristics)
Configuration with RRM (hooked up on Fieldbus segment)
H2 - High Speed Field Bus
Rosemount 5400 Series Transmitter
HART Modem
Power
Modbus, Levelmaster Emulation / RS-485
Control System
RS-232 / RS-485 Converter
PC 5400 Setup in RRM
PC 5400 Setup in RRM through Tunneling
Field Communicator
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2.4 Process characteristics
Dielectric constant
A key parameter for measurement performance is reflectivity. A high dielectric constant of the media provides better reflection and enables a longer measuring range.
Foam
Rosemount 5400 Series Radar Transmitter measurement in foamy applications depends on the foam properties; light and airy or dense and heavy, high or low dielectrics, etc. If the foam is conductive and creamy, the transmitter may measure the surface of the foam. If the foam is less conductive, the microwaves may penetrate the foam and measure the liquid surface.
Turbulence
A calm surface gives better reflection than a turbulent surface. For turbulent applications, the maximum range of the radar transmitters is reduced. The range depends on the frequency, the antenna size, the dielectric of the material, and the degree of turbulence. Consult Tables 2-2 and
2-3 on page 16 for the expected maximum range with the variables listed.
Temperature/pressure/density and vapor
Temperature, pressure, product density, and vapor generally have no impact on measurements.
Condensation
For applications where heavy condensation and vapors may occur, the low frequency version Rosemount 5401 is recommended.
Tank characteristics
The conditions inside the tank have a significant impact on measurement performance. For more information see “Vessel characteristics” on page 35.
Solid surface
The surface of solid materials is rarely flat or horizontal. The angle of repose, or surface inclination, will change as the vessel fills and empties. There is often a lot of dust during the fill cycle. The dielectric value of many solids is fairly low. See Table 2-1 on page 2-13 for common solids characteristics.
For solids applications, the high frequency version Rosemount 5402 with 4 inch cone antenna is available.
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Table 2-1. Sample Solids Applications
(1)
Applications
Common characteristics
Particle size Vapor space
Dust or
Powder
Small
(<1 in.)
Larger
(>1 in.)
Dust
Steam or
Condensation
Wood chip bins Yes Yes Yes Yes Possible
Grain silo - small kernel grains
Yes Yes No Yes No
Grain silo - large kernel grains
No Yes No No No
Lime stone silo No Yes Yes Possible No
Cement - raw mill silo Yes Yes No Yes No
Cement - finished product silo
Yes Yes No Yes No
Coal bin Yes Yes Yes Yes Yes
Saw dust Yes Yes No Yes No
High consistency ­pulp stock
No No No No Ye s
Alumina Yes Yes No Yes No
Salt No Yes Yes No No
(1) Air purging might be needed in dusty environments.
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2.5 Components of the transmitter
The Rosemount 5400 Series Radar Transmitter is available with a die-cast aluminum or stainless steel (SST) housing containing advanced electronics for signal processing.
The radar electronics produces an electromagnetic pulse that is emitted through the antenna. There are different antenna types and sizes available for various applications.
The transmitter head has separate compartments for electronics and terminals, and can be removed without opening the tank. The head has two entries for conduit/cable connections.
The tank connection consists of a Tank Seal and a flange (ANSI, EN (DIN) or JIS).
Figure 2-5. Transmitter Components
B
G
H
A
E
F
D
C
A. Display Panel B. Cable Entry: ½" NPT.
Optional adapters: M20 C. Tank Seal D. Flange E. Terminal side F. Cable Entry: ½" NPT.
Optional adapters: M20 G. Transmitter head with Radar electronics H. Antenna
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2.6 Antenna selection guide/measuring range
The measuring range depends on the microwave frequency, antenna size, the dielectric constant (H
r
) of the liquid, and process conditions. A higher dielectric constant value produces a
stronger reflection. The figures in the tables below are guidelines for optimum performance. Larger measuring ranges may be possible. For more information, contact your local Emerson Process Management representative.
A. Oil, gasoline or other hydrocarbons, and petrochemicals (H
r
= 1.9-4.0). In pipes or with
ideal surface conditions, for some liquefied gases (H
r
= 1.4-4.0).
B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone
(H
r
= 4.0-10.0).
C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (H
r
> 10.0).
