Rosemount 5408 Operating Manual

Reference Manual

00809-0100-4408, Rev BB

April 2018

Rosemount™ 5408 and 5408:SIS Level Transmitters

Non-Contacting Radar

Rosemount 5408 and 5408:SIS Level Transmitters – Non-Contacting Radar

NOTICE

Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product.

For technical assistance, contacts are listed below:

Customer Central

Technical support, quoting, and order-related questions.

•United States - 1-800-999-9307 (7:00 am to 7:00 pm CST)

•Asia Pacific65 777 8211

North American Response Center

Equipment service needs.

•1-800-654-7768 (24 hours a day — includes Canada)

•Outside of these areas, contact your local Emerson representative.

WARNING!

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

•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.

•For installations in hazardous locations, the transmitter must be installed according to the Rosemount 5408 and 5408:SIS Product Certifications document and System Control Drawing (D7000002-885).

Explosions could result in death or serious injury.

•Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications.

•Before connecting a Field Communicator in an explosive atmosphere, ensure the instruments are installed in accordance with intrinsically safe or non-incendive field wiring practices.

•In Explosion-proof/Flameproof and Non-Incendive/Type n installations, do not remove the transmitter covers when power is applied to the unit.

•Both transmitter covers must be fully engaged to meet Explosion-proof/Flameproof requirements.

Electrical shock could cause 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 mains power to the transmitter is off and the lines to any other external power source are disconnected or not powered while wiring the transmitter.

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.

Any substitution of non-recognized parts may jeopardize safety. Repair, e.g. substitution of components etc., may also jeopardize safety and is under no circumstances allowed.

•Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and jeopardize safety. Unauthorized changes that interfere with the integrity of the welds or flanges, such as making additional perforations, compromise product integrity and safety. Equipment ratings and certifications are no longer valid on any products that have been damaged or modified without the prior written permission of Emerson. Any continued use of product that has been damaged or modified without the written authorization is at the customer’s sole risk and expense.

CAUTION!

Hot surfaces

The flange and process seal may be hot at high process temperatures. Allow to cool before servicing.

CAUTION!

The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings.

For information on Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.

Contents

Contents

Chapter 1	Introduction		.....................................................................................................................	1
	1.1	Using this manual ...........................................................................................................................		1
	1.2	Product .............................................................................................................recycling/disposal		1
Chapter 2	Transmitter Overview ......................................................................................................			3
	2.1	Measurement ..................................................................................................................principle		3
	2.2	Process ...................................................................................................................characteristics		4
		2.2.1 ...........................................................................................................	Dielectric constant	4
		2.2.2 .......................................................................................................	Foam and turbulence	4
		2.2.3 .................................................................................................................................	Dust	5
		2.2.4 ....................................................................................................................	Solid surface	5
	2.3	Vessel characteristics .....................................................................................................................		6
		2.3.1 ........................................................................................................	In - tank obstructions	6
		2.3.2 ......................................................................................................................	Tank shape	6
	2.4	Application .....................................................................................................................examples		6
	2.5	Components ......................................................................................................of the transmitter		8
	2.6	System .......................................................................................................................integration		10
Chapter 3	Mechanical Installation ..................................................................................................			13
	3.1	Safety messages ...........................................................................................................................		13
	3.2	Confirm ..................................................................................................................approval type		13
	3.3	Installation ...........................................................................................................considerations		14
		3.3.1 .........................................................................................................	Mounting position	14
		3.3.2 ...............................................................................................	Free space requirements	15
		3.3.3 ..................................................................................................................	Antenna size	16
		3.3.4 .......................................................................................................	Antenna inclination	16
		3.3.5 ........................................................................................................	Non - metallic tanks	17
		3.3.6 ..........................................................................................	Beam width and beam angle	17
		3.3.7 .....................................................................................................	Nozzle requirements	19
		3.3.8 ......................................................................................	Still pipe/chamber installations	21
		3.3.9 .....................................................................................................	Ball valve installation	24
	3.4	Mounting ................................................................................................................preparations		25
		3.4.1 ........................................................................	Assemble the segmented cone antenna	25
		3.4.2 ..............................................................................	Shorten the extended cone antenna	26
	3.5	Mount the ..............................................................................................................cone antenna		28
		3.5.1 ................................................................................................................	Protective cap	28
		3.5.2 .............................................................................................................	Flanged version	29
		3.5.3 ...................................................	Flanged version with air purge ring (option code PC1)	30
		3.5.4 .....................................	Threaded version, antenna diameter (D) < Thread diameter (d)	31
		3.5.5 .....................................	Threaded version, antenna diameter (D) > Thread diameter (d)	34
		3.5.6 ..........................................................................................................	Bracket mounting	36
		3.5.7 ...................................................................................................	Align transmitter head	38
	3.6	Mount the ...................................................................................................process seal antenna		40
		3.6.1 .............................................................................................................	Flanged version	40
		3.6.2 ..........................................................................................................	Tri - Clamp version	42
	3.7	Mount the .......................................................................................................parabolic antenna		43
		3.7.1 .............................................................................................................	Flanged version	43

