Rosemount Tank Radar 5402 Radar Level Gauge User Manual Book 5400 RevAB

Rosemount Tank Radar AB Radar Level Gauge Book 5400 RevAB

Userds manual

www.rosemount.comReference Manual 00809-0100-4026, Rev ABAugust 2004Rosemount 5400 SeriesTwo-wire Radar Level Transmitter

$Reference Manual 00809-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comRosemount 5400 SeriesRosemount 5400 Series Radar Transmitter may be protected by one or more U.S. Patents pending and foreign patents pending.Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.HART is a registered trademark of the HART Communication Foundation.Teflon, VITON, and Kalrez are registered trademarks of E.I. du Pont de Nemours & Co.AMS Suite is a trademark of Emerson Process Management.Cover Photo: 5400_08NOTICERead 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, Rosemount Inc. has two toll-free assistance numbers.Customer Central: 1-800-999-9307(7:00 a.m. to 7:00 p.m. CST)Technical support, quoting, and order-related questions.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 Rosemount representative.NOTICEThere are no health hazards from the Rosemount 5400 Series transmitter. The microwave power density in the tank is only a small fraction of the allowed power density according to international standards.The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on Rosemount nuclear-qualified products, contact your local Rosemount Sales Representative.This product is designed to meet FCC and R&TTE requirements.This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.$

Reference Manual 00809-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comTable of ContentsSECTION 1IntroductionSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2SECTION 2Transmitter OverviewTheory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Components of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Dielectric constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Turbulence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Temperature/Pressure/Density and Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Tank Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Antenna Selection Guide/Measuring Range . . . . . . . . . . . . . . . . . . . . 2-5SECTION 3InstallationSafety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Socket Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Free Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Recommended Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Beam Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Vessel Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Disturbing objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Mounting a standard cone antenna . . . . . . . . . . . . . . . . . . . . . . . . 3-9Mounting in Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Recommendations for pipe installations . . . . . . . . . . . . . . . . . 3-10Mounting in Bypass Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Antenna Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Cable/conduit entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Cable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Hazardous Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13External Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Maximum Loop Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Connecting the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Non-Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . 3-16Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 SeriesTOC-2SECTION 4Configuration/Start-UpSafety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Echo Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Advanced Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Tank Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Tank Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Tank Type and Tank Bottom Type . . . . . . . . . . . . . . . . . . . . . . 4-3Pipe Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Hold Off Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Process Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Rapid Level Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Turbulent Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Solid Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Product Dielectric Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Strapping Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Output Source/Primary Variable . . . . . . . . . . . . . . . . . . . . . . . . 4-6Upper/Lower Range Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Alarm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Echo Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Amplitude Threshold Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Registration of False Echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Configuration Using Rosemount Radar Master . . . . . . . . . . . . . . . . . 4-11System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Help In RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Installing the RRM software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Specifying the COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13To set the COM port buffers . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Specifying Measurement Units. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Guided Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14Using the Setup Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Configuration using a 275/375 Handheld Communicator . . . . . . . . . 4-20AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23SECTION 5OperationSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Viewing Measurement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Using the Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Specifying Display Panel Variables . . . . . . . . . . . . . . . . . . . . . . . . 5-3Using a Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Using Rosemount Radar Master (RRM) . . . . . . . . . . . . . . . . . . 5-3Using AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Viewing Measurement Data in RRM . . . . . . . . . . . . . . . . . . . . . . . 5-5Viewing Measurement Data in AMS Suite . . . . . . . . . . . . . . . . . . . 5-6