Table 2-2. Rosemount 5402, Maximum Recommended Measuring Range, ft (m)
High frequency antennas
Dielectric constant
(1)
(1) A. Oil, gasoline or other hydrocarbons, and petrochemicals (
H
r
= 1.9-4.0)
In pipes or with ideal surface conditions, for some liquefied gases (
H
r
= 1.4-4.0)
B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone (
H
r
= 4.0-10.0)
C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (
H
r
> 10.0)
A B C A B C A B C
2-in. Cone/ Process seal
33 (10) 49 (15) 66 (20) 82 (25) 115 (35) 115 (35) 9.8 (3) 20 (6) 33 (10)
3-in. Cone/ Process seal
49 (15) 66 (20) 98 (30) 82 (25) 115 (35) 115 (35) 13 (4) 30 (9) 39 (12)
4-in. Cone/ Process seal
66 (20) 82 (25) 115 (35) 82 (25) 115 (35) 115 (35) 23 (7) 39 (12) 49 (15)
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Table 2-3. Rosemount 5401, Maximum Recommended Measuring Range, ft (m)
Low Frequency Antennas
Dielectric Constant
(1)
(1) a. Oil, gasoline or other hydrocarbons, and petrochemicals (
H
r
= 1.9-4.0)
In pipes or with ideal surface conditions, for some liquefied gases (
H
r
= 1.4-4.0)
b. Alcohols, concentrated acids, org anic solvents, oil/water mixtures, and acetone (
H
r
= 4.0-10.0)
c. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (
H
r
> 10.0)
a b c a b c a b c
3-in. Cone
(2)
(2) Pipe installations only. NA = Not Applicable.
NA NA NA 82 (25) 115 (35) 115 (35) NA NA NA
4-in. Cone / Rod
(3)
(3) Pipe installations are not allowed with rod antennas.
23 (7) 39 (12) 49 (15) 82 (25) 115 (35) 115 (35) 13 (4) 26 (8) 39 (12)
6-in. Cone
43 (13) 66 (20) 82 (25) 82 (25) 115 (35) 115 (35) 20 (6) 33 (10) 46 (14)
8-in. Cone
66 (20) 82 (25) 115 (35) 82 (25) 115 (35) 115 (35) 26 (8) 39 (12) 52 (16)
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Table 2-4. Model and Antenna Guide
Model and antenna guide
5402 5401
This table gives guidelines on which model and antenna to select, depending on application.
G = Good AD = Application Dependent (consult
your local Emerson Process Management representative)
NR = Not Recommended
Cone (preferred) Process seal Cone (preferred) Rod
Best choice for a broad range of applications, free propagation and pipe installations.
Ideal for small tanks and corrosive applications. Also good for heav y antenna condensation/build-up.
Suitable for some extreme process conditions.
Suitable for small process connections, and corrosive environmen t.
Tank considerations
Installation close to smooth tank wall G G G G Multiple units on the same tank G G G G Internal obstructions, directly in path
(1)
NR NR AD AD
Internal obstructions, avoidance
(1)
(1) The obstruction should not be within the radar beam. Preferred choices due to more narrow radar beam: Model 5402, and cone antenna.
G G NR NR
Beam angle 2” 19°
3” 14° 4” 9°
2” 19° 3” 14° 4” 9°
4” 37° 6” 23° 8” 17°
37°
Antenna extends below nozzle G G G G Antenna recessed in smooth nozzle up to
6 ft (2 m)
GG NR
(2)
(2) If tall nozzle, use extended antenna.
NR
(3)
(3) The active part must protrude beneath the nozzle.
Antenna recessed in nozzle with irregularities, such as bad welds
AD
(4)
(4) An e xtended cone antenna must be used.
AD AD
(4)
NR
(3)
Stilling well mounting G 2”- 4” pipe G 2”- 4” pipe G 3”- 8” pipe NR Valves G G NR NR Long ranges (>115’ / 35 m) NR NR NR NR Cleanability of antenna AD G AD G
Process medium characteristics
Vapor (light, medium) G G G G Vapor (heavy) NR AD G G Condensing vapor/product build-up
(5)
(5) Build-up can often be avoided or reduced by using heat-tracing or cleaning arrangements.
AD G G AD Boiling/Turbulent surface (low/medium) G G G G Boiling/Turbulent surface (heav y) AD AD G
(6)
(6) Use a 6 or 8 in. (150-200 mm) cone antenna.
NR Boiling/Turbulent surface (still-pipe) G G G NR Foam
(7)
(7) Foam can either reflect, be invisible, or absorb the radar signal. Pipe mounting is advantageous since it reduces the foaming tendency.
NR NR AD AD
Foam (still-pipe)
(7)
GG GNR
Corrosive products (options available) G
(8)
(8) Other wetted material options include Alloy C-276 and Alloy 400. See the Rosemount 5400 Series Product Data Sheet (Document No. 00813-0100-4026) for details.
G
(8)
G
(8)
G Materials with ver y low dielectric G G G AD Changing density/dielectric/pH/
pressure/temperature
GG GG
Coating/viscous/crystallizing liquids G G G G Solids, granules, powders G NR NR NR
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