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Reference Manual
00809-0100-4026, Rev KB
June 2016
Rosemount™ 5400 Level Transmitter
Two-Wire Non-Contacting Radar
Reference Manual |
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00809-0100-4026, Rev KB |
June 2016 |
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Contents
Section 1: Introduction
1.1 Using this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Product recycling/disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2: Transmitter Overview
2.1 Theory of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.3 System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.4 Process characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.5 Components of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.6 Antenna selection guide/measuring range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 3: Mechanical Installation
3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.2 Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.3 Mounting considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.3.1 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.3.2 Special considerations in solids applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.3.3 Mounting in pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.3.4 Condensation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.3.5 Nozzle considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.3.6 Nozzle recommendations and requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3.3.7 Service space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.3.8 Beam width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.3.9 Vessel characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.3.10Disturbing objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.3.11Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.4.1 Cone antenna with flange connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.4.2 Cone antenna with threaded tank connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.4.3 Cone antenna with threaded tank connection and customer supplied flange . . . . . . . 38 3.4.4 Process seal antenna with flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.4.5 Parabolic antenna with flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.4.6 Parabolic antenna with welded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.4.7 Parabolic antenna with threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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3.4.8 Adjust inclination of parabolic antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.4.9 Rod antenna with threaded connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 3.4.10Rod antenna with flanged connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 3.4.11Tri Clamp tank connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3.4.12Bracket mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Section 4: Electrical Installation
4.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 4.2 Wiring and power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.3 Cable/conduit entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.4 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.5 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.6 Hazardous areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.7 External circuit breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.8 Connecting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 4.9 HART® communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.9.1 Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 4.9.2 Load limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 4.9.3 Non-intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 4.9.4 Intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 4.9.5 Type N approvals: non-sparking / energy-limited power supply . . . . . . . . . . . . . . . . . . . 82 4.9.6 Transient protection terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.10FOUNDATION Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.10.1Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.10.2Non-intrinsically safe power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 4.10.3Intrinsically safe power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 4.10.4Type N approvals: non-sparking / energy-limited power supply. . . . . . . . . . . . . . . . . . . 87
4.11HART to Modbus Converter (HMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 4.11.1Connecting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 4.11.2Connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 4.11.3RS-485 bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 4.11.4Installation cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 4.11.5External HART devices (slaves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.12Establish HART communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 4.12.1Connect to the MA/MB terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 4.12.2Connect to the HART terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 4.13Optional devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 4.13.1Tri-Loop™ HART to analog converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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4.13.2751 Field Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.13.3Emerson™ Smart Wireless THUM™ Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Section 5: Basic Configuration/Start-up
5.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 5.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.2.1 Basic configuration parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.2.2 Configuration tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.3 Basic configuration parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.3.1 Measurement units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.3.2 Tank geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.3.3 Process conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 5.3.4 Volume configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 5.3.5 Analog output (HART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 5.3.6 Level and distance calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 5.3.7 Echo tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 5.3.8 ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.4 Basic configuration using RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.4.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.4.2 Help in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.3 Installing the RRM software for HART communication . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.4 Specifying the COM port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 5.4.5 To set the COM port buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 5.4.6 Specifying measurement units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 5.4.7 Installing the RRM software for FOUNDATION Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 5.4.8 Specifying measurement units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.4.9 Using the Setup functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 5.4.10Guided setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 5.4.11Using the Setup functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 5.5 Configuration using a Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 5.6 Basic configuration using AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.7 Configuration using DeltaV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 5.7.1 Advanced configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 5.8 FOUNDATION Fieldbus overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 5.8.1 Assigning device tag and node address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 5.8.2 Foundation Fieldbus block operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 5.9 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 5.9.1 Radar level transmitter - level value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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5.9.2 Radar level transmitter - level value in percent (%). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 5.10Tri-Loop™ HART to Analog Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 5.11HART multidrop configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Section 6: Operation
6.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 6.2 Viewing measurement data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 6.2.1 Using the display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 6.2.2 Specifying display panel variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 6.2.3 Viewing measurement data in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 6.2.4 Viewing measurement data in AMS Suite and DeltaV. . . . . . . . . . . . . . . . . . . . . . . . . . . 156 6.3 LCD display error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 6.4 LED error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Section 7: Service and Troubleshooting
7.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 7.2 Troubleshooting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 7.3 Service overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 7.3.1 Analyzing the measurement signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 7.3.2 Surface pulse not found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 7.3.3 Registration of false echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 7.3.4 Using the Echo Curve Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 7.3.5 Using the Echo Curve Analyzer with a Field Communicator. . . . . . . . . . . . . . . . . . . . . . 169 7.4 Analog output calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 7.5 Logging measurement data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 7.6 Backing up the transmitter configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 7.7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 7.8 Configuration report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 7.9 Viewing input and holding registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 7.10Reset to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 7.11Surface search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 7.12Using the Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 7.13Write protecting a transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 7.14Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 7.14.1Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 7.14.2Device status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 7.14.3Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 7.14.4Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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7.14.5Measurement status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 7.14.6Volume calculation status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 7.14.7Analog Output status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 7.14.8Application errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 7.15Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 7.15.1Resource block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 7.15.2Transducer block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 7.15.3Analog Input (AI) function block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 7.16Service support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Section 8: Safety Instrumented Systems
(4-20 mA Only)
8.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 8.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 8.2.1 Applicable models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 8.2.2 Skill level of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 8.3 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 8.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 8.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 8.5.1 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 8.5.2 Alarm and saturation levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 8.5.3 Amplitude threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8.5.4 Write protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8.5.5 Site acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8.6 Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8.6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8.6.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 8.7 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 8.7.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 8.7.2 Failure rate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 8.7.3 Useful lifetime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 8.8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Appendix A: Reference Data
A.1 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 A.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 A.1.2 4-20 mA HART® (output option code H). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 A.1.3 Foundation™ Fieldbus (output option code F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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A.1.4 Rosemount 2410 Tank Hub connectivity (output option code U) . . . . . . . . . . . . . . . . 208 A.1.5 RS-485 with Modbus communication (output option code M). . . . . . . . . . . . . . . . . . . 209 A.1.6 Display and configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 A.1.7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 A.1.8 Temperature limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 A.1.9 Process temperature and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
A.2 Performance specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 A.2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 A.2.2 Measuring range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 A.2.3 Solids applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 A.2.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
A.3 Physical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 A.3.1 Material selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 A.3.2 Housing and closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 A.3.3 Engineered solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 A.3.4 Tank connection and antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
A.4 Dimensional drawings and mechanical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 A.4.1 Process connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 A.5 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Appendix B: Product Certifications
B.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 B.2 European Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.3 Ordinary Location Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.4 Telecommunication compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.4.1 FCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.4.2 IC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.4.3 R&TTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.5 Installing Equipment in North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.6 USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 B.7 Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 B.8 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 B.9 International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 B.10Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 B.11China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 B.12EAC – Belarus, Kazakhstan, Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 B.13Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 B.14India. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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B.15Ukraine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 B.16Republic of Korea . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 B.17Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 B.18Additional Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 B.19Pattern Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 B.20Conduit plugs and adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 B.21Approval drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Appendix C: Advanced Configuration
C.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 C.2 Tank geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 C.2.1 Distance offset (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 C.2.2 Minimum level offset (C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 C.2.3 Hold off distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 C.2.4 Calibration distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 C.3 Advanced analog output settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 C.4 Advanced transmitter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 C.4.1 Antenna type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 C.4.2 Empty tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 C.4.3 Full tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 C.4.4 Double bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 C.4.5 Surface echo tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 C.4.6 Filter settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 C.5 Advanced functions in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 C.5.1 Empty tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 C.5.2 Full tank handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 C.5.3 Double bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 C.5.4 Surface echo tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 C.5.5 Hold off setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 C.6 Signal Quality Metrics (SQM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 C.6.1 Available diagnostics measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 C.6.2 How to verify if Signal Quality Metrics is supported. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 C.6.3 View Signal Quality Metrics values in RRM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Appendix D: Performing Proof Test
D.1 Performing proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 D.2 Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 D.3 RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
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D.4 AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Appendix E: Level Transducer Block
E.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 E.1.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 E.1.2 Channel definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 E.2 Parameters and descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 E.3 Supported units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 E.3.1 Unit codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 E.4 Diagnostics device errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Appendix F: Register Transducer Block
Appendix G: Advanced Configuration Transducer Block
Appendix H: Resource Block
H.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 H.2 Parameters and descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 H.2.1 PlantWeb alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 H.2.2 Alarm priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 H.2.3 Recommended actions for PlantWeb alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Appendix I: Analog-Input Block
I.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 I.2 Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 I.3 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 I.4 Signal conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 I.5 Block errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 I.6 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 I.7 Alarm detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
I.7.1 Status handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 I.8 Configure the AI block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
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Rosemount™ 5400 Level Transmitter
NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product.
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 Pacific65 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.
NOTICE
There are no health hazards from the Rosemount 5400 Level Transmitter. The microwave power density in the tank is only a small fraction of the allowed power density according to international standards.
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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 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 services other than those contained in this manual unless you are qualified.
Process leaks could result in death or serious injury.
Make sure 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 Field 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.
To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.
To avoid process leaks, only use O-rings designed to seal with the corresponding flange adapter.
All connection head covers must be fully engaged to meet explosion-proof requirements.
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 Level 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 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) 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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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 the written authorization is at the customer’s sole risk and expense.
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.
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1.1Using this manual
This manual provides installation, configuration and maintenance information for the Rosemount™ 5400 Level Transmitter.
Section 2: Transmitter Overview contains an introduction to theory of operation and a description of the transmitter. Information on applications, process and vessel characteristic, and an antenna selection guide are also included.
Section 3: Mechanical Installation contains mounting considerations and mechanical installation instructions.
Section 4: Electrical Installation contains electrical installation instructions.
Section 5: Basic Configuration/Start-up provides instructions on configuration of the transmitter using the Field Communicator, the Rosemount Radar Master software, AMS™ Device Manager, and DeltaV™. Information on software functions and configuration parameters are also included.
Section 6: Operation contains operation techniques such as viewing measurement data and display functionality.
Section 7: Service and Troubleshooting provides troubleshooting techniques for the most common operating problems, as well as diagnostic and error messages, and service instructions.
Section 8: Safety Instrumented Systems (4-20 mA Only) contains identification, commissioning, maintenance, and operations information for safety-certified transmitter used in Safety Instrumented Systems (SIS) applications.
Appendix A: Reference Data supplies reference and specification data, as well as ordering information.
Appendix B: Product Certifications contains hazardous locations certifications and approval drawings.
Appendix C: Advanced Configuration provides procedures for advanced transmitter configuration such as surface echo tracking and empty tank handling. Instructions on how to use Signal Quality Metrics functions are also included.
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.
1.2Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of in accordance with local and national legislation/regulations.
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Section 2 Transmitter Overview
Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3
Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4
System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6
Process characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8
Components of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 10
Antenna selection guide/measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 11
2.1Theory of operation
The Rosemount 5400 Level Transmitter is a smart, two-wire continuous level transmitter. A Rosemount 5400 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
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Signal amplitude |
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Distance |
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Level |
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Time |
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Tank height |
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2.2Application 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 can be advantageous in risk reduction systems:
Continuous measurement may reduce or simplify proof-tests
Multiple Rosemount 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 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 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 can be used in mounting configurations other than standard nozzles:
Fits most existing pipes: 2- to 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 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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2.3System architecture
The Rosemount 5400 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 can also be configured with the AMS™ Suite and DeltaV™ software, and other tools that support Electronic Device Description Language (EDDL) functionality.
Figure 2-2. HART System Architecture
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J
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A.Integral display
B.Rosemount 5400
C.4-20 mA/HART
D.Rosemount 751 Field Signal Indicator
E.Field Communicator
F.3 x 4-20 mA
G.Tri-Loop
H.HART modem
I.Rosemount Radar Master or AMS Suite
J.DCS
Note
For HART communication, a minimum load resistance of 250 within the loop is required.
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Figure 2-3. FOUNDATION Fieldbus System Architecture |
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FOUNDATION
Fieldbus B
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6200 ft (1900 m) max J 
(depending upon cable
characteristics)
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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
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H |
C |
F |
I |
A. |
Rosemount 5400 |
F. |
PC 5400 Setup in Rosemount Radar Master |
B. |
Power |
G. |
Control System |
C. |
Field Communicator |
H. |
RS-232/RS-485 Converter |
D. |
Modbus, Levelmaster Emulation/RS-485 |
I. |
PC 5400 Setup in Rosemount Radar Master via Tunneling |
E.HART modem
Transmitter Overview |
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Transmitter Overview |
Reference Manual |
June 2016 |
00809-0100-4026, Rev KB |
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2.4Process 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 Table 2-2 on page 11 and Table 2-3 on page 12 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 34.
8 |
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Reference Manual |
Transmitter Overview |
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00809-0100-4026, Rev KB |
June 2016 |
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Solid surface
The surface of solid materials is rarely flat or horizontal. The 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 9 for common solids characteristics.
For solids applications, the high frequency version Rosemount 5402 with 4 inch cone or parabolic antenna is available.
Table 2-1. Sample Solids Applications(1)
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Particle size |
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Vapor space |
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Dust or |
Small |
Larger |
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Steam or |
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powder |
(<1 in.) |
(>1 in.) |
Dust |
condensation |
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Wood chip bins |
Yes |
Yes |
Yes |
Yes |
Possible |
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Grain silo - small |
Yes |
Yes |
No |
Yes |
No |
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kernel grains |
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Grain silo - large kernel |
No |
Yes |
No |
No |
No |
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grains |
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Lime stone silo |
No |
Yes |
Yes |
Possible |
No |
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Cement - raw mill silo |
Yes |
Yes |
No |
Yes |
No |
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Cement - finished |
Yes |
Yes |
No |
Yes |
No |
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product silo |
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Coal bin |
Yes |
Yes |
Yes |
Yes |
Yes |
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Saw dust |
Yes |
Yes |
No |
Yes |
No |
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High consistency - |
No |
No |
No |
No |
Yes |
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pulp stock |
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Alumina |
Yes |
Yes |
No |
Yes |
No |
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Salt |
No |
Yes |
Yes |
No |
No |
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1.Air purging might be needed in dusty environments.
Transmitter Overview |
9 |
Transmitter Overview |
Reference Manual |
June 2016 |
00809-0100-4026, Rev KB |
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2.5Components of the transmitter
The Rosemount 5400 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 E
B
C
D
A.Display Panel
B.Cable Entry: ½" NPT Optional adapters: M20
C.Tank Seal
D.Flange
F
G
H
E.Terminal side
F.Cable Entry: ½" NPT. Optional adapters: M20
G.Transmitter head with Radar electronics
H.Antenna
10 |
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Transmitter Overview |
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00809-0100-4026, Rev KB |
June 2016 |
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2.6Antenna selection guide/measuring range
The measuring range depends on the microwave frequency, antenna size, the dielectric constant ( r) of the liquid, and process conditions. A higher dielectric constant value produces a stronger reflection. The figures in the tables below are guidelines for optimum performance. Larger measuring ranges may be possible. For more information, contact your local Emerson™ Process Management representative.
A.Oil, gasoline or other hydrocarbons, and petrochemicals ( r = 1.9-4.0). In pipes or with ideal surface conditions, for some liquefied gases ( r = 1.4-4.0).
B.Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone ( r = 4.0-10.0).
C.Conductive liquids, e.g. water based solutions, dilute acids, and alkalis ( r > 10.0).
Table 2-2. Rosemount 5402, Maximum Recommended Measuring Range, ft (m)
High |
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antennas |
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Dielectric constant(1) |
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A |
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B |
C |
A |
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B |
C |
A |
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C |
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2-in. Cone/ |
33 |
49 |
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66 |
82 |
115 |
115 |
9.8 |
20 ( |
33 |
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Process seal |
(10) |
(15) |
(20) |
(25) |
(35) |
(35) |
(3) |
6) |
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(10) |
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3-in. Cone/ |
49 |
66 |
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98 |
82 |
115 |
115 |
13 |
30 |
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39 |
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Process seal |
(15) |
(20) |
(30) |
(25) |
(35) |
(35) |
(4) |
(9) |
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4-in. Cone/ |
66 |
82 |
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115 |
82 |
115 |
115 |
23 |
39 |
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49 |
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Process seal |
(20) |
(25) |
(35) |
(25) |
(35) |
(35) |
(7) |
(12) |
(15) |
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1. A. Oil, gasoline or other hydrocarbons, and petrochemicals ( r = 1.9-4.0) In pipes or with ideal surface conditions, for some liquefied gases
( r = 1.4-4.0)
B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone ( r = 4.0-10.0)
C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis ( r > 10.0)
Transmitter Overview |
11 |
Transmitter Overview |
Reference Manual |
June 2016 |
00809-0100-4026, Rev KB |
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Table 2-3. Rosemount 5401, Maximum Recommended Measuring Range, ft (m)
Low |
Frequency |
Antennas |
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Dielectric Constant(1) |
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A |
B |
C |
A |
B |
C |
A |
B |
C |
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3-in. Cone(2) |
N/A |
N/A |
N/A |
82 |
115 |
115 |
N/A |
N/A |
N/A |
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(25) |
(35) |
(35) |
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4-in. Cone / |
23 |
39 |
49 |
82 |
115 |
115 |
13 |
26 |
39 |
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Rod(3) |
(7) |
(12) |
(15) |
(25) |
(35) |
(35) |
(4) |
(8) |
(12) |
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6-in. Cone |
43 |
66 |
82 |
82 |
115 |
115 |
20 |
33 |
46 |
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(13) |
(20) |
(25) |
(25) |
(35) |
(35) |
(6) |
(10) |
(14) |
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8-in. Cone |
66 |
82 |
115 |
82 |
115 |
115 |
26 |
39 |
52 |
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(20) |
(25) |
(35) |
(25) |
(35) |
(35) |
(8) |
(12) |
(16) |
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1. |
A. Oil, gasoline or other hydrocarbons, and petrochemicals ( r = 1.9-4.0) In pipes or with ideal surface conditions, for some liquefied gases |
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( r = 1.4-4.0) |
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B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone ( r = 4.0-10.0) |
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2. |
C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis ( r > 10.0) |
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Pipe installations only. NA = Not Applicable. |
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3. |
Pipe installations are not allowed with rod antennas. |
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12 |
Transmitter Overview |
Reference Manual |
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Transmitter Overview |
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00809-0100-4026, Rev KB |
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June 2016 |
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Table 2-4. Model and Antenna Guide |
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Model and antenna guide |
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Rosemount 5402 |
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Rosemount 5401 |
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Cone (preferred) |
Process seal |
Parabolic |
Cone (preferred) |
Rod |
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This table gives guidelines on which |
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model and antenna to select, depending |
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on application. |
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G = Good |
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AD = Application Dependent (consult |
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your local Emerson Process |
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Management representative) |
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NR = Not Recommended |
Best choice for a |
Ideal for small tanks |
Only for solids |
Suitable for some |
Suitable for small |
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broad range of |
and corrosive |
applications.Good |
extreme process |
process |
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applications, free |
applications. Good for |
for long ranges. |
conditions. |
connections, and |
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propagation and |
heavy antenna |
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corrosive |
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pipe installations. |
condensation/build-up. |
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environment. |
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Tank considerations |
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Installation close to smooth tank wall |
G |
G |
AD |
G |
G |
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Multiple units on the same tank |
G |
G |
G |
G |
G |
||
Internal obstructions, directly in path(1) |
NR |
NR |
NR |
AD |
AD |
||
Internal obstructions, avoidance(1) |
G |
G |
AD |
NR |
NR |
||
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2” 19° |
2” 19° |
|
4” 37° |
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Beam angle |
3” 14° |
3” 14° |
4.5° |
6” 23° |
37° |
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4” 9° |
4” 9° |
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8” 17° |
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Antenna extends below nozzle |
G |
G |
G |
G |
G |
||
Antenna recessed in smooth nozzle up |
G |
G |
NR |
NR(2) |
NR(3) |
||
to 6 ft (2 m) |
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Antenna recessed in nozzle with |
AD(4) |
AD |
AD |
AD(4) |
NR(3) |
||
irregularities, such as bad welds |
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Stilling well mounting |
G (2- to 4-in. pipe) |
G (2- to 4-in. pipe) |
NR |
G (3- to 8-in. pipe) |
NR |
||
Valves |
G |
G |
NR |
NR |
NR |
||
Long ranges (>115’ / 35 m) |
NR |
NR |
NR |
NR |
NR |
||
Cleanability of antenna |
AD |
G |
G(5) |
AD |
G |
||
Process medium characteristics |
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Vapor (light, medium) |
G |
G |
G |
G |
G |
||
Vapor (heavy) |
NR |
AD |
AD |
G |
G |
||
Condensing vapor/product build-up(6) |
AD |
G |
G(5) |
G |
AD |
||
Boiling/Turbulent surface (low/medium) |
G |
G |
G |
G |
G |
||
Boiling/Turbulent surface (heavy) |
AD |
AD |
G |
G(7) |
NR |
||
Boiling/Turbulent surface (still-pipe) |
G |
G |
NR |
G |
NR |
||
Foam(8) |
NR |
NR |
N/A |
AD |
AD |
||
Foam (still-pipe)(8) |
G |
G |
NR |
G |
NR |
||
Corrosive products (options available) |
G(9) |
G(9) |
NR |
G(9) |
G |
||
Materials with very low dielectric |
G |
G |
G |
G |
AD |
||
Changing density/dielectric/pH/ |
G |
G |
G |
G |
G |
||
pressure/temperature |
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Coating/viscous/crystallizing liquids |
G |
G |
G(5) |
G |
G |
||
Solids, granules, powders |
G |
NR |
G |
NR |
NR |
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1.The obstruction should not be within the radar beam. Preferred choices due to more narrow radar beam: Rosemount 5402, and cone antenna.
2.If tall nozzle, use extended antenna.
3.The active part must protrude beneath the nozzle.
4.An extended cone antenna must be used.
5.Air purging might be needed.
6.Build-up can often be avoided or reduced by using heat-tracing or cleaning arrangements.
7.Use a 6 or 8 in. (150-200 mm) cone antenna.
8.Foam can either reflect, be invisible, or absorb the radar signal. Pipe mounting is advantageous since it reduces the foaming tendency.
9.Other wetted material options include Alloy C-276 and Alloy 400. See the Rosemount 5400 Series Product Data Sheet for details.
Transmitter Overview |
13 |
Transmitter Overview |
Reference Manual |
June 2016 |
00809-0100-4026, Rev KB |
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14 |
Transmitter Overview |
Reference Manual |
Mechanical Installation |
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00809-0100-4026, Rev KB |
June 2016 |
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Section 3 Mechanical Installation
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 Mounting considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35
3.1Safety 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.
Mechanical Installation |
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Mechanical Installation |
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June 2016 |
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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 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 services other than those contained in this manual unless you are qualified.
Process leaks could result in death or serious injury.
Make sure 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 Field 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.
To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.
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 Level 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.
Any substitution of non-authorized parts or repair, other than exchanging the complete transmitter head or probe 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.
16 |
Mechanical Installation |
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