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

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Reference Manual

00809-0100-4026, Rev HA

November 2014

Rosemount 5400 Series

Superior Performance Two-Wire Non-Contacting Radar Level Transmitter

iii

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.

Reference Manual

00809-0100-4026, Rev HA

November 2014

Reference Manual

00809-0100-4026, Rev HA

Contents

November 2014

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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Contents

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

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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Introduction

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 accurate  Gives 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-tests  Multiple 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 product  Wide material offering such as PTFE, Alloy C-276 and Alloy 400  Works 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 practice  Almost 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 content  Unaffected by density changes  No 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-mounting  Can 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

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

) 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

= 1.9-4.0). In pipes or with

ideal surface conditions, for some liquefied gases (H

= 1.4-4.0).

B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone

= 4.0-10.0).

C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (H

> 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 (

= 1.9-4.0)

In pipes or with ideal surface conditions, for some liquefied gases (

= 1.4-4.0)

B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone (

= 4.0-10.0)

C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (

> 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 (

= 1.9-4.0)

In pipes or with ideal surface conditions, for some liquefied gases (

= 1.4-4.0)

b. Alcohols, concentrated acids, org anic solvents, oil/water mixtures, and acetone (

= 4.0-10.0)

c. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (

> 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.

(3)

(3) The active part must protrude beneath the nozzle.

Antenna recessed in nozzle with irregularities, such as bad welds

(4)

(4) An e xtended cone antenna must be used.

AD AD

(4)

(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.

(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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Section 3 Mechanical Installation

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19

Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21

Mounting considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36

3.1 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.

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Failure to follow safe installation and service guidelines could result in death or serious injury.

 Make sure only qualified personnel perform installation or service.  Use the equipment only as specified in this manual. Failure to do so may impair the

protection provided by the equipment.

 Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g.

substitution of components etc. may also jeopardize safety and is under no circumstances allowed.

Process leaks could result in death or serious injury.

 Make sure that the transmitter is handled carefully. If the Process Seal is damaged, gas

might escape from the tank if the transmitter head is removed from the antenna.

Explosions could result in death or serious injury.

 Verify that the operating environment of the transmitter is consistent with the

appropriate hazardous locations specifications.

 In an Explosion-proof/Flameproof installation, do not remove the transmitter cover

when power is applied to the unit.

 Before connecting a HART

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.

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)

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3.2 Installation procedure

Follow these steps for proper installation:

Review installation

considerations

(see page 22)

Mount the transmitter

(see page 36)

Wire the transmitter

(see page 43)

Make sure covers and

cable/conduit

connections are tight

Power up the

transmitter

Configure the

transmitter

(see page 73)

Veri fy me asureme nts

Ground the housing

(see page 46)

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3.3 Mounting considerations

Before installing a Rosemount 5400 Series transmitter, consider specific mounting requirements, vessel, and process characteristics.

3.3.1 Mounting location

For optimal performance, the transmitter should be installed in locations with a clear and unobstructed view of the level surface (A):

 Filling inlets creating turbulence (B), and stationary metallic objects with horizontal

surfaces (C) should be kept outside the signal beam – see page 33 for beamwidth information

 Agitators with large horizontal blades may reduce the performance of the transmitter,

so install the transmitter in a location where this effect is minimized. Vertical or slanted blades are often invisible to radar, but create turbulence (D)

 Do not install the transmitter in the center of the tank (E)  Because of circular polarization, there is no clearance distance requirement from the

tank wall if it is flat and free of obstructions such as heating coils and ladders (F). Usually, the optimal location is

/4 of the diameter from the tank wall

Note

Proper mounting position is important to consider.

Figure 3-1. Proper Mounting Position

 The antenna is normally aligned vertically

(D) (A) (E) (B) (F) (C)

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 A metal still-pipe can be used to avoid disturbing objects, turbulence, and foam (G)

Figure 3-2. Mounting in Still-Pipe

 The walls in non-metallic tanks are invisible to the radar signal, so nearby objects

outside of the tank may be detected

 Choose the largest possible antenna diameter for installation. A larger antenna

concentrates the radar beam, will be less susceptible to obstruction interference, and assures maximum antenna gain

 Multiple Rosemount 5400 Series transmitters can be used in the same tank without

interfering with each other (H)

Figure 3-3. Multiple Rosemount 5400 Series Transmitters in the Same Tank

(G)

(H)

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3.3.2 Special considerations in solids applications

 The transmitter should be mounted as close to the center of the tank as possible, but

not in the center of the tank. A general practice is to mount the transmitter at

/3 tank

radius from the tank wall, see Figure 3-4.

Figure 3-4. Transmitter Location in Solids Applications

 The radar signal must never be shaded by the inlet nor the injected product, see

Figure 3-5.

Figure 3-5. Install the Transmitter with a Clear and Unobstructed View

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3.3.3 Mounting in pipes

Still-pipe mounting is recommended for tanks with extremely turbulent surface conditions. All cone antenna sizes for the Rosemount 5400 Series of transmitters can be used for Still-pipe installations. The 3 in. (75 mm) antenna for the 5401 is designed for use in Still-pipes only. Rod antennas are not recommended for Still-pipes.

When the transmitter is mounted on a Still-pipe, the inclination should be within 1°. The gap between the antenna and the Still-pipe may be up to 0.2 in. (5 mm).

Figure 3-6. Mount the Transmitter Vertically

Recommendations for pipe installations

 The pipe interior must be smooth  Not suitable for adhesive products  At least one hole is above the product surface  The hole diameter Ø should not exceed 10 % of the pipe diameter D  Holes should only be drilled on one side

Max. 0.2 in (5 mm)

max. 1 °

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Figure 3-7. Recommended Hole Size for Pipe Installations

3.3.4 Installation considerations

Generally, the radar signal is unaffected by condensation and low pressure steam. If affected, the lower microwave frequencies are less affected. The critical point is the tank penetration, which acts as a cold spot, where the condensation will form. The radar antenna is located at this cold spot.

If droplets of water build up on the antenna parts, the microwave signal may get partially or even entirely blocked if the antenna is not designed for easy drip-off. Therefore, here it is beneficial to use as large opening for the microwaves as possible, which is the main reason for the oversized PTFE seal in the Rosemount 5400 Series Cone Antennas. An even better solution is to use a Process Seal Antenna if the process pressure permits that.

To reduce the cold spot within the nozzle, it is always recommended to insulate the nozzle. By doing so, the temperature in the nozzle will be the same as in the rest of the vessel and condensation will thus be reduced. If the temperature in the tank is much higher than the ambient temperature (i.e. tank is heated and located in a cold area), it might be necessary to

heat trace the nozzle in addition to the insulation.

Figure 3-8. Insulate Nozzle to Avoid Condensation

min. 6 in. (150 mm)

max. Ø: D/10.

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3.3.5 Nozzle considerations

Special considerations may have to be taken because of the nozzle, depending on the selection of transmitter model and antenna.

5402 with cone antenna

The antenna can be recessed in smooth nozzles up to 6 ft (2 m). If the inside of the nozzle contains disturbing objects, use the extended cone (I).

Figure 3-9. Nozzle Considerations for 5402 with Cone Antenna

5402 with process seal antenna

The antenna can be used on nozzles up to 6 ft (2 m), (J). Disturbing objects inside the nozzle (K) may impact the measurement, and should therefore be avoided.

The flange on the tank should have a flat or raised face. Other tank flanges may be possible, please consult your local Emerson Process Management representative for advice.

Figure 3-10. Nozzle Considerations for 5402 with Process Seal Antenna

Spray nozzle

(I)

Smooth nozzle

Bad weldings

(K) Bad welding

(J)

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5401 with cone antenna

The antenna should extend 0.4 in. (10 mm), or more, below the nozzle (L). If required, use the extended cone solution.

Figure 3-11. Nozzle Considerations for 5401 with Cone Antenna

5401 with rod antenna

The active part of the rod antenna should protrude below the nozzle (M).

Figure 3-12. Nozzle Considerations for 5401 with Rod Antenna

Still-pipes in metallic materials

If used correctly, pipe measurement can be advantageous in many applications:

 The 5402 is the preferred choice for smaller pipe diameters  Use the 5401 for larger pipe diameters (6-8 in./150-200 mm),

pipes with larger holes or slots, or for dirty/sticky media

 Use cone or process seal antennas - not the rod antenna  The gap between the cone antenna and the still-pipe is limited to 0.2 in. (5 mm). If

required, order an oversized antenna and cut on location (N). Only applicable to 5401 cone antennas and cone antennas with wetted flange plate (i.e. straight antennas).