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		3.7.2	Threaded version ...........................................................................................................	45
		3.7.3	Welded version ..............................................................................................................	49
		3.7.4	Adjust the inclination of the antenna .............................................................................	53
		3.7.5	Connect the air purging .................................................................................................	56
	3.8	Adjust display orientation (optional) ............................................................................................		57
Chapter 4	Electrical Installation ......................................................................................................			59
	4.1	Safety messages ...........................................................................................................................		59
	4.2	Cable selection .............................................................................................................................		59
	4.3	Cable gland/conduit .....................................................................................................................		60
	4.4	Power supply ................................................................................................................................		60
	4.5	Load limitations ............................................................................................................................		60
	4.6	Hazardous areas ...........................................................................................................................		60
	4.7	Wiring diagram ............................................................................................................................		61
	4.8	Grounding ....................................................................................................................................		62
	4.9	Connect wiring and power up .......................................................................................................		63
	4.10	Optional devices ..........................................................................................................................		66
		4.10.1	Rosemount™ 333 HART Tri-Loop™ .................................................................................	66
Chapter 5	Configuration		.................................................................................................................	69
	5.1	Safety messages ...........................................................................................................................		69
	5.2	Overview ......................................................................................................................................		69
	5.3	System readiness .........................................................................................................................		69
		5.3.1	Confirm correct device driver ........................................................................................	69
	5.4	Get started with your preferred configuration tool .......................................................................		70
		5.4.1	Configuration tools ........................................................................................................	70
		5.4.2	Rosemount Radar Master Plus .......................................................................................	71
		5.4.3	AMS Device Manager .....................................................................................................	71
		5.4.4	Field Communicator ......................................................................................................	72
	5.5	Confirm HART revision capability .................................................................................................		72
		5.5.1	Switch HART revision mode ...........................................................................................	72
	5.6	Configure device using Guided Setup ...........................................................................................		73
		5.6.1	Configure using Rosemount Radar Master Plus ..............................................................	73
		5.6.2	Configure using AMS Device Manager ...........................................................................	73
		5.6.3	Configure using Field Communicator .............................................................................	73
	5.7	Verify level ...................................................................................................................................		73
		5.7.1	Use Rosemount Radar Master Plus .................................................................................	74
		5.7.2	Use AMS Device Manager and Field Communicator .......................................................	74
	5.8	Establish multidrop communication .............................................................................................		75
		5.8.1	Use Rosemount Radar Master Plus .................................................................................	75
		5.8.2	Use AMS Device Manager ..............................................................................................	75
		5.8.3	Use Field Communicator ...............................................................................................	75
	5.9	Use with the Rosemount 333 HART Tri-Loop ................................................................................		75
Chapter 6	Operation ......................................................................................................................			77
	6.1	LCD display screen messages .......................................................................................................		77
		6.1.1	Startup screen sequence ...............................................................................................	77
		6.1.2	Variable screens .............................................................................................................	78
	6.2	Set up the LCD display ..................................................................................................................		79
		6.2.1	Use Rosemount Radar Master Plus .................................................................................	79
		6.2.2	Use AMS Device Manager and Field Communicator .......................................................	79
	6.3	View measurement data ..............................................................................................................		79
		6.3.1	Use Rosemount Radar Master Plus .................................................................................	79

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			Contents
	6.3.2	Use AMS Device Manager and Field Communicator .......................................................	80
	6.3.3	Interpret measurement status .......................................................................................	80
6.4	Device status ................................................................................................................................		81
	6.4.1	Check device status .......................................................................................................	81
Chapter 7 Service and Troubleshooting ..........................................................................................			85
7.1	Safety messages ...........................................................................................................................		85
7.2	Diagnostic messages ....................................................................................................................		85
7.3	Troubleshooting guide .................................................................................................................		91
7.4	Service and troubleshooting tools ................................................................................................		97
	7.4.1	Using the echo curve .....................................................................................................	97
	7.4.2	Managing disturbance echoes .....................................................................................	101
	7.4.3	Perform an analog loop test .........................................................................................	107
	7.4.4	Use the TEST terminal ..................................................................................................	108
	7.4.5	Calibrate analog out ....................................................................................................	110
	7.4.6	Save a backup file of the device configuration ..............................................................	110
	7.4.7	Download configuration from file to device .................................................................	111
	7.4.8	Restore to default settings ...........................................................................................	111
	7.4.9	Use the simulation mode .............................................................................................	111
	7.4.10	View input registers .....................................................................................................	112
	7.4.11	View/edit holding registers ..........................................................................................	112
	7.4.12	Write protect a transmitter ..........................................................................................	113
7.5	Application challenges ...............................................................................................................		114
	7.5.1	Handling disturbances at top of tank ...........................................................................	114
	7.5.2	Tracking of weak surface echoes close to tank bottom ................................................	116
	7.5.3	Handling ghost echoes in still pipes .............................................................................	119
	7.5.4	Handling strong double bounce echoes .......................................................................	120
7.6	Replace the transmitter head .....................................................................................................		122
7.7	Cleaning or replacing the PTFE sealing .......................................................................................		124
	7.7.1	Flanged version ...........................................................................................................	125
	7.7.2	Tri Clamp version .........................................................................................................	126
7.8	Service support ..........................................................................................................................		128
Chapter 8 Safety Instrumented Systems (4-20 mA only) ...............................................................			131
8.1	Safety messages .........................................................................................................................		131
8.2	Terms and definitions .................................................................................................................		131
8.3	Safety Instrumented System (SIS) certification ...........................................................................		133
8.4	Safety certified identification .....................................................................................................		134
8.5	Installation .................................................................................................................................		135
	8.5.1	Measuring range ..........................................................................................................	136
8.6	Configuration .............................................................................................................................		136
	8.6.1	Prerequisites ................................................................................................................	136
	8.6.2	Configure device using Guided Setup ..........................................................................	136
	8.6.3	Set operational mode ..................................................................................................	136
	8.6.4	Enable safety mode .....................................................................................................	137
	8.6.5	Alarm and saturation levels ..........................................................................................	137
8.7	Site acceptance ..........................................................................................................................		138
8.8	Proof-testing ..............................................................................................................................		138
	8.8.1	Overview .....................................................................................................................	138
	8.8.2	Perform 1-point level and analog output verification ...................................................	139
	8.8.3	Perfom 2-point level and analog output verification ....................................................	142
	8.8.4	Perform analog output verification ..............................................................................	144

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	8.8.5	Perform level deviation monitoring .............................................................................	144
	8.8.6	Product repair ..............................................................................................................	145
8.9	Specifications .............................................................................................................................		145
	8.9.1	Failure rate data ...........................................................................................................	145
	8.9.2	Safety deviation ...........................................................................................................	145
	8.9.3	Transmitter response time ..........................................................................................	145
	8.9.4	Diagnostic test interval ................................................................................................	145
	8.9.5	Turn-on time ...............................................................................................................	145