Reference Manual 00809-0100-4026, Rev ABAugust 2004TOC-3Rosemount 5400 SeriesSECTION 6Service and TroubleshootingSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Viewing Input and Holding Registers . . . . . . . . . . . . . . . . . . . . . . . 6-2Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Logging Measurement Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Backing Up the Transmitter Configuration . . . . . . . . . . . . . . . . . . . 6-4Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Using the Spectrum Plot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Surface Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Peak Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Record Tank Spectra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Configuration Mode Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7File Mode Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Reset to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Surface Search. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Using the Simulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Enter Service Mode in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Write Protecting a Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13Measurement Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14Volume Calculation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15Analog Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15Application Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16APPENDIX AReference DataSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Process Temperature and Pressure Rating . . . . . . . . . . . . . . . . . . A-3Temperature restrictions due to O-ring selection . . . . . . . . . . . A-3Pressure restrictions due to flange selection. . . . . . . . . . . . . . . A-3Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5APPENDIX BProduct CertificatesSafety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1European Atex Directive Information . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Flame Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Hazardous Locations Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5Factory Mutual (FM) Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5Canadian Standards Association (CSA) Approval . . . . . . . . . . . . . B-6Approval Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7APPENDIX C275 HART CommunicatorIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 SeriesTOC-4Basic Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6Action Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6ON/OFF Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6Directional Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6HOT Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7Alphanumeric and Shift Keys . . . . . . . . . . . . . . . . . . . . . . . . . .C-7Menus and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8Online Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-9HART Fast Key Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-9HART Field Communicator Diagnostic Messages . . . . . . . . . . . . .C-9APPENDIX DAdvanced ConfigurationTank Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Distance Offset (G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Minimum Level Offset (C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2Hold Off Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2Calibration Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2Advanced Analog Output Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Advanced Transmitter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Antenna Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Tank Connection Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Empty Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Empty Tank Detection Area . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Bottom Echo Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Tank Bottom Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Extra Echo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5Level Alarm is not set when Tank is Empty. . . . . . . . . . . . . . . .D-5Full Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5Full Tank Detection Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5Level above Hold Off Distance Possible . . . . . . . . . . . . . . . . . .D-5Level Alarm is Not Set when Tank is Full . . . . . . . . . . . . . . . . .D-5Double Bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5Surface Echo Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Slow Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Slow Search Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Double Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Upper Product Dielectric Constant . . . . . . . . . . . . . . . . . . . . . .D-6Select Lower Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Echo Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Close Distance Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6Filter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7Damping Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7Activate Jump Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7Advanced Functions in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8Empty Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8Bottom Echo Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8Empty Tank Detection Area . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9Extra Echo Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-10Full Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11Double Bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12

Reference Manual 00809-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comSection 1 IntroductionSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2SAFETY MESSAGES Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the saftey messages listed at the beginning of each section before performing an operation preceded by this symbol.Failure to follow these installation 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.Explosions could result in death or serious injury.• Verify that the operating environment of the transmitter is consistent with the appropriate hazardous locations certifications.• Before connecting a 275/375 Handheld Communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices.Electrical shock could cause death or serious injury.• Use extreme caution when making contact with the leads and terminals.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.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series1-2MANUAL OVERVIEW This manual provides installation, configuration and maintenance information for the Rosemount 5400 Series Radar Transmitter.Section 2: Transmitter Overview• Theory of Operation• Descripton of the transmitter• Process and vessel characteristicsSection 3: Installation• Mounting considerations• Mechanical installation• Electrical installationSection 4: Configuration/Start-Up• Configuration instructions• Configuration using the RRM software• Configuration using a 275/375 Field CommunicatorSection 5: Operation• Viewing measurement data with a Display panel• Viewing measurement data with Rosemount Radar MasterSection 6: Service and Troubleshooting• Error and Warning Codes• Communication ErrorsAppendix A: Reference Data• Troubleshooting• Specifications• Ordering InformationAppendix B: Product Certificates• Examples of labels• European ATEX Directive information• FM approvals• CSA approvals•DrawingsAppendix C: 275 HART Communicator•Features• Connections• Diagnostic messagesAppendix D: Advanced Configuration• Advanced Tank Geometry• Advanced Transmitter Configuration

Reference Manual 00809Rev AB-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comSection 2 Transmitter OverviewTheory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1Components of the transmitter . . . . . . . . . . . . . . . . . . . . . page 2-2System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-3Antenna Selection Guide/Measuring Range . . . . . . . . . . page 2-5Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-4THEORY OF OPERATION The Rosemount 5400 Series Radar Transmitter is a smart, two-wire continuous level transmitter. A 5400 transmitter is installed at the tank top and emits short microwave pulses towards the product surface in the tank. When a pulse reaches the surface of the material it is measuring, 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 from which the level is calculated.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 5400 Series.TDR_PRINCIPLES(2).EPSRadar pulseTimeSignal amplitudeLevelDistanceTank Height