 The inside of the chamber must be of a constant diameter

(L) 0.4 in. (10 mm) or more

Active part starts here

(M)

Max. 4 or 10 in. (100 or 250 mm) for short and long version respectively

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Note

Match antenna size to the stilling well diameter.

Figure 3-13. Nozzle Considerations for Still-Pipes in Metallic Materials

Ball-valve installation

The Rosemount 5400 Series transmitter can be isolated from the process by using a valve:

 The 5402 is the preferred choice for long nozzle measurement  Use the largest possible antenna  Use a full-port ball valve  Ensure there is no edge between the ball valve and the nozzle or stilling well, the inside

should be smooth

 Valves can be combined with stilling wells

(N)

Max. 0.2 in. (5 mm)

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3.3.6 Nozzle recommendations and requirements

The Rosemount 5400 Series is mounted on a nozzle by using appropriate flanges. For best performance, it is recommended that the nozzle meets the following recommendations for height (L) and diameter:

Figure 3-14. Mounting of the Rosemount 5400 Series Transmitter

Table 3-1. Minimum Nozzle Diameter and Recommended Maximum Nozzle Height for Cone Antennas

Model Antenna / material

max

in. (mm)

Min. diameter in. (mm)

5402

(1)

Cone 2 in. (50 mm) SST 6.1 (155) 2.2 (55)

Cone 3 in. (75 mm) SST 5.5 (140) 2.8 (72)

Cone 4 in. (100 mm) SST 8.5 (215) 3.8 (97)

Cone 2 in. (50 mm) Alloy C-276, Alloy 400 5.5 (140) 2.2 (55)

Cone 3 in. (75 mm) Alloy C-276, Alloy 400 6.5 (165) 2.8 (72)

Cone 4 in. (100 mm) Alloy C-276, Alloy 400 9.6 (240) 3.8 (97)

5401 Cone 3 in. (75 mm) SST Pipe installations only

Cone 4 in. (100 mm) SST 5.5 (140) 3.8 (97)

Cone 6 in. (150 mm) SST 6.9 (175) 5.7 (145)

Cone 8 in. (200 mm) SST 10.2 (260) 7.6 (193)

Cone 3 in. (75 mm) Alloy C-276, Alloy 400 Pipe installations only

Cone 4 in. (100 mm) Alloy C-276, Alloy 400 5.5 (140) 3.8 (97)

Cone 6 in. (150 mm) Alloy C-276, Alloy 400 6.9 (175) 5.7 (145)

Cone 8 in. (200 mm) Alloy C-276, Alloy 400 10.2 (260) 7.6 (193)

Minimum diameter

> 0.4 in. (10 mm)

Minimum diameter

Process seal antenna Rod antenna Cone antenna Extended cone antenna

> 0.4 in. (10 mm)

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Table 3-2. Minimum Nozzle Diameter and Maximum Nozzle Height for Rod Antennas

Table 3-3. Minimum Nozzle Diameter and Recommended Maximum Nozzle Height for Process Seal Antennas

Table 3-4. Minimum Nozzle Diameter and Maximum Nozzle Height for Extended Cone Antennas

Install the transmitter as follows:

 Align the antenna vertically.  Choose the largest antenna diameter possible. A larger receiving area concentrates the

radar beam and ensures maximum antenna gain. Increased antenna gain permits greater margin for weak surface echoes. A larger antenna also results in smaller beam angle and thereby, less interference from any internal structures in the tank.

 For best measurement performance, the antenna should extend below the nozzle

0.4 in. (10 mm) or more.

For more information, see “Nozzle considerations” on page 27.

(1) For Rosemount 5402, the values for maximum nozzle height are recommendations. Note that the Rosemount 5402

with cone antenna can be recessed in smooth nozzles up to 6 ft (2m).

Model Antenna L

max

in. (mm) Min. diameter in. (mm)

5401

(1)

(1) For Rosemount 5401, the values for minimum nozzle diameter and maximum nozzle height are requirements.

Rod (short) 4.0 (100) 1.5 (38)

Rod (long) 10 (250) 1.5 (38)

Model Antenna L

max

in. (mm) Min. diameter in. (mm)

5402

(1)

(1) For Rosemount 5402, the values for maximum nozzle height are recommendations. Note that the Rosemount 5402

with process seal antenna can be recessed in smooth nozzles up to 6 ft (2m).

Process Seal 2 in. (50 mm) 19.7 (500) 2.0 (51)

Process Seal 3 in. (75 mm) 19.7 (500) 3.0 (77)

Process Seal 4 in. (100 mm) 19.7 (500) 4.0 (102)

Model Antenna

max

in. (mm)

Min. diameter in. (mm)

5402

(1)

(1) For Rosemount 5402, the values for maximum nozzle height are recommendations.

Extended Cone Antenna, S3

(2)

(2) The extended cone antennas are available in 5 in. (125 mm) step increments from 10 to 50 in. (250-1250 mm). Consult

your local Emerson Process Management representative for more information. Expect long lead times for sizes other than the 20 in. (500 mm) version.

20 in. (500 mm) See Tab l e 3 -1

5401

Extended Cone Antenna, S3

(2)

20 in. (500 mm) See Tab l e 3 -1

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3.3.7 Service space

For easy access to the transmitter, mount it with sufficient service space.

There is no requirement on clearance distance from the tank wall, provided it is flat and free of obstructions such as heating coils and ladders. The optimal location is often

/4 of the tank

diameter.

Figure 3-15. Service Space Recommendations

Service space Antenna type Distance in. (mm)

A Cone, rod, process seal 20 (500)

Cone, rod 24 (600)

Process seal 33 (850)

Inclination Antenna type Maximum angle

CCone, rod, process seal3°

Rod antenna Cone antenna

Process seal antenna

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3.3.8 Beamwidth

The following recommendations should be considered when mounting the transmitter:

 The transmitter should be mounted with as few internal structures as possible within

the beam angle

 The flat tank wall can be located within the antenna beam angle if there is a minimum

distance from the transmitter to the tank wall (see Figure 3-15 for preferred installation)

Figure 3-16. Beamwidth at Various Distances from the Flange

Table 3-5. Beamwidth for the Rosemount 5402 Model (in ft [m])

Distance

Antenna

2 in. (DN 50) cone/

process seal

3 in. (DN 80) cone/

process seal

4 in. (DN 100) cone/

process seal

16 ft (5 m) 4.9 (1.5) 3.3 (1.0) 3.3 (1.0)

33 ft (10 m) 9.8 (3.0) 6.6 (2.0) 4.9 (1.5)

49 ft (15 m) 14.8 (4.5) 9.8 (3.0) 8.2 (2.5)

66 ft (20 m) 19.7 (6.0) 13.1 (4.0) 9.8 (3.0)

Distance

5401 (low frequency)

5402 (high frequency)

16 ft (5 m)

33 ft (10 m)

49 ft (15 m)

66 ft (20 m)

Beamwidth

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Table 3-6. Beamwidth for the Rosemount 5401 Model (in ft [m])

Figure 3-17. Beam Angle

Table 3-7. Beam Angle for the Rosemount 5402

Table 3-8. Beam Angle for the Rosemount 5401

Distance

Antenna

4 in. (DN 100)

cone /rod

6 in. (DN 150)

cone

8 in. (DN 200)

cone

16 ft (5 m) 9.8 (3..0) 6.6 (2.0) 4.9 (1.5)

33 ft (10 m) 21.3 (6.5) 13.1 (4.0) 9.8 (3.0)

49 ft (15 m) 32.8 (10) 19.7 (6.0) 14.8 (4.5)

66 ft (20 m) 41 (12.5) 26.2 (8.0) 19.7 (6.0)

Antenna Beam angle

2 in. (50 mm) cone / process seal 19°

3 in. (75 mm) cone / process seal 14°

4 in. (100 mm) cone / process seal, rod 9°

Antenna Beam angle

3 in. (75 mm) cone Pipe installations only

4 in. (100 mm) cone / rod 37°

6 in. (150 mm) cone 23°

8 in. (200 mm) cone 17°

Beam angle

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3.3.9 Vessel characteristics

Heating coils, agitators and other objects in the tank may lead to disturbing echoes and noise in the measurement signal. Vertical structures cause minimal effect since the radar signal is scattered rather than directed back to the antenna.