Appendices and reference

Appendix A Specifications and Reference Data ................................................................................			147
A.1	Performance specifications ........................................................................................................		147
	A.1.1	General ........................................................................................................................	147
	A.1.2	Measuring range ..........................................................................................................	148
	A.1.3	Environment ................................................................................................................	150
A.2	Functional specifications ............................................................................................................		151
	A.2.1	General ........................................................................................................................	151
	A.2.2	Display and configuration ............................................................................................	151
	A.2.3	4-20 mA HART .............................................................................................................	153
	A.2.4	Diagnostics ..................................................................................................................	155
	A.2.5	Process temperature and pressure rating ....................................................................	156
	A.2.6	Temperature limits ......................................................................................................	157
	A.2.7	Flange rating ...............................................................................................................	158
	A.2.8	Conditions used for flange strength calculations .........................................................	159
	A.2.9	Air purging ..................................................................................................................	161
	A.2.10	System integration ......................................................................................................	162
A.3	Physical specifications ................................................................................................................		163
	A.3.1	Material selection ........................................................................................................	163
	A.3.2	Engineered solutions ...................................................................................................	163
	A.3.3	Housing and enclosure ................................................................................................	163
	A.3.4	Tank connection ..........................................................................................................	164
	A.3.5	Flange dimensions .......................................................................................................	164
	A.3.6	Antenna versions .........................................................................................................	164
	A.3.7	Material exposed to tank atmosphere ..........................................................................	164
A.4	Ordering Information .................................................................................................................		165
	A.4.1	Rosemount 5408 Level Transmitter .............................................................................	165
	A.4.2	Rosemount 5408:SIS Level Transmitter .......................................................................	170
A.5	Availability of process connections .............................................................................................		176
A.6	Spare parts and accessories ........................................................................................................		178
	A.6.1	Accessories ..................................................................................................................	185
A.7	Dimensional drawings ................................................................................................................		186
	A.7.1	Standard flanges ..........................................................................................................	190

Appendix B Product Certifications ...................................................................................................		193
B.1	European directive information ..................................................................................................	193
B.2	Safety Instrumented Systems (SIS) .............................................................................................	193
B.3	Telecommunication compliance ................................................................................................	193
B.4	FCC ............................................................................................................................................	194
B.5	IC ...............................................................................................................................................	194
B.6	Radio Equipment Directive (RED) 2014/53/EU ...........................................................................	195
B.7	Installing equipment in North America .......................................................................................	196

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			Contents
B.8	U.S.A. .........................................................................................................................................		196
	B.8.1	E5 Explosionproof (XP), Dust-Ignitionproof (DIP) .........................................................	196
	B.8.2	I5 Intrinsic Safety (IS), Non-Incendive (NI) ....................................................................	198
B.9	Canada .......................................................................................................................................		199
	B.9.1	E6 Explosionproof, Dust-Ignitionproof .........................................................................	199
	B.9.2	I6 Intrinsically Safe and Non-Incendive Systems ...........................................................	201
B.10	Europe .......................................................................................................................................		203
	B.10.1	E1 ATEX Flameproof ....................................................................................................	203
	B.10.2	I1 ATEX Intrinsic Safety ................................................................................................	204
	B.10.3	N1 ATEX Type N: Non-Sparking ....................................................................................	206
B.11	International ..............................................................................................................................		206
	B.11.1	E7 IECEx Flameproof ....................................................................................................	206
	B.11.2	I7 IECEx Intrinsic Safety ................................................................................................	207
	B.11.3	N7 IECEx Type N: Non-Sparking ...................................................................................	209
B.12	Brazil ..........................................................................................................................................		209
	B.12.1	E2 INMETRO Flameproof ..............................................................................................	209
	B.12.2	I2 INMETRO Intrinsic Safety .........................................................................................	210
	B.12.3	N2 INMETRO Type N: Non-Sparking .............................................................................	210
B.13	China ..........................................................................................................................................		211
	B.13.1	E3 Flameproof .............................................................................................................	211
	B.13.2	I3 Intrinsic Safety .........................................................................................................	211
	B.13.3	N3 Type N: Non-Sparking .............................................................................................	211
B.14	India ...........................................................................................................................................		212
	B.14.1	Intrinsic Safety .............................................................................................................	212
	B.14.2	Flameproof Safety .......................................................................................................	212
	B.14.3	Intrinsic Safety and Flameproof ...................................................................................	212
B.15	Republic of Korea .......................................................................................................................		212
	B.15.1	IP Intrinsic Safety .........................................................................................................	212
B.16	Additional certifications .............................................................................................................		213
	B.16.1	QT Safety-certified to IEC 61508:2010 with certificate of FMEDA data .........................	213
	B.16.2	Suitable for intended use .............................................................................................	213
	B.16.3	U1 Overfill prevention ..................................................................................................	213
	B.16.4	QA 3-A .........................................................................................................................	213
B.17	Installation drawings ..................................................................................................................		214
Appendix C Configuration Parameters ............................................................................................			221
C.1	Menu tree ..................................................................................................................................		221
C.2	Device setup ..............................................................................................................................		223
	C.2.1	HART protocol .............................................................................................................	223
	C.2.2	Units ............................................................................................................................	224
	C.2.3	Analog output .............................................................................................................	224
	C.2.4	Display .........................................................................................................................	225
	C.2.5	Security .......................................................................................................................	225
	C.2.6	Device Information ......................................................................................................	226
C.3	Level setup .................................................................................................................................		227
	C.3.1	Geometry ....................................................................................................................	227
	C.3.2	Environment ................................................................................................................	235
	C.3.3	Volume ........................................................................................................................	236
	C.3.4	Scaled variable .............................................................................................................	236
	C.3.5	Antenna .......................................................................................................................	237
	C.3.6	Advanced ....................................................................................................................	239
C.4	Alert setup .................................................................................................................................		245

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C.4.1	Measurement recovery ................................................................................................	245
C.4.2	Signal quality alert .......................................................................................................	245
C.4.3	High/low user defined alert ..........................................................................................	246

vi	Reference Manual

Introduction

1 Introduction

1.1Using this manual

The sections in this manual provide information on installing, operating, and maintaining the Rosemount™ 5408 and 5408:SIS Level Transmitters – Non-Contacting Radar.

The sections are organized as follows:

Chapter 2 provides an introduction to theory of operation, a description of the transmitter, information on typical applications, and process characteristics.

Chapter 3 contains mechanical installation instructions.

Chapter 4 contains electrical installation instructions.

Chapter 5 provides instructions on configuration of the transmitter.

Chapter 6 contains operation and maintenance techniques.

Chapter 7 provides troubleshooting techniques for the most common operating problems.

Chapter 8 contains identification, commissioning, maintenance, and operations information for safety-certified transmitter used in Safety Instrumented Systems (SIS) applications.

Appendix A supplies reference and specification data, as well as ordering information.

Appendix B contains safety approval information and approval drawings.

Appendix C provides extended information about the configuration parameters.

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.

Rosemount 5408 and 5408:SIS Level Transmitters

1

Introduction

2	Reference Manual

Transmitter Overview

2 Transmitter Overview

2.1Measurement principle

The Rosemount™ 5408 and 5408:SIS are two-wire transmitters for continuous level measurements over a broad range of liquids, slurries, and solids. The measurement principle is fast-sweep Frequency Modulated Continuous Wave (FMCW).

The transmitter continuously emits signal sweeps with a constantly varying frequency towards the product surface. Since the transmitter continuously changes the frequency of the transmitted signal, there will be a difference in frequency between the transmitted and the reflected signals (see Figure 2-1).

The frequency of the reflected signal is subtracted from the frequency of the signal transmitted at that moment, resulting in a low frequency signal which is proportional to the distance to the product surface. This signal is further processed to obtain fast, reliable, and highly accurate level measurements. See Figure 2-2 for a schematic overview of the signal processing.

Figure 2-1: FMCW-method
	&
$	'
IP [
ILQ
I
IRXW
IPLQ
W	%
f≈d=distance

A.Frequency (GHz)

B.Time (s)

C.Transmitted signal

D.Reflected signal

IRXW ILQ

G

Rosemount 5408 and 5408:SIS Level Transmitters

3

Transmitter Overview

Figure 2-2: Flowchart of the Signal Processing

Microwave module

A/D coverter

Fast Fourier transform (FFT)

Peak search

Peak interpolation

Echo tracker

Echo identifier

Distance filtering

Variable calculation

Aout handler		LCD handler		HART

2.2Process characteristics

2.2.1Dielectric 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.

2.2.2Foam and turbulence

Foaming liquids or turbulence may cause weak and varying surface echo amplitudes. The effects of turbulence are usually minor, but in the most challenging conditions, the transmitter may be mounted in a still pipe. In addition, measurement performance can be optimized by configuring the appropriate process conditions settings, see

Process conditions.

4	Reference Manual

Transmitter Overview

Measurement in foamy applications depends largely on the foam properties. When the foam is light and airy, the actual product level is measured. For heavy and dense foam, the transmitter may measure the level of the foam’s upper surface. The Double Surface Handling function allows the user to select if the foam layer or product surface should be used as output (see Double surface handling).

2.2.3Dust

Dust is often present in solids applications, and even if the non-contacting radar is not affected by the dust in the vapor space, dust can be sticky and create a layer on the antenna. If this layer becomes too thick, it may affect the measurement. This is best managed by using air purging.

2.2.4Solid surface

Solids have some common characteristics which may cause weak and varying surface reflections. The surface is rarely flat or horizontal, the angle of the sloping surface differs during filling and emptying, and the dielectric constant of many solids is fairly

low.Table 2-1 presents common characteristics of some solids applications.

The parabolic antenna is ideal for applications with weak surface reflections. A larger diameter concentrates the radar beam and ensures maximum antenna gain. The parabolic antenna comes with a swivel connection that adjusts for angled tank roofs.

Table 2-1: Common Characteristics of Solids Applications

	Common characteristics
	Particle size			Vapor space
Applications	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	Yes
Alumina	Yes	Yes	No	Yes	No
Salt	No	Yes	Yes	No	No

Rosemount 5408 and 5408:SIS Level Transmitters

5

Transmitter Overview

2.3Vessel characteristics

2.3.1In-tank obstructions

The transmitter should be mounted so that objects such as heating coils, ladders, and agitators 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.

Vertical and inclined structures cause minimal effect since the radar signal is scattered rather than directed back to the antenna.

2.3.2Tank shape

The shape of the tank bottom affects the measurement signal when the product surface is close to the tank bottom. The transmitter has built-in functions which optimize measurement performance for various bottom shapes.

2.4Application examples

The Rosemount 5408 and 5408:SIS are ideal for level measurements over a broad range of liquid and solids applications. The transmitters are virtually unaffected by changing density, temperature, pressure, media dielectric, pH, and viscosity. Non-contacting radar level is ideal for harsh conditions such as corrosive and sticky media, or when internal tank obstructions are a limiting factor.

Storage and buffer tanks

The Rosemount 5408 provides accurate and reliable level measurement for both metallic or non-metallic vessels containing almost any liquid (e.g. oil, gas condensate, water, chemicals).

Reactors

The Rosemount 5408 is ideal for the most challenging applications, including reactors where there can be agitation, foaming, condensation as well as high temperatures and pressures.

6	Reference Manual

Transmitter Overview

Blenders and mixers

The Rosemount 5408 can help you withstand the rigors of blenders and mixing tanks. Easy to install and commission, it is also unaffected by virtually any fluid property change.

Open atmospheric applications

The Rosemount 5408 measures reliably in open applications, from short range sumps or ponds to long range dams.

Still pipe and chamber installations

The Rosemount 5408 is an excellent choice for level measurement in tanks with still pipes. It may also be used in chambers, but guided wave radar is generally the best fit for these applications. See Section 3.3.8 for installation guidelines.

Rosemount 5408 and 5408:SIS Level Transmitters					7

Transmitter Overview

Bulk solids

The Rosemount 5408 is the ideal solution for small to medium sized silos with rapid level changes. The narrow beam avoids internal obstructions while still keeping good level measurement.

Safety applications

The Rosemount 5408:SIS is the ideal choice for safety functions such as overfill prevention, level deviation monitoring or dry-run prevention.

SIL2

2.5Components of the transmitter

Figure 2-3 shows the different components of the transmitter. There are different antenna types and sizes available for various applications.

8	Reference Manual

Transmitter Overview

Figure 2-3: Components

* *

+

&
'	,

(	-
	.
)

/		1
		3
	0	2
		s r

A.	Terminal compartment	I.	Alignment marker (one per side)
B.	Transmitter housing (aluminum or stainless steel)	J.	Threaded process connection (NPT or BSPP
			(G))
C.	Sensor module with signal processing electronics	K.	Air purge ring (option code PC1 for cone an-
			tenna)
D.	External ground screw	L.	Integrated air purge connection
E.	Flanged process connection	M.	Parabolic antenna
F.	Cone antenna	N.	Parabolic antenna with swivel mount
G.	Two cable/conduit entries (½-14 NPT, M20 x 1.5,	O.	Process seal antenna
	or G½)
	Optional adapters: eurofast™ and minifast™
H.	LCD display (optional)	P.	Tri-Clamp process connection

Rosemount 5408 and 5408:SIS Level Transmitters

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Transmitter Overview

2.6System integration

The 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 signal. The transmitter can be configured for either HART Revision 6 (default) or 7 (option code HR7). The HART Revision can be switched in field.

By using the optional Rosemount 333 HART Tri-Loop™, the digital HART signal can be converted into 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 combined with the Emerson™ Wireless 775 THUM™ Adapter to wirelessly communicate HART data with IEC 62591 (WirelessHART®) technology. In addition, the transmitter can be connected to a Rosemount 751 Field Signal Indicator, or it can be equipped with an LCD display.

The transmitter can easily be configured by using a PC with the Rosemount Radar Master Plus software (running in the Instrument Inspector™ Application), a Field Communicator, the AMS Device Manager, or any other Device Descriptor (DD) or Field Device Integration (FDI) compatible host system.

The Rosemount 5408 and 5408:SIS are compliant with NAMUR NE 107 Field Diagnostics for standardized device diagnostic information.

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Transmitter Overview

Figure 2-4: System Architecture

)

(

&

*

'

+

,

A.Emerson Wireless 775 THUM Adapter

B.Rosemount 5408

C.Rosemount 751

D.Field Communicator

E.Approved IS barrier (for Intrinsically Safe installations only)

F.Rosemount 333

G.Host/DCS system

H.HART modem

I.Rosemount Radar Master Plus or AMS Device Manager

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Transmitter Overview

12	Reference Manual

Mechanical Installation

3 Mechanical Installation

3.1Safety messages

Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that potentially raises safety issues is indicated by a warning symbol (). Refer to the following safety messages before performing an operation preceded by this symbol.

WARNING!

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

•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.

•For installations in hazardous locations, the transmitter must be installed according to the Rosemount 5408 and 5408:SIS Product Certifications document and System Control Drawing (D7000002-885).

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.

Explosions could result in death or serious injury.

•Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications.

3.2Confirm approval type

For hazardous locations transmitters labeled with multiple approval types:

Permanently mark the checkbox of the selected approval type(s).

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Mechanical Installation

Figure 3-1: Label with Multiple Approval Types

3.3Installation considerations

Before installing the transmitter, follow recommendations for mounting position, sufficient free space, nozzle requirements, etc.

3.3.1Mounting position

When finding an appropriate location on the tank for the transmitter, the conditions of the tank must be carefully considered.

Consider the following guidelines when mounting the transmitter:

•For optimal performance, the transmitter should be installed in locations with a clear and unobstructed view of the product surface.

•The transmitter should be mounted with as few internal structures as possible within the signal beam, see Section 3.3.6.

•Do not install the transmitter in the center of the tank.

•Do not mount close to or above the inlet stream.

•Multiple Rosemount 5408 and 5408:SIS Level Transmitters can be used in the same tank without interfering with each other.

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Mechanical Installation

Figure 3-2: Recommended Mounting Position

/

3.3.2Free space requirements

If the transmitter is mounted close to a wall or other tank obstructions such as heating coils and ladders, noise might appear in the measurement signal. Therefore the following minimum clearance, according to Table 3-1, must be maintained.

For easy access to the transmitter, mount it with sufficient service space (see Table 3-2).

Figure 3-3: Free Space Requirements

/

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Mechanical Installation

Table 3-1: Distance to Tank Wall (L)

Application	Minimum	Recommended
Liquids	8 in. (200 mm)	½ of tank radius
Solids	8 in. (200 mm)	⅔ of tank radius

Table 3-2: Free Space Requirements

Description	Distance
Service space width (A)	20 in. (500 mm)
Service space height (B)	24 in. (600 mm)

3.3.3Antenna size

Choose as large antenna diameter as possible. A larger antenna diameter concentrates the radar beam and ensures maximum antenna gain. Increased antenna gain permits greater margin for weak surface echoes.

In addition, a larger antenna diameter results in a smaller beam angle and thereby, less interference from any internal structures in the tank.

3.3.4Antenna inclination

Ensure the antenna is aligned perpendicular to the product surface (see Figure 3-4). The parabolic antenna comes with a swivel connection that adjusts for angled tank roofs.

Note that if the surface echo is weak in solids applications, then a small inclination of the parabolic antenna toward the surface slope may improve the performance.

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Mechanical Installation

Figure 3-4: Inclination

A

Max. 3°

90°

B

Max. 1.5°

90°

A.Cone antenna/process seal antenna

B.Parabolic antenna

3.3.5Non-metallic tanks

The walls in non-metallic tanks can be invisible to the radar signal, so nearby objects outside the tank may cause disturbing radar echoes. Wherever possible, the transmitter should be positioned so that objects close to the tank are kept outside the signal beam.

3.3.6Beam width and beam angle

The transmitter should be mounted with as few internal structures as possible within the signal beam. Refer to Table 3-3 for beam angle and Table 3-4 for beam width at different distances.

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Mechanical Installation

Figure 3-5: Beam Angle and Beam Width

:

Table 3-3: Beam Angle

Antenna size	Beam angle (α)
2-in. (DN50) cone/process seal	18°
3-in. (DN80) cone/process seal	14°
4-in. (DN100) cone/process seal	10°
8-in. (DN200) parabolic	4.5°

Table 3-4: Beam Width, ft. (m)

		Beam width (W)
		2-in. cone/ process		3-in. cone/ process	4-in. cone/ process
Distance (D)		seal		seal	seal	Parabolic
16	(5)	5.2 (1.6)		4.0 (1.2)	2.9 (0.9)	1.3 (0.4)
33	(10)	10.4	(3.2)	8.1 (2.5)	5.7 (1.8)	2.6 (0.8)
49	(15)	15.6	(4.8)	12.1 (3.7)	8.6 (2.6)	3.9 (1.2)
66	(20)	20.8	(6.3)	16.1 (4.9)	11.5 (3.5)	5.2 (1.6)
82	(25)	26.0	(7.9)	20.1 (6.1)	14.3 (4.4)	6.4 (2.0)
98	(30)	31.2	(9.5)	24.2 (7.4)	17.2 (5.3)	7.7 (2.4)
131 (40)		41.6	(12.7)	32.2 (9.8)	23.0 (7.0)	10.3 (3.1)

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Mechanical Installation

3.3.7Nozzle requirements

In order to allow the microwaves to propagate undisturbed, the nozzle dimensions should be kept within the specified limits as given in Table 3-5, Table 3-6, and Table 3-7.

Nozzle requirements for cone antenna

For best performance, the cone antenna should extend at least 0.4 in. (10 mm) below the nozzle. If required, use the extended cone antenna versions (option code S1 or S2).

However, the antenna can be recessed in smooth nozzles up to 4 ft. (1.2 m). Note that if the inside of the nozzle has irregularities (e.g. due to bad welding, rust, or deposit), then use the extend cone antenna.

Figure 3-6: Mounting of the Cone Antenna

H

> 0.4 in. (10 mm)

D

Table 3-5: Nozzle Requirements for Cone Antenna, in Inches (Millimeters)

		Recommended maximum nozzle height (H)(2)(3)
Antenna size	Minimum nozzle diameter (D)(1)	Antenna	Antenna with air purge ring (code PC1)
2-in. (DN50)	1.94 (49.3)	5.71 (145)	4.69 (119)
3-in. (DN80)	2.80 (71.0)	5.63 (143)	4.61 (117)
4-in. (DN100)	3.78 (96.0)	6.54 (166)	5.51 (140)

(1)The antennas are sized to fit within schedule 80 or lower schedules.

(2)The values are valid for cone antennas without antenna extension.

(3)For liquid applications, the cone antenna can be recessed in smooth nozzles up to 4 ft. (1.2 m), but note that the accuracy may be reduced in the region close to the nozzle.

Nozzle requirements for process seal antenna

The antenna can be used on nozzles up to 4 ft. (1.2 m). Disturbing objects inside the nozzle may impact the measurement, and should therefore be avoided.

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Mechanical Installation

Figure 3-7: Mounting of the Process Seal Antenna

Table 3-6: Nozzle Requirements for Process Seal Antenna

		Recommended maximum nozzle height
Antenna size	Minimum nozzle diameter (D)(1)	(H)(2)
2-in. (DN50)	1.77 in. (45 mm)	4 ft. (1.2 m)
3-in. (DN80)	2.76 in. (70 mm)	4 ft. (1.2 m)
4-in. (DN100)	2.76 in. (70 mm)	4 ft. (1.2 m)

(1)The antennas are sized to fit within schedule 120 or lower schedules.

(2)For hygienic applications, the nozzle height (H) must not exceed 2 × nozzle diameter (D) to ensure cleanability. Maximum nozzle height is 5 in. (127 mm).

Nozzle requirements for parabolic antenna

See Table 3-7 for nozzle height recommendations at different inclination angle.

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