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series2-2COMPONENTS OF THE TRANSMITTERThe Rosemount 5400 Series Radar Transmitter has a die-cast aluminum housing which contains advanced electronics for signal processing. The radar electronics produces the 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. The head 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 2-2. Transmitter components.Cable Entry:½" NPT.Optional adapters: M20TRANSMITTER_COMPONENTS.EPSTransmitter Head with Radar ElectronicsAntennaDisplay Panel Terminal sideCable Entry:½" NPT.Optional adapters: M20FlangeTank Seal

Reference Manual 00809-0100-4026, Rev ABAugust 20042-3Rosemount 5400 SeriesSYSTEM ARCHITECTUREThe 5400 Series Radar Level Transmitter is a powerful radar level transmitter suitable for non-contact level measurements in process tanks and other types of tanks. It is designed for easy installation and maintenance free operation.The Rosemount 5400 Series Radar Transmitter is loop-powered which means it uses the same two wires for both power supply and output signal. The output is a 4-20 mA analog signal superimposed with a digital HART signal.Figure 2-3. System Integration.The Rosemount 5400 Series Radar Transmitter can easily be configured by using a PC and the Rosemount Radar Master (RRM) software package or via a 275/375 Handheld Communicator. RRM offers configuration and service capabilities and functions for presentation of measurement data. The transmitter is also compatible with the AMS™ Suite software which can be used for configuration.For stand-alone systems, or as a complement to a PC or a control system, you can monitor level data using an analog output. As an option, the Rosemount 5400 Series Radar Level Transmitter can be equipped with a Display for monitoring measurement data.SYSTEM_5400.EPS375 Field Communicator275 HART Communicator PC with RRM or AMS SuiteControl SystemDisplay (optional)HARTModemRosemount 5400 Series Radar Transmitter

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series2-4PROCESS CHARACTERISTICSDielectric constant The reflectivity of the product is a key parameter for measurement performance. A high dielectric constant of the media gives better reflection and thus enables a longer measuring range.Foam How well the Rosemount 5400 Series Radar Transmitter measures in foamy applications depends upon the properties of the foam; light and airy or dense and heavy, high or low dielectrics, etc. If the foam is conductive and creamy the transmitter will probably measure the surface of the foam. If the foam is less conductive the microwaves will probably penetrate the foam and measure the liquid surface.Turbulence A calm surface gives better reflection than a turbulent surface. For turbulent applications the low frequency version Rosemount 5401 is recommended.Temperature/Pressure/Density and VaporTemperature and pressure generally has no impact on measurements. Measurements are also insensitive to product density and vapor.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 3-8.

Reference Manual 00809-0100-4026, Rev ABAugust 20042-5Rosemount 5400 SeriesANTENNA SELECTION GUIDE/MEASURING RANGEThe measuring range primarily depends on the antenna type and size, the dielectric constant (εr) of the liquid and process conditions. For optimum performance, make sure not to exceed the maximum measuring range values below.A. Oil, gasoline and other hydrocarbons, petrochemicals (εr =1.9-4.0).B. Alcohols, concentrated acids, organic solvents, oil/water mixtures and acetone (εr =4.0-10.0).C. Conductive liquids, e.g. water based solutions, dilute acids and alkalis (εr>10.0).Table 2-1. Measuring range for the Rosemount 5401 model.Low FrequencyAntennasUnits: feet (m)Dielectric ConstantABCABCABCCone, 2 in(1) NA NA NA 66 (20) 66 (20) 66 (20) NA NA NACone, 3 in(1) NA NA NA 66 (20) 66 (20) 66 (20) NA NA NACone, 4 in 20 (6) 33 (10) 43 (13) 66 (20) 66 (20) 66 (20) 9.9 (3) 16 (5) 23 (7)Cone, 6 in 33 (10) 49 (15) 66 (20) 66 (20) 66 (20) 66 (20) 16 (5) 23 (7) 30 (9)Cone, 8 in 49 (15) 66 (20) 66 (20) 66 (20) 66 (20) 66 (20) 23 (7) 30 (9) 36 (11)(1) Pipe installations only. NA=Not Applicable.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series2-6