The shape of the tank bottom affects the measurement signal when the product surface is close to the tank bottom. The Rosemount 5400 Series has built-in functions which optimize measurement performance for various bottom shapes (see “Tank type and tank bottom type”

on page 76).

3.3.10 Disturbing objects

The Rosemount 5400 Series transmitter should be mounted so that objects such as heating coils, ladders, etc. are not in the radar signal path. These objects may cause false echoes resulting in reduced measurement performance. However, the transmitter has built-in functions designed to reduce the influence from disturbing objects where such objects cannot be totally avoided.

The Rosemount 5402 has a narrower radar beam that is particularly suitable in installations with tall or narrow nozzles, or nozzles close to the tank wall. It may also be used to avoid disturbing objects in the tank.

3.3.11 Valves

The Rosemount 5400 Series transmitter can be isolated from the process by using a valve:

 Use a full-port ball valve.  The 5402 is the required and the Process Seal Antenna is the preferred choice, since it

does not require a spool piece. The cone antenna can also be used.

 Ensure there is no edge between the ball valve and the nozzle/pipe, the inside should

be smooth.

Valves can be combined with stilling wells.

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3.4 Mounting

Mount the transmitter on a nozzle on top of the tank making sure only qualified personnel perform the installation.

The transmitter housing must not be opened.

If the transmitter housing must be removed for service, make sure the PTFE sealing is carefully protected against dust and water.

3.4.1 Cone antenna flange connection

Figure 3-18. Mounting the Rosemount 5400 with Cone Antenna and Flange

1. Place a gasket on top of the tank flange.

2. Lower the transmitter with antenna and flange into the tank nozzle.

3. Tighten the bolts and nuts with sufficient torque for the flange and gasket choice.

A. Transmitter housing B. Nut, 40 Nm (30 Lbft) C. Bolt D. Nut E. Locking screw F. F la nge G. Cone antenna H. Gasket I. Tank flange J. Nozzle

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3.4.2 Process seal antenna

(1)

Figure 3-19. Mounting the Rosemount 5400 with Process Seal and Flange

1. Place the antenna on top of the nozzle.

2. Mount the flange and tighten the bolts cross-wise. For torque information, see Ta bl e 3 -9 .

3. Mount the transmitter head and tighten the nut to 40 Nm (30 Lbft).

4. Re-tighten the flange bolts after 24 hours.

(1) The mounting information applies to the updated Process Seal antenna design, released in February 2012. Antennas manufactured before

this date have wetted O-rings and require a different installation procedure. For detailed information on the updated Process Seal antenna, see the Rosemount 5400 Series Reference Manual - Supplementary Information for Process Seal Antennas Manual Supplement (Document No. 00809-0700-4026).

A. Transmitter housing B. Nut, 40 Nm (30 Lbft) C. Nut D. Locking screw (ATEX) E. Bolt F. F la nge G. Process Seal antenna H. Tank flange I. Nozzle

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Table 3-9. Tightening Torque for Process Seal Flanges

3.4.3 Rod antenna threaded connection

Figure 3-20. Mounting the Rosemount 5400 with Rod Antenna and Threaded Tank Connection

1. Lower the transmitter and antenna into the tank.

2. Turn the transmitter until it is properly secured in the process connection.

3. Make sure the cable entries and display face the right direction.

Note

Tank connections with NPT threads require a sealant for pressure-tight joints.

Flange Tor que (Nm) Torq ue (Lb ft)

2 in. (50 mm), 150 lb. 40 30 2 in. (50 mm), 300 lb. 40 30 3 in. (75 mm), 150 lb. 60 44 3 in. (75 mm), 300 lb. 60 44 4 in. (100 mm), 150 lb. 50 37 4 in. (100 mm), 300 lb. 50 37 DN 50 PN 40 40 30 DN 80 PN 40 60 44 DN 100 PN 16 50 37 DN 100 PN 40 50 37 50A 10K 40 30 80A 10K 60 44 100A 10K 50 37 150A 10K 50 37

A. Transmitter housing B. Nut, 60 Nm (44 Lbft) C. Locking screw (ATEX) D. Sealant threads E. Rod antenna

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3.4.4 Rod antenna flanged connection

Figure 3-21. Mounting the Rosemount 5400 with Rod Antenna and Flange

1. Place a gasket on top of the tank flange

(1)

. The gasket thickness and material must be

suitable for the process.

2. Lower the transmitter with antenna and flange into the tank nozzle.

3. Tighten the bolts and nuts with sufficient torque for the flange and gasket choice.

(1) Gasket is optional for the All-PFA version of the rod antenna.

A. Transmitter housing B. Bolt C. Gasket (optional for the All PFA version) D.Nut E. Locking screw (ATEX) F. F la nge G. PFA plate (only All PFA version, 1R, 2R) H. Tank flange I. Nozzle J. Rod antenna

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3.4.5 Tri-Clamp™ tank connection

Figure 3-22. Mounting the Rosemount 5400 using a Tri-Clamp

1. Place a gasket on top of the tank flange.

2. Lower the transmitter and antenna into the tank.

3. Fasten the Tri-Clamp to the tank with a clamp.

4. To rotate the transmitter housing, loosen the nut.

5. Rotate the transmitter housing so the cable entries / display face the desired direction.

6. Tighten the nut.

A. Nut B. Rod antenna C. Gasket D. Tank connection E. Tri-Clamp F. Clamp

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3.4.6 Bracket mounting on wall

Figure 3-23. Bracket Mounting the Rosemount 5400, on Wall

1. Mount the bracket directly to the wall with screws suitable for the purpose.

2. Mount the transmitter with antenna to the bracket, then secure the installation with the three supplied screws.

A. Transmitter housing B. Antenna C. Bracket

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3.4.7 Bracket mounting on pipe

Figure 3-24. Bracket Mounting the Rosemount 5400, on Pipe

1. Put the two U-bolts through the holes of the bracket. Holes are available for both vertical and horizontal pipe mounting.

2. Put the clamping brackets on the U-bolts and around the pipe.

3. Fasten the bracket to the pipe with the four supplied nuts.

4. Mount the transmitter with antenna to the bracket, and secure with the three supplied screws.

A. U-bolts B. Bracket C. Clamping bracket D. Screws E. Transmitter housing F. S cr ew G. Antenna

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Section 4 Electrical Installation

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43

Wiring and power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44

Cable/conduit entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46

Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46

Hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47

External circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47

HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49

OUNDATION fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55

HART to Modbus Converter (HMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 60

Establish HART communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 66

Optional devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 69

4.1 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.

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Additional warnings or restrictions may apply depending on type of Hazardous approval. See

Appendix B: Product Certifications for details.

4.2 Wiring and power supply requirements

Wiring and power supply requirements can be dependent upon the approval certification. As with all F

OUNDATION™ fieldbus requirements, a conditioned power supply and terminating

resistors are required for proper operation.

Failure to follow safe installation and service guidelines could result in death or serious injury.

 Make sure only qualified personnel perform installation or service.  Use the equipment only as specified in this manual. Failure to do so may impair the

protection provided by the equipment.

 Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g.

substitution of components etc. may also jeopardize safety and is under no circumstances allowed.

 Do not perform any service other than those contained in this manual unless you are

qualified.

Process leaks could result in death or serious injury.

 Make sure that the transmitter is handled carefully. If the process seal is damaged, gas

might escape from the tank if the transmitter head is removed from the antenna.

Explosions could result in death or serious injury.

 Verify that the operating environment of the transmitter is consistent with the

appropriate hazardous locations specifications.

 In an Explosion-proof/Flameproof installation, do not remove the transmitter cover

when power is applied to the unit.

 Before connecting a HART

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.

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.

High voltage that may be present on leads could cause electrical shock.

 Avoid contact with leads and terminals.  Make sure the main power to the Rosemount 5400 transmitter is off and the lines to

any other external power source are disconnected or not powered while wiring the gauge.

Antennas with non-conducting surfaces.

 Antennas with non-conducting surfaces (e.g. rod antenna and process seal antenna)

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4.3 Cable/conduit entries

The electronics housing has two entries with ½ - 14 NPT threads. Optional M20×1.5 adapters are also available. The connections shall be according to national, local, and plant electrical codes.

Properly seal unused ports to prevent moisture or other contamination from entering the terminal compartment of the electronics housing. Install wiring with a drip loop with the bottom of the loop lower than the cable/conduit entry.

Figure 4-1. Cable Entries

Note

Use the enclosed metal plug to seal the unused port. The temporary orange plastic plugs used at delivery are not sufficient seals! Failure to use the metal plug to seal the unused port invalidates product certification.

4.3.1 Conduit electrical connector wiring (using minifast®)

For wiring details, refer to pin-out drawing and the cordset manufacturer’s installation instructions.

Figure 4-2. Quick Connect Housing Pin-Out

For Rosemount 5400 Series transmitters with conduit electrical connector M, refer to the cordset manufacturer’s installation instructions for wiring details.

Remove the orange protective plastic plugs, used for transportation. Seal any unused port with the enclosed metal plug.

Cable Entry (see

Figure 2-5 on page 14

)

Cable Entry (see

Figure 2-5 on page 14)

“+” “-”

No connection

Ground

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4.4 Grounding

When wiring the transmitters, the grounding should be completed such that:

 The loop is grounded at the power supply.  When transmitters are installed on metal tanks, ensure there is a metal-to-metal

connection between the device and the tank.

 If the tank is non-metallic, the housing must be grounded to an earth ground that is

separate from the power supply. The external ground terminal may be used for this purpose.

 If the tank is cathodically protected, the housing must be grounded to an earth ground

that is outside of the cathodic protection system ground. Use the external terminal for this purpose.

When transient protection terminal block is used, the ground wire should be separate from the signal wire. Use the external ground terminal.

Make sure grounding is done (including IS ground inside Terminal compartment) according to Hazardous Locations Certifications, national and local electrical codes.

The most effective transmitter housing grounding method is a direct connection to earth ground with minimal (< 1 :) impedance.

Note

Grounding the transmitter housing using the threaded conduit connection may not provide a sufficient ground. The transient protection terminal block will not provide transient protection unless the transmitter housing is properly grounded. Use the above guidelines to ground the transmitter housing. Do not run transient protection ground wire with signal wiring; the ground wire may carry excessive current if a lightning strike occurs.

Note

After installation and commissioning, make sure that no ground currents exist from high ground potential differences in the installation.

4.5 Cable selection

Use shielded twisted pair wiring for the Rosemount 5400 Series. The cables must be suitable for the supply voltage and approved for use in hazardous areas, where applicable. For instance, in the U.S., explosion-proof conduits must be used in the vicinity of the vessel. For the ATEX flameproof approval version of the Rosemount 5400 Series, suitable conduits with sealing device or flameproof cable glands must be used depending on local requirements.

Use 18 AWG to 12 AWG wiring to minimize the voltage drop to the transmitter.

For Modbus

units (RS-485 bus), the following rules apply:

 2 cables are used for communication: 24 AWG shielded twisted pair wiring is

recommended to get an impedance of 120 :

 2 cables are used for power: AWG 16-18 cables must be used

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Note

Avoid running instrument cable next to power cables in cable trays or near heavy electrical equipment.

It is important that the instrument cable shield be:

- trimmed close and insulated from touching the transmitter housing

- continuously connected throughout the segment

- connected to a good earth ground at the power supply end

4.6 Hazardous areas

When the Rosemount 5400 Series transmitter is installed in a hazardous area, all national and local regulations and specifications in applicable certificates must be observed.

4.7 External circuit breaker

For compliance with Low Voltage Directive 2006/95/EC, an external circuit breaker should be installed.

4.7.1 Connecting the transmitter

The Rosemount 5400 Series accepts power supplies ranging from 16 Vdc to 42.4 Vdc. It uses 4-20 mA power superimposed with a HART signal.

To connect the transmitter:

1. Verify that the power supply is disconnected.

2. Remove the terminal block cover (see Figure 4-3).

3. Pull the cable through the cable gland/conduit. For explosion-proof/ flameproof installations, only use cable glands or conduit entry devices certified explosion-proof or flameproof. Install the wiring with a drip loop where the bottom of the loop must be lower than the cable/conduit entry.

4. To connect the wires, see the illustrations on the following pages.

5. Remove the orange protective plastic plugs used for transportation. Seal any unused port with the enclosed metal plug.

6. Mount the cover and make sure it is fully engaged to meet explosion-proof requirements (adapters are required if M20 glands are used). For ATEX, IECEx, NEPSI, INMETRO, and TIIS installations, lock the cover with the locking screw.

7. Connect the power supply.

Note

Use PTFE tape or other sealant at the NPT threads in the cable entries.

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Figure 4-3. Terminal Compartment and External Ground Screw

Note

Remove the orange, protective, plastic plugs, used for transportation. Seal any unused port with the enclosed metal plug.

Cable entry NPT ½ in.-14, or M20 X 1.5 adapter

External ground screw

Blind plug Supplied for unused conduit opening.

Terminals for signal and power supply

Cable entry NPT ½ in.-14, or M20 X 1.5 adapter

Locking screw

Internal ground screw

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4.8 HART

4.8.1 Power requirements

The Rosemount 5400 Series transmitter operates with a power supply ranging from 16 - 42.4 Vdc (16 - 30 Vdc in IS applications, 20 - 42.4 Vdc in explosion-proof / flameproof applications and in non-sparking / energy-limited applications).

All configuration tools for HART communication, such as the Field Communicator and Rosemount Radar Master, require a minimum load resistance (R

) of 250 : within the loop in

order to function properly.

Terminals in the transmitter housing provide connections for signal wiring. The Rosemount 5400 Series operates with the following power supplies:

Table 4-1. Minimum Input Voltage (U

) at Different Currents

4.8.2 Load limitations

Maximum load resistance (R) is determined by the voltage level of the external power supply (U

), as described by:

Figure 4-4. Non-Hazardous Installations, and Non-Sparking / Energy-Limited Power Supply

Hazardous approval

Current

3.75 mA 21.75 mA

Minimum input voltage (UI)

Non-Hazardous Installations and Intrinsically Safe Installations

16 Vdc 11 Vdc

Explosion-proof / Flameproof Installations

20 Vdc 15.5 Vdc

10 2016 30

200

400

600

800

1000

1200

1400

40 50

42.424

586

1387

External Power Supply Voltage UE(V)

Maximum Load Resistance R(

Operating region

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Figure 4-5. Intrinsically Safe Installations

Figure 4-6. Explosion-Proof / Flameproof Installations

Note

For flameproof/explosion-proof installations, the diagram is only valid if the HART load resistance is at the + side and if the - side is grounded. Otherwise, the load resistance value is limited to 435 :.

Note

Rosemount 5400 Series Transmitters with flameproof/explosion-proof output have a built-in barrier; no external barrier needed.

External Power Supply Voltage UE(V)

Maximum Load Resistance R(

Operating region

10 20 30

200

400

600

800

1000

1200

1400

40 50

24 42.4

1148

348

External Power Supply Voltage UE(V)

Maximum Load Resistance R(

Operating region

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4.8.3 Non-intrinsically safe power supply

With a non-intrinsically safe power supply in non-hazardous installations or explosion-proof/flameproof installations, wire the transmitter as shown in Figure 4-7.

Note

Make sure the power supply is off when connecting the transmitter.

Figure 4-7. Wiring for Non-Intrinsically Safe Power Supply (HART)

The Field Communicator and the HART modem require a minimum load resistance of 250 : within the loop to function properly.

Note

The diagram is valid only if the HART load resistance is at the + side and if the - side is grounded, otherwise the load resistance value is limited to 435 :.

Note

For explosion-proof/flameproof installations make sure the transmitter is grounded to the I.S. ground terminal inside the terminal compartment in accordance with national and local electrical codes.

Rosemount 5400 Series Radar Level Transmitter

Field Communicator

HART modem

Load Resistance 250 W

Power Supply

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4.8.4 Intrinsically safe power supply

With an intrinsically safe power supply, wire the transmitter as shown in Figure 4-8.

Note

Make sure the instruments in the loop are installed according to intrinsically safe field wiring practices.

Ins tallation also nee ds to co mply with the applicable installation/ contro l drawing . See “Approval

drawings” on page 230.

Figure 4-8. Wiring Diagram for Intrinsically Safe Power Supply (HART)

The Field Communicator and the HART modem require a minimum load resistance within the loop of 250 : to function properly. For maximum load resistance see Figure 4-5.

For Safety Instrumented Systems information, see Section 8: Safety Instrumented Systems

(4-20 mA Only).

For IS parameters, see Appendix B: Product Certifications.

Rosemount 5400 Series radar level transmitter

Approved IS barrier

RL=250 W

Power supply

Field communicator

HART modem

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4.8.5 Type N approvals: non-sparking / energy-limited power supply

With a non-sparking / energy- limited power supply, wire the transmitter as shown in

Figure 4-9.

Figure 4-9. Wiring Diagram for Non-Sparking / Energy-Limited Power Supply (HART)

Rosemount 5400 Series Radar Level Transmitter

Field Communicator

HART modem

Load Resistance 250 W

Power Supply

HART: Un=42.4 V

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4.8.6 Transient protection terminal block

For a terminal block with transient protection, wire the transmitter as shown in Figure 4-10.

Figure 4-10. Wiring Diagram for Transient Protection Terminal Block (HART)

Rosemount 5400 Series Radar Level Transmitter

Field Communicator

Load Resistance 250 W

HART modem

Power Supply

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4.9 FOUNDATION fieldbus

4.9.1 Power requirements

Terminals in the transmitter housing provide connections for signal wiring.

The Rosemount 5400 transmitter is powered over F

OUNDATION fieldbus with standard fieldbus

power supplies.

The transmitter operates with the following power supplies:

The Rosemount 5400 Series with F

OUNDATION fieldbus operates using a power supply ranging

from 9-32 Vdc (9-30 Vdc in IS applications, 16-32 Vdc in explosion-proof / flameproof applications, and 9-17.5 Vdc in FISCO, IS applications).

Grounding

Signal wiring of the fieldbus segment cannot be grounded. Grounding out one of the signal wires will shut down the entire fieldbus segment.

Shield wire ground

To protect the fieldbus segment from noise, grounding techniques for shield wire usually require a single grounding point for shield wire to avoid creating a ground loop. The ground point is typically at the power supply.

Approval type Power supply (Vdc)

IS 9 - 30

Explosion-proof/flameproof 16 - 32

None 9 - 32

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Connecting fieldbus devices

Figure 4-11. Rosemount 5400 Series Radar Transmitter Field Wiring

Signal wiring

Power supply

OUNDATION

fieldbus

configuration

tool

Ter mi na to r s

6200 ft (1900 m) max

(depending upon cable characteristics)

Integrated power

conditioner

and filter

(Trunk)

(Spur)

(The power supply, filter, first terminator, and configuration tool are typically located in the control room.)

fieldbus

segment

fieldbus

devices on

segment

Intrinsically safe installations may allow fewer devices per IS barrier due to current limitations.

Configuration with RRM (in a fieldbus system hooked up on a fieldbus segment).

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4.9.2 Non-intrinsically safe power supply

With non-intrinsically safe power supply in Non-hazardous installations or Explosion-proof/Flameproof installations, wire the transmitter as shown in Figure 4-12.

Rosemount 5400 Series Transmitters with Explosion-proof/Flameproof Output have a built-in barrier; no external barrier needed.

Note

Make sure that the power supply is off when connecting the transmitter.

Figure 4-12. Wiring for Non-Intrinsically Safe Power Supply (FOUNDATION fieldbus)

Note

For explosion-proof/flameproof installations make sure that the transmitter is grounded to the IS ground terminal inside the terminal compartment in accordance with national and local electrical codes.

Rosemount 5400 Series radar transmitter

Field communicator

Fieldbus modem

Power supply

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4.9.3 Intrinsically safe power supply

When your power supply is intrinsically safe, wire the transmitter as shown in Figure 4-13.

Note

Make sure that the instruments in the loop are installed in accordance with intrinsically safe field wiring practices.

Ins tallation also nee ds to co mply with the applicable installation/ contro l drawing . See “Approval

drawings” on page 230.

Figure 4-13. Wiring Diagram for Intrinsically Safe Power Supply (FOUNDATION fieldbus)

Rosemount 5400 Series Radar Transmitter

For IS Parameters, see

Appendix B: Product Certifications.

Approved IS Barrier

Field Communicator

Fieldbus modem

Power supply

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4.9.4 Type N approvals: non-sparking / energy-limited power supply

With a non-sparking / energy-limited power supply, wire the transmitter as shown in

Figure 4-14.

Figure 4-14. Wiring Diagram for Non-Sparking / Energy-Limited Power Supply (FOUNDATION fieldbus)

Rosemount 5400 Series radar level transmitter

OUNDATION fieldbus: U

= 32 V

Power supply

Field communicator

Fieldbus modem

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4.10 HART to Modbus Converter (HMC)

The Rosemount 5400 Series RS-485 with Modbus communication transmitter version operates using a power supply ranging from 8-30 Vdc (max. rating). See the Rosemount 5300/5400 Series with HART to Modbus Converter Manual Supplement (Document No. 00809-0500-4530) for details.

Power consumption:

< 0.5 W (with HART address = 1) < 1.2 W (incl. four HART slaves)

4.10.1 Connecting the transmitter

1. Disconnect/shut off the electrical power to transmitter head and then open the

instrument cover. Do not remove the cover in an explosive atmosphere with a live circuit.

2. Pull the cable through the cable gland/conduit. For the RS-485 bus, use shielded

twisted pair wiring, preferably with an impedance of 120 : (typically 24 AWG) in order to comply with the EIA-485 standard and EMC regulations. The maximum cable length is 4000 ft (1200 m).

3. Make sure that the transmitter housing is grounded, then connect wires according to

Figure 4-15 and Ta bl e 4- 2 . Connect the lead that originates from the “A” line from the

RS-485 bus to the terminal marked MB, and the lead that originates from the “B” line to the terminal marked MA.

4. If it is the last transmitter on the bus, connect the 120 : termination resistor.

5. Connect the leads from the positive side of the power supply to the terminal marked

POWER +, and the leads from the negative side of the power supply to the terminal marked POWER -. The power supply cables must be suitable for the supply voltage and ambient temperature, and approved for use in hazardous areas, where applicable.

6. Attach and tighten the housing cover. Tighten the cable gland, then plug and seal any

unused terminals, and connect the power supply.

Note

Rosemount 5400 Series transmitters with flameproof/explosion-proof output have a built-in barrier; no external barrier needed.

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Figure 4-15. Field Wiring Connections

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

Ambients > 60 ºC Use wiring rated for min 90 ºC

RS-485 Bus

Power supply

HART

HART -

120W

If it is the last transmitter on the bus, connect the 120 W

termination

resistor

MODBUS

(RS-485)

erter

120W

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4.10.2 Connection terminals

The connection terminals are described in Tab l e 4 - 2 below:

Table 4-2. Connection Terminals

Figure 4-16. Connection Terminals for Rosemount 5400 with HART to Modbus Converter

Connector label Description Comment

HART + Positive HART connector Connect to PC with RRM software, Field

Communicator, or other HART config urators.

HART - Negative HART connector

Modbus RS-485 B connection (RX/TX+)

(1)

(1) The designation of t he connectors does not follow the EIA-485 standard, which states that RX/TX- should be referred to as 'A' and

RX/TX+ as 'B'.

Connect to Remote Terminal Unit (RTU)

Modbus RS-485 A connection (RX/TX-)

(1)

POWER + Positive Power input terminal

Apply +8 Vdc to +30 Vdc (max. rating)

POWER - Negative Power input terminal

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

Ambients > 60 ºC Use wiring rated for min 90 ºC

HART +

HART -

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4.10.3 RS-485 bus

 The Rosemount 5400 transmitter does not provide electrical isolation between the

RS-485 bus and the transmitter power supply

 Maintain a bus topology and minimize stub length  Figure 4-17 identifies multidrop wiring topology, where up to 32 devices may be wired

on one RS-485 bus

 The RS-485 bus needs to be terminated once at each end, but should not be terminated

elsewhere on the bus

4.10.4 Installation cases

Install the Rosemount 5400 Series Transmitter as shown in Figure 4-17.

 Use common ground for Modbus Master and Power Supply  The Power cables and RS-485 Bus are in the same cable installation  A ground cable is installed and shall be used (cable size > 4 mm according to

IEC60079-14, or size according to applicable national regulations and standards). A properly installed threaded conduit connection may provide sufficient ground.

 The cable shielding is grounded at master site (optional)

Note

The HMC equipped transmitter contains intrinsically safe circuits that require the housing to be grounded in accordance with national and local electrical codes. Failure to do so may impair the protection provided by the equipment.

Figure 4-17. Multidrop Connection of Rosemount 5400 Series Transmitters

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

Ambients > 60 ºC Use wiring rated for min 90 ºC

Power supply

120 W

RS-485 bus

BAModbus

master

External ground screw

Internal ground screw

External ground screw

Internal ground screw

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Alternatively, the Rosemount 5400 Series Transmitter can be installed as shown in Figure 4-18. If this wiring layout is used, there is an increased risk for communication disturbances due to differences in potential between grounding points. By using the same grounding point for Modbus Master and Power Supply, this risk is reduced.

Figure 4-18. Alternative Multidrop Connection of Rosemount 5400 Series Transmitters

Star topology

For a star topology connection of the Rosemount 5400 Series transmitters, the transmitter with the longest cable run needs to be fitted with a 120 : termination resistor.

Figure 4-19. Star Topology Connection of Rosemount 5400 Series Transmitters

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

Ambients > 60 ºC Use wiring rated for min 90 ºC

Power supply

120 W

120 :

RS-485 bus

BAModbus

master

External ground screw

Internal ground screw

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

MODBUS

(RS-485)

erter

Ambients > 60 ºC Use wiring rated for min 90 ºC

For a star topology connection, connect the 120 :



termination resistor to the transmitter with the longest cable run.

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4.10.5 External HART devices (slaves)

The HMC supports up to four external HART devices. The external devices are separated by using the HART address. The address must be different between the external devices and only addresses 1 to 5 are allowed for multiple slaves. Connect the devices one at a time and change the short address prior to connecting the next device by using a HART Configuration Tool such as RRM, or a Field Communicator.

Note

The power supply from the HMC to external HART devices is not intrinsically safe. In a hazardous environment, any external HART device connected to the HMC must have Flameproof/Explosion-proof certification.

The HMC cyclically polls the HART devices for measurement values. The update rate depends on the number of connected devices and is shown in Tab l e 4 - 3 .

Table 4-3. Approximate Update Rates for Measurement Values

Figure 4-20. The HMC Module Supports up to Four External Devices (slaves)

No. of devices (slaves) Approx. update rate

12 seconds 23 seconds 34 seconds 45 seconds 55 seconds

MODBUS

POWER

HART

(RS-485)

HART to Modbus Converter

Ambients > 60 ºC Use wiring rated for min 90 ºC

Power supply

RS-485 bus

Up to four external devices

External HART device 2

External HART device 1

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4.11 Establish HART communication

The Rosemount 5400 Series can be configured using the RRM PC software or a Field Communicator. Configuration is done by sending HART commands through the HMC to the Rosemount 5400 transmitter electronics. To establish HART communication, connect to the MA/MB terminals, or to the HART terminals. Both alternatives are described below.

4.11.1 Connect to the MA/MB terminals

The Rosemount 5400 level transmitter can be configured with RRM using the MA, MB terminals.

An RS-485 Converter is required to connect to the transmitter.

The transmitter will try to establish communication using different protocols during 20 second timeslots from time of startup.

Figure 4-21. RS-485 Communication after Startup

The transmitter will continue to use a communication protocol once communication has been established.

To configure the Rosemount 5400 level transmitter using RRM and the MA, MB terminals, do the following:

1. Connect the RS-485 Converter to the MA, MB connectors.

2. Start RRM and open Communication Preferences.

HART 20 seconds

Modbus RTU 20 seconds

Configured protocol (Modbus RTU, Levelmaster, or Modbus ASCII) 20 seconds

HART 20 seconds

Time

0 s 20 s 40 s 60 s 80 s 100 s

Configured protocol (Modbus RTU, Levelmaster, or Modbus ASCII) 20 seconds

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3. Enable HART communication and make sure the port for the RS-485 Converter is

selected. Use the following settings:

4. Connect the power wires (or cycle power) to the transmitter.

5. Wait 20 seconds and then open the Search Device window in RRM (also see Note on

page 68). Make sure HART address 1 is being scanned.

6. Connect to the transmitter and perform the necessary configuration.

7. After completing the configuration, disconnect the RS-485 Converter, connect the

Modbus communication wires and cycle power to the transmitter

8. Verify that communication between the transmitter and the RTU is established (can

take up to 60 seconds from startup).

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Note

Take the following into consideration if there are multiple Rosemount 5400 Modbus units on the bus:

By default, the transmitters have HART address 1. It will not be possible to establish communication on HART address 1 if several transmitters have the same address. In this case, there are alternative solutions to establish communication:

1. Select the Scan by Tag option in the Search Device window in RRM and enter the HART

Device Tag of the transmitter. Communication can now be established with an individual transmitter even if several devices have the same HART address.

2. Make sure the Rosemount 5400 transmitter is alone on bus. Disconnect or turn off

power from any other dcevies.

4.11.2 Connect to the HART terminals

To configure the Rosemount 5400 transmitter, connect the communicator or PC to the HART terminals using a HART modem, see Figure 4-16 on page 62. Both the configuration tool and the RS-485 bus can be connected simultaneously. Configuration data is sent with HART commands through the HMC to the Rosemount 5400 transmitter electronics.

Note that the power supply must be connected during configuration, see also “Connecting the

transmitter” on page 47.

Note

Measurement data is not updated to the Modbus Master when a configuration tool is connected.

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4.12 Optional devices

4.12.1 Tri-Loop™ HART to analog converter

The Rosemount 5400 Series transmitter outputs a HART signal with four process variables. The Model 333 HART Tri-Loop provides up to three additional analog 4-20 mA outputs.

Figure 4-22. Wiring Diagram for HART Tri-Loop

Configure Channels 1, 2, and 3 to reflect the units in addition to Upper Range Values and Lower Range Values for secondary, tertiary, and fourth variables (variable assignment is configured in the Rosemount 5400 Series). It is also possible to enable or disable a channel from this menu.

Ch. 3 Ch. 2 Ch. 1

Each Tri-Loop channel receives power from control room

Channel 1 must be powered for the Tri-Loop to operate

Device receives power from control room

!250

HART Burst command 3/ analog output

IS barrier

DIN rail mounted HART Tri-Loop

Control room

Burst input to Tri-Loop

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4.12.2 751 Field Signal Indicator

Figure 4-23. Wiring Diagram for a Rosemount 5400 Series Transmitter with a 751 Field Signal Indicator

Power supply

Rosemount 5400 Series radar transmitter

751 Field Signal Indicator

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4.12.3 Smart Wireless THUM™ Adapter

The Rosemount 5400 Series can be combined with the Smart Wireless THUM Adapter.

For more information, see the Smart Wireless THUM

™

Adapter for Rosemount Process Level Transmitter Applications Technical Note (Document No. 00840-0100-4026) and the Smart Wireless THUM™ Adapter Reference Manual (Document No. 00809-0100-4075).

Figure 4-24. Wiring Diagram for a Rosemount 5400 Series with the Smart Wireless THUM Adapter

Rosemount 5400 Series radar transmitter with THUM Adapter

Rosemount Field Communicator

RRM/Rosemount

Configuration Tool

4-20 mA/HART

Smart wireless gateway

AMS® configurator

DCS/host system

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Section 5 Basic Configuration/Start-up

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 73

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 74

Basic configuration parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 75

Basic configuration using RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 84

Configuration using a Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 101

Basic configuration using AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 105

Configuration using DeltaV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 106

OUNDATION fieldbus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 112

Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 115

Tri-Loop™ HART to Analog Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 117

HART multidrop configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 118

5.1 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 safety messages listed at the beginning of each section before performing an operation preceded by this symbol.

Explosions could result in death or serious injury.

Verify that the operating environment of the gauge is consistent with the appropriate hazardous locations certifications.

Before connecting a HART

-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.

Do not remove the gauge cover in explosive atmospheres when the circuit is alive.

 All connection head covers must be fully engaged to meet explosion-proof

requirements.

Failure to follow safe installation and servicing guidelines could result in death or serious injury.

Make sure only qualified personnel perform the installation. 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 service other than those contained in this manual unless you are

qualified.

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5.2 Overview

The configuration of a Rosemount 5400 Series transmitter is normally a simple and straightforward task. If the transmitter is pre-configured at the factory according to ordering specifications in the Configuration Data Sheet, no further basic configuration is required, unless tank conditions have changed.

The Rosemount 5400 Series supports a set of advanced configuration options that can be used to handle special tank conditions and applications. For further information on advanced configuration options, see Appendix C: Advanced Configuration.

5.2.1 Basic configuration parameters

The basic configuration includes parameters for a standard configuration which is sufficient in most cases. The basic configuration comprises the following items:

 Measurement Units  Tank Configuration

- Tank Geometry

- Environment

- Volume

 Analog Output  Echo Tuning: see page 83 for more information on the Amplitude Threshold Curve

(ATC), and “Echo tuning” on page 83 for more information on False Echo Registration

5.2.2 Configuration tools

There are several tools available for basic configuration of a Rosemount 5400 Series transmitter:

 RRM. Note that RRM is required for advanced configuration features.

See “Basic configuration using RRM” on page 84 for information on using RRM to configure the Rosemount 5400 Series.

 Rosemount Field Communicator.

See “Configuration using a Field Communicator” on page 101 for the Field Communicator Menu Tree.

 DTM (compliant with version 1.2 of the FDT

/DTM™ specification) is also available

supporting configuration in, for instance, Yokogawa Fieldmate/PRM, E+H

FieldCare,

and PACTware



AMS® Suite software (for HART). See “Basic configuration using AMS Suite” on page 105 for information on configuring AMS Suite.

 DeltaV

(only for FOUNDATION™ fieldbus). See “Configuration using DeltaV” on page 106 for information on configuring the Rosemount 5400 Series transmitter using DeltaV.

 Other tools that support EDDL functionality.

RRM is a user-friendly, Windows

™

based software package that includes waveform plots,

offline/online configuration Wizard, logging, and extensive online help.

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To communicate with the transmitter using RRM, a HART modem (part number 03300-7004-0001 or 03300-7004-0002) or a F

OUNDATION fieldbus modem (part number

03095-5108-0001 for PCMCIA) is required. For F

OUNDATION fieldbus communication you will

also need the National Instruments Communication Manager software (see “Installing the RRM

software for F

OUNDATION fieldbus” on page 88).

5.3 Basic configuration parameters

This chapter describes the basic parameters that need to be configured for a Rosemount 5400 transmitter. If the transmitter is factory-configured according to the ordering specifications in the Configuration Data Sheet, no further basic configuration is needed unless conditions have changed since the ordering date.

Different configuration tools are described at the end of this section.

5.3.1 Measurement units

Measurement units can be specified for presentation of Level, Level Rate, Volume and Tem per atu re va lues.

5.3.2 Tank geometry

Tank height

The Tank Height is the distance between the Upper Reference Point, at the underside of the transmitter flange or the threaded adapter, and the Lower Reference Point, close to or at the bottom of the tank (see Figure 5-2 for further information on Upper Reference Points for various tank connections). The transmitter measures the distance to the product surface and subtracts this value from the Tank Height to determine the product level.

Figure 5-1. Tank Geometry

Tan k h eig ht (R )

Product level

Upper reference point

Lower reference point (Level = 0)

Tra nsi tion zon e

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Figure 5-2. Upper Reference Point

Tank type and tank bottom type

The Rosemount 5400 Series transmitter is optimized according to the Tank Type and Tan k Bottom Type configuration by automatically setting some parameters to predefined default

values.

Select Tank Bottom Type Flat Inclined if the bottom inclination is between 10 and 30 degrees. If the inclination is less than 10 degrees, but there are disturbing objects on the tank floor (like heating coils) within the radar beam, this selection should also be used. If the inclination is greater than 30 degrees, use the Cone Ta nk B ottom Ty pe.

Table 5-1. Tank Type and Tank Bottom Type

Figure 5-3. Transmitter Optimization for Different Tank Types and Bottom Shapes

Tan k type Tank bottom type

Vertical cylinder Flat, dome, cone, flat inclined/obstructed Horizontal cylinder Not used Spherical Not used Cubical Flat, dome, cone, flat inclined/obstructed

Cone antenna

Rod antenna with flange

Rod antenna with threaded tank connection

Upper reference point

Adapter

Flange

Process seal antenna

Flat Dome ConeFlat inclined Spherical

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Pipe diameter

When the transmitter is mounted in a still-pipe, the inner diameter of the pipe must be specified. The pipe diameter is used to compensate for the lower microwave propagation speed inside the pipe. An incorrect value gives a scale factor error. If locally supplied still-pipes are used, make sure the inner diameter is noted before the pipe is installed.

Transition zone

The measurement accuracy is reduced within the transition zone region 6 in. (150 mm) from the lower end of the antenna. It is recommended that the Upper Range Value (20 mA) be set outside the transition zone.

5.3.3 Process conditions

Describe the conditions of the tank according to the tank environment parameters for process conditions listed below. For best performance, choose only if applicable, and no more than

two options.

Rapid level changes

Optimize the transmitter for measurement conditions where the level changes quickly from the filling and emptying of the tank. As a default standard, a Rosemount 5400 Series transmitter is able to track level changes of up to 1.5 in./s (40 mm/s). When the Rapid Level Changes check-box is selected, the transmitter can track level changes of up to 8 in./s (200 mm/s).

Turbulent sur face

This parameter should be used if the tank has a turbulent surface. The reason for the turbulence might be splash loading, agitators, mixers, or boiling product. Normally, the waves in a tank are quite small and cause local rapid level changes. By setting this parameter, the performance of the transmitter will improve when there are small and quickly changing amplitudes and levels.

Foam

Setting this parameter optimizes the gauge for conditions with weak and varying surface echo amplitudes, such as foam. When the foam is light and airy, the actual product level is measured. For heavy and dense foam, the transmitter measures the level of the foam’s upper surface.

Product dielectric range

The Dielectric Constant is related to the reflectivity of the product. By setting this parameter, measurement performance can be optimized. However, the transmitter will still be able to perform properly, even if the actual Dielectric Constant differs from the configured value.

Solid product

Setting this parameter optimizes the device for solid products, for example concrete or grains. For instance, this parameter can be used when the application is a silo with product pile-up. The transmitter will be optimized for weak echoes and a sloping surface which is typical when measuring at solid materials. This option shall only be used for a Rosemount 5402 with a 4” cone antenna.

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5.3.4 Volume configuration

For volume calculations, choose one of the standard tank shapes or the strapping option. Select None if volume calculation is not used. For the standard tanks, a Volume Offset parameter can be specified which can be used for a non-zero volume that corresponds to the zero level. This may be useful, for example, if the user wants to include the product volume below the zero level.

Volume calculation is performed by using a predefined tank shape or a strapping table. One of the following standard tank shapes can be chosen:

 Sphere  Vertical cylinder  Horizontal cylinder  Vertical bullet  Horizontal bullet

The following parameters must be entered for a standard tank shape:

 Tank diameter  Tank height (not for spherical tanks)  Volume offset

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Standard tank shapes

Figure 5-4. Standard Tank Shapes

Vertical cylinder

Vertical cylinder tanks are specified by diameter, height, and volume offset.

Horizontal cylinder

Horizontal cylinder tanks are specified by diameter, height, and volume offset.

Vertical bullet

Vertical bullet tanks are specified by diameter, height, and volume offset. The volume calculation model for this tank shape estimates that the radius of the bullet end is equal to the diameter/2.

Horizontal bullet

Horizontal bullet tanks are specified by diameter, height, and volume offset. The volume calculation model for this tank shape estimates that the radius of the bullet end is equal to the diameter/2.

Sphere

Spherical tanks are specified by diameter and volume offset.

Diameter Height

Diameter

Height

Diameter Height

Diameter

Height

Diameter

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Strapping table

The Strapping Table option is used when the tank shape deviates significantly from an ideal sphere or cylinder, or when high volume accuracy is required.

The Strapping Table divides the tank into segments. Level values and corresponding volumes are entered at the bottom of the tank. These figures can typically be obtained from tank drawings or from a certificate provided by the tank manufacturer. A maximum of 20 strapping points can be entered. For each level value the corresponding total volume up to the specified level is entered.

The volume value is interpolated if the product surface is between two level values in the table.

Figure 5-5. Strapping Points

Actual tank bottom may look like this.

Using only 3 strapping points results in a level-to-volume profile that is more angular than the actual shape.

Using 10-15 of the points at the bottom of the tank yields a level-to-volume profile that is similar to the actual tank bottom.

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5.3.5 Analog output (HART)

For the analog output, the output source (primary value), range values, and alarm mode are specified.

Figure 5-6. Standard Range Value Settings

Output source/primary variable

Specify the source to control the analog output. Typically, the Primary Value is configured to be the Product Level.

Upper/lower range value

Enter the range values that correspond to the analog output values 4 and 20 mA. The 20 mA point should be set below the Transition Zone, since the measurement accuracy is reduced in this region. For information on the Transition Zone, see “Performance specifications” on

page 189.

If a measured value goes beyond the measurement range, the transmitter enters saturation mode (if limit alarm is disabled) or alarm mode, depending on the current configuration.

Alarm mode

Choose the desired Alarm mode to specify the analog output state when there is a failure or a measurement error.

High: the output current is set to the High Alarm Limit.

Low: the output current is set to the Low Alarm Limit.

20 mA Upper Range Value (URV)

Product level

4 mA Lower Range Value (LRV)

Range 0-100 %

Lower reference point (Level=0)

Upper reference point

Tra nsi ti on z one

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Freeze Current: the output current is set to the last valid value at the time when the error occurs.

Default settings for alarm mode:

 Measurement errors: Output current = High  Measured value out of range: transmitter enters saturation mode (if Limit Alarm is

disabled)

Table 5-2. Analog Output: Standard Alarm Value vs. Saturation Value

In saturation mode, if the primary variable is not in low alarm mode, the minimum output is 3.9 mA. If the primary variable is not in high alarm mode, the maximum output is 20.8 mA.

Table 5-3. Analog Output: NAMUR-compliant Alarm Value vs. Saturation Value

5.3.6 Level and distance calibration

Level and distance calibration may be necessary when using a nozzle or pipe or if there are disturbances in the near zone caused by a physical object.

Non-metallic (e.g. plastic) vessels and installation geometry may introduce an offset for the zero reference point. This offset may be up to ± 25 mm. The offset can be compensated for using Distance Calibration.

When calibrating the transmitter, it is important that the product surface is calm and that the tank is not being filled or emptied.

A complete calibration is performed in two steps:

1. Calibrate the distance measurement by adjusting the Calibration Offset parameter.

2. Calibrate the level measurement by adjusting the Tank Height.

Level 4–20 mA saturation value 4–20 mA alarm value

Low 3.9 mA 3.75 mA

High 20.8 mA 21.75 mA

Level 4–20 mA saturation value 4–20 mA alarm value

High 20.5 mA 22.5 mA

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Distance calibration

1. Measure the actual distance between the Upper Reference Point and the product surface.

2. Adjust the Calibration Distance so that the Distance measured by the transmitter corresponds to the actual distance. The Calibration Distance parameter is available via HART command [2, 3, 2, 4, 1], or RRM:

a. Select the Ta n k icon under Device Config/Setup in the RRM workspace. b. In the Tan k window, select the Geometry tab. c. Select the Advanced button. d. Enter the desired value in the Calibration Distance field and select the Store button.

Level calibration

1. Measure the actual Product Level.

2. Adjust the Tank H eigh t so the product level measured by the transmitter corresponds to the actual product level.

Figure 5-7. Distance and Level Calibration

5.3.7 Echo tuning

When Basic Configuration is performed, the transmitter may need to be tuned to handle disturbing objects in the tank. There are different methods available for handling disturbance echoes with the Rosemount 5400 Series Transmitter:

 ATC  False echo registration, see “Registration of false echoes” on page 135

The Guided Setup in the RRM configuration program includes a Measure and Learn function which automatically registers false echoes and creates an ATC (see “Guided setup” on page 92).

The created ATC is based on the present tank spectra and process condition settings. Disturbances below the product surface might not be handled by the Measure and Learn function.

Refere nce point

Distance

Reference point

Tank height

Level

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5.3.8 ATC

Setting up an ATC makes tracking of the product surface more robust in the presence of noise and weak disturbing echoes. The ATC is normally used for filtering out disturbances with an amplitude smaller than the amplitude of the product surface echo.

The ATC is designed as a number of individually adjustable amplitude threshold points.

Figure 5-8. Weak Disturbing Echoes can be Filtered Out by Creating an Amplitude Threshold

To create an ATC, the Measure and Learn function is available in the RRM program.

5.4 Basic configuration using RRM

The RRM is a user-friendly software tool that allows configuration of the Rosemount 5400 transmitter. Choose either of the following methods to configure a Rosemount 5400 transmitter with RRM:

 Guided Setup, if you are unfamiliar with the Rosemount 5400 Series transmitter (see

page 92)

 Setup functions, if you are already familiar with the configuration process, or for

changes to the current settings (see page 100)

5.4.1 System requirements

Hardware

COM Port: 1 serial COM por t or 1 USB port

Graphical Card (minimum/recommended): screen resolution 800 x 600/1024 x 768.

Hard drive space: 100 MB

ATC

Measurement signal

Amplitude, mV

Distance, m

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Software

Operating Systems supported:

 Windows XP  Windows 7

5.4.2 Help in RRM

From the Help menu, select the Contents option to access help information. Help is also available from a Help button in most windows.

5.4.3 Installing the RRM software for HART communication

To install the RRM:

1. Insert the installation CD into the CD-ROM drive.

2. If the installation program is not started automatically, select Run from the Windows Start bar.

3. Enter D:\RRM\Setup.exe where D is the CD-ROM drive.

4. Follow the instructions on the screen.

5. Make sure that HART is chosen as default protocol.

6. Set COM Port Buffers to 1, see page 88.

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Getting started

1. From the Start menu, select Programs > Rosemount > Rosemount Radar Master or select the RRM icon in the Windows workspace.

2. If the Search Device window did not appear automatically, select menu option Device > Search.

3. In the Search Device window, select communication protocol HART and select the Start Scan button (select the Advanced button to specify start and stop address). Now RRM searches for the transmitter.

4. The Search Device window presents a list of found transmitters.

5. Select the desired transmitter and press OK to connect. If communication does not work, check that the correct COM port is configured correctly and is connected to the computer. See “Specifying the COM port” on page 87. Verify from the Communication Preferences window that HART communication is enabled.

6. The RRM Status Bar can be used to verify that RRM is communicating with the transmitter:

RRM communicates with the transmitter

No communication with the transmitter

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5.4.4 Specifying the COM port

If communication is not established, open the Communication Preferences window and check that the correct COM Port is selected:

1. From the View menu, select Communication Preferences in RRM.

Figure 5-9. Communication Settings

2. Make sure that HART communication is enabled.

3. Check which COM port is connected to the modem.

4. Select the COM port option matching the actual COM port on the PC that is connected to the transmitter.

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5.4.5 To set the COM port buffers

The COM port Receive Buffer and Transmit Buffer need to be set to 1 by doing the following:

1. In the Microsoft

Windows Control Panel, open the System option.

2. Select the Hardware tab and click the Device Manager button.

3. Expand the Ports node in the tree view.

4. Click the right mouse button on the selected COM port and then select Properties.

5. Select the Port Settings tab and click the Advanced button.

6. Drag the Receive Buffer and Tran smit Buf fer slides to 1.

7. Click the OK button.

8. Reboot the computer.

5.4.6 Specifying measurement units

Measurement units for data presentation in RRM can be specified when the RRM program is installed. Units can also be changed as follows:

1. Select the Application Preferences option from the View menu.

2. Select the Measurement Units tab.

3. Select the desired units for Length, Level Rate, Volume, and Te m pe ra tu re .

5.4.7 Installing the RRM software for FOUNDATION fieldbus

To install the RRM for FOUNDATION fieldbus communication:

1. Start by installing the National Instruments Communication Manager software. See National Instruments manual (Getting started with your PCMCIA-FBUS and the NI-FBUS™ software) for more information.

2. Insert the RRM installation CD into your CD-ROM drive.

3. If the installation program is not automatically started, select Run from the Windows Start bar.

4. Type D:\RRM\Setup.exe where D is the CD-ROM drive.

5. Follow the instructions on the screen.

6. Make sure that F

OUNDATION fieldbus is selected as default protocol.

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

Specifications and Main Features

Frequently Asked Questions

User Manual