Reference Manual 00809-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comSection 3 InstallationSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-2Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-9Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-13SAFETY 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 ( ). Please refer to the following safety messages before performing an operation preceded by this symbol.Explosions could result in death or serious injury:Verify that the operating environment of the transmitter is consistent with the appropriate hazardous locations certifications.Before connecting a HART-based 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.Failure to follow safe installation and servicing guidelines could result in death or serious injury:Make sure only qualified personnel perform the installation.Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment.Do not perform any service other than those contained in this manual unless you are qualified.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 5400 transmitter is off and the lines to any other external power source are disconnected or not powered while wiring the gauge.To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-2INSTALLATION PROCEDUREFollow these steps for proper installation:Review Installation Considerations(see page 3-3)Mount the transmitter(see page 3-9)Wire the transmitter(see page 3-13)Make sure covers and cable/conduit connections are tight.Power Up the transmitterConfigure the transmitter(see page 4-1)Verify measurements

Reference Manual 00809-0100-4026, Rev ABAugust 20043-3Rosemount 5400 SeriesMOUNTING CONSIDERATIONSBefore you install the Rosemount 5400 Series, be sure to consider specific mounting requirements, vessel characteristics and process characteristics. Socket Recommendation The Rosemount 5400 Series is mounted on a nozzle by using appropriate flanges. For best performance it is recommended that the socket meets the following recommendations:Figure 3-1. Mounting of the 5400 Series transmitter.Table 3-1. Requirements on socket height and width.The transmitter should be installed as follows:• The antenna must be aligned vertically. • Choose as large antenna diameter as possible. A larger receiving area concentrates the radar beam and ensures maximum antenna gain. Increased antenna gain means greater margin for weak surface echoes. A larger antenna also results in smaller beam angle and thereby, less interference from any internal structures in the tank.• For best measurement performance, the antenna should extend below the nozzle 0.4 inches (10 mm) or more.SOCKETREQ.EPSLMinimum Diameter>0.4 inch/10 mm5401 Antenna L max inch (mm) Min. Diameter inch (mm)Cone 4 in. 5.5 (140) 3.8 (97)Cone 6 in. 6.9 (175) 5.7 (145)Cone 8 in. 10.2 (260) 7.6 (193)5402 Antenna L max inch (mm) Min. Diameter inch (mm)Cone 2 in. 5.5 (140) 2.2 (55)Cone 3 in. 5.5 (140) 2.8 (72)Cone 4 in. 8.5 (215) 3.8 (97)

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-4Free Space For easy access to the transmitter make sure that it is mounted with sufficient service space.Mounting close to a tank wall, nozzle or obstruction, may have a negative influence on measurement perfomance. For maximum measurement performance the transmitter should be mounted according to the following recommendations:Figure 3-2. Free space recommendations.Service space Distance inch (mm)A19.7 (500)B23.6 (600)C. Inclination Maximum angleCone antenna 3°D. Minimum distance to tank wall Distance inch (mm)Cone antenna 5401 19.7 (500)FREESPACE.EPSABCD

Reference Manual 00809-0100-4026, Rev ABAugust 20043-5Rosemount 5400 SeriesRecommended Mounting PositionWhen finding an appropriate mounting position for the transmitter the conditions of the tank must be carefully considered. The transmitter should be mounted so that the influence of disturbing objects is reduced to a minimum.Figure 3-3. It is important to consider the proper mounting position.• Disturbing objects and filling inlets creating turbulence should be kept at a distance, outside the signal beam (see Figure 3-4 for beam width information).• Avoid to install the transmitter at the centre of the tank roof.• A bridle / still-pipe can be used to avoid interference from disturbing objects, turbulence or foam.MOUNTING_RESTRICTIONS.EPS

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-6Beam Width • The transmitter should be mounted with as few internal structures as possible within the beam angle.• The flat tank wall can be located within the antenna beam angle as long as there is a minimum distance from the transmitter to the tank wall (see Figure 3-2 for preferred installation).Figure 3-4. Beam width at various distances from the flange.Table 3-2. Beam Diameter at different distances for the Rosemount 5401 model.Table 3-3. Beam Diameter at different distances for the Rosemount 5402 model.BEAM_DIAMETER_2.EPSDistance5401(low frequency)5402(high frequency)DistanceCone Antenna4 in./DN 100 6 in./DN 150 8 in./DN 200Beam Diameter, ft (m)16 ft (5 m) 11.5 (3.5) 6.6 (2.0) 4.9 (1.5)33 ft (10 m) 23.0 (7.0) 13.1 (4.0) 9.8 (3.0)49 ft (15 m) 32.8 (10) 19.7 (6.0) 14.8 (4.5)66 ft (20 m) 42.7 (13) 26.2 (8.0) 19.7 (6.0)DistanceCone Antenna2 in. /DN 50 3 in./DN 80 4 in./DN 100Beam Diameter, ft (m)16 ft (5 m) 4.9 (1.5) 3.3 (1.0) 3.3 (1.0)33 ft (10 m) 11.5 (3.5) 8.2 (2.5) 4.9 (1.5)49 ft (15 m) 16.4 (5.0) 11.5 (3.5) 8.2 (2.5)66 ft (20 m) 21.3 (6.5) 16.4 (5.0) 9.8 (3.0)

Reference Manual 00809-0100-4026, Rev ABAugust 20043-7Rosemount 5400 SeriesFigure 3-5. Beam angle.Table 3-4. Beam Angle for the Rosemount 5401 model.Table 3-5. Beam Angle for the Rosemount 5402 model.Beam AngleBEAMWIDTH2.EPSSAntenna Half Power Beam WidthCone 2 in. (Still Pipe)Cone 3 in. (Still Pipe)Cone 4 in. 37°Cone 6 in. 23°Cone 8 in. 17°Antenna Half Power Beam WidthCone 2 in. 19°Cone 3in. 14°Cone 4in. 9°

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-8Vessel Characteristics Heating coils, agitators and other objects in the tank may lead to disturbing echoes and noise in the measurement signal. Vertical structures cause minimal effect since the radar signal is scattered rather than directed back to the antenna.The shape of the tank bottom affects the measurement signal when the product surface is close to the tank bottom. The Rosemount 5400 Series has built-in functions which optimize measurement performance for various bottom shapes (see “Tank Type and Tank Bottom Type” on page 4-3).Disturbing objects The 5400 Series transmitter should be mounted so that objects such as heating coils, ladders etc. are not within 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 in case such objects can not be totally avoided.

Reference Manual 00809-0100-4026, Rev ABAugust 20043-9Rosemount 5400 SeriesMECHANICAL INSTALLATIONMount the transmitter on a nozzle on top of the tank. Make sure only qualified personnel performs the installation.The transmitter housing must not be opened. If a software update or other service action is required that involves opening the housing, it must be done by a suitably trained service technician.Mounting a standard cone antennaFigure 3-6. Mounting the 5400 on a tank nozzle.1. Place a gasket with thickness and of material suitable to the process on top of the tank flange. 2. Lower the transmitter with antenna and flange into the tank nozzle.3. Tighten the bolts and nuts with sufficient torque regarding flange and gasket choice. See also “Process Temperature and Pressure Rating” on page A-3.Transmitter housingBoltGasketFlangeTank flangeAntennaMOUNT_TH_FLANGE.EPSNut

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-10Mounting in Pipes Still Pipe mounting is recommended for tanks where surface conditions are extremely turbulent. All antenna sizes for the 5400 Series transmitter can be used for Still Pipe installations. The 2 and 3 inch antennas for 5401 are designed for use in Still Pipes and Bypass Pipes only.When the transmitter is mounted in a Still Pipe the inclination should be within 1°. Figure 3-7. Mount the transmitter vertically.The gap between the antenna and the Still Pipe may be up to 0.2 inch (5 mm).Figure 3-8. Maximum gap between antenna and Still pipe.Recommendations for pipe installations• The pipe must be smooth on the inside.• Not suitable for adhesive products.• Make sure that at least one slot is above the product surface.• Slot area should not exceed the following limits:Table 3-6. Recommended maximum slot area for pipe installations.STILLPIPE_TANK_V2.EPSmax. 1 °STILLPIPE_REQS.EPSmax. 0.2 inch (5 mm)Antenna size 2” 3” 4” 6” 8”Max. slot area (feet2/m2) 0.43/0.04 1.08/0.1 3.23/0.3 11.8/1.1 26.9/2.5

Reference Manual 00809-0100-4026, Rev ABAugust 20043-11Rosemount 5400 SeriesMounting in Bypass PipesIn tanks with turbulent conditions it is recommended to mount the transmitter on a bridle pipe.Figure 3-9. Bridle mounting is recommended for tanks with extremely turbulent surface conditions.In pipes with inlet pipe diameter Ø<2 inch (51 mm) the gap D between pipe and antenna should be less than 0.2 inch (5 mm). If the inlet pipe diameter Ø>2 inch (51 mm) the gap D between pipe and antenna should be less than 0.04 inch (1 mm).The distance A between the antenna and the nearest inlet pipe should be at least 2 inch (50 mm).Figure 3-10. Recommended specifications for bridles with pipe inlets.BRIDLE_V2.EPSMinimum 12 in. (300 mm)max. 1 °BRIDLE_REQUIREMENTS.EPSA > 2 in./50 mmØØ (in./mm) D (in./mm)<2/51 <0.2/5>2/51 <0.04/1D

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-12Antenna Extension The Cone Antenna Extension is suitable for tanks with high nozzles or tanks where measurements should be avoided in the region close to the nozzle. Using the Cone Antenna Extension may lead to slightly reduced accuracy.Use the Antenna Extension if:• the nozzle is high and there is a rough surface at the inside of the nozzle, such as rust, bad weldings etc. See “Socket Recommendation” on page 3-3,• there are disturbing objects close to the tank opening.Figure 3-11. The extended antenna is useful for tanks with high nozzles.Figure 3-12. Dimensions of Antenna Extension.ANTENNA_EXTENSION.EPSCone Size (inch) A25.6 in.(143 mm)11.1 in.(283 mm)15.9 in.(403 mm)37.4 in.(188 mm)12.9 in.(328 mm)17.6 in.(448 mm)49.8 in.(250 mm)15.4 in.(390 mm)20.1 in.(510 mm)611.2 in.(285 mm)16.7 in.(425 mm)21.5 in.(545 mm)814.5 in.(376 mm)20.1 in.(510 mm)24.8 in.(630 mm)A3.9/7.9/11.8 in.(100/240/360 mm)EXTENSION.EPS

Reference Manual 00809-0100-4026, Rev ABAugust 20043-13Rosemount 5400 SeriesELECTRICAL INSTALLATIONCable/conduit entries The electronics housing has two entries with ½ - 14 NPT threads. Optional M20×1.5 adapters are also available. The connections are made in accordance with national, local and plant electrical codes.Make sure that unused ports are properly sealed to prevent moisture or other contamination from entering the terminal block compartment of the electronics housing. Install wiring with a drip loop. The bottom of the loop must be lower than the cable/conduit entry.NOTE!Use the enclosed metal plug to seal any unused port.Grounding The housing should always be grounded in accordance with national and local electrical codes. Failure to do so may impair the protection provided by the equipment. The most effective grounding method is direct connection to earth ground with minimal impedance. There are two grounding screw connections provided. One is inside the Terminal compartment of the housing and the other is located on one of the cooling fins below the housing. The internal ground screw is identified by a ground symbol: .NOTE!Grounding the transmitter via threaded conduit connection may not provide sufficient ground.NOTE!In the Explosionproof/Flameproof version the electronics is grounded via the transmitter housing. After installation and commissioning make sure that no ground currents exist due to high ground potential differences in the installation.Cable Selection Use shielded twisted pair wiring for the Rosemount 5400 Series. The cables must be suitable for the supply voltage and approved for use in hazardous areas, where applicable. For instance, in the U.S., explosionproof conduits must be used in the vicinity of the vessel. For the ATEX flameproof approval version of the Rosemount 5400 Series, suitable conduits with sealing device or flameproof (EEx d) cable glands must be used depending on local requirements.Use 18 AWG to 12 AWG wiring in order to minimize the voltage drop to the transmitter.Hazardous Areas When the Rosemount 5400 Series transmitter is installed in hazardous area, national and local regulations and specifications in applicable certificates must be observed.External Circuit Breaker For complicance with Low Voltage Directive 73/23/EEG an external circuit breaker should be installed.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-14Power Requirements Terminals in the transmitter housing provide connections for signal wiring.The 5400 transmitter operates with the following power supplies:Maximum Loop ResistanceThe maximum current loop resistance can be obtained from the following diagrams:Figure 3-13. Intrinsically Safe installation.See Figure 3-17 for wiring information.Figure 3-14. Non-hazardous installation.See Figure 3-16 for wiring information.Approval Type Power Supply (VDC)IS 14 - 30None 14 - 42.4MAX_LOAD_INTRINSIC.EPSMAX_LOAD_NON_INTRINSIC.EP

Reference Manual 00809-0100-4026, Rev ABAugust 20043-15Rosemount 5400 SeriesConnecting the TransmitterThe Rosemount 5400 Series accepts power supplies ranging from 14 VDC to 42.4 VDC. It uses 4-20 mA power superimposed with a HART signal.To connect the transmitter:1. Make sure that the power supply is switched off.2. Remove the terminal block cover.3. Pull the cable through the cable gland/conduit. Install wiring with a drip loop. The bottom of the loop must be lower than the cable/conduit entry.4. Connect wires according to Figure 3-16 for non-intrinsically safe power supplies and according to Figure 3-17 for Intrinsically safe power supplies.5. Use the enclosed metal plug to seal any unused port.6. Mount the cover and tighten the cable gland. Make sure that the cover is fully engaged to meet explosion-proof requirements.Note that adapters are required if M20 glands are used.7. Switch on the power supply.NOTE!Use Teflon tape or other sealant at the NPT threads in the Cable Entries.Figure 3-15. Terminal compartment and external ground screw.Cable entries.Internal Ground screw.Terminals for signal and power supply.External Ground screw.GROUNDINGSCREW.EPS/JUNCTION_BOX.EPS11324

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-16Non-Intrinsically Safe Power SupplyWith non-intrinsically safe power supply in Non-hazardous installations or Explosionproof/Flameproof installations, wire the transmitter as shown in Figure 3-16. NOTE!Make sure that the power supply is off when connecting the transmitter.Figure 3-16. Wiring for non-intrinsically safe power supply.The 275/375 Handheld Communicator and the HART Modem require a minimum load resistance of 250 Ohm within the loop in order to function properly. For maximum loop resistance see Figure 3-14.Power supplyWIRING_NON_IS.EPS275/375 Handheld CommunicatorLoad resistanceHART Modem5400 Series Radar TransmitterRRMAMS Suite 250 Ω

Reference Manual 00809-0100-4026, Rev ABAugust 20043-17Rosemount 5400 SeriesIntrinsically Safe Power SupplyWhen your power supply is intrinsically safe, wire the transmitter as shown in Figure 3-17.NOTE!Make sure that the instruments in the loop are installed in accordance with intrinsically safe field wiring practices.Figure 3-17. Wiring diagram for intrinsically safe power supply.The 275/375 Handheld Communicator and the HART Modem require a minimum load resistance within the loop of 250 Ohm in order to function properly. For maximum load resistance see Figure 3-13. Power supplyWIRING_IS.EPS275/375 Handheld CommunicatorHART Modem5400 Series Radar TransmitterApproved IS BarrierLoad resistance 250 ΩRRMAMS Suite

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series3-18

Reference Manual 00809-0100-4026, Rev ABAugust 2004 Rosemount 5400 Serieswww.rosemount.comSection 4 Configuration/Start-UpSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-3Echo Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-8Configuration Using Rosemount Radar Master . . . . . . . . page 4-11Configuration using a 275/375 Handheld Communicator page 4-20AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-23SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.Explosions could result in death or serious injury:Verify that the operating environment of the gauge is consistent with the appropriate hazardous locations certifications.Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices.Do not remove the gauge cover in explosive atmospheres when the circuit is alive.Failure to follow safe installation and servicing guidelines could result in death or serious injury:Make sure only qualified personnel perform the installation.Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment.Do not perform any service other than those contained in this manual unless you are qualified.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-2OVERVIEW Configuration of a Rosemount 5400 transmitter is normally a simple and straight-forward task. If the transmitter is pre-configured at factory according to the ordering specifications in the Configuration Data Sheet, no further Basic Configuration is required unless tank conditions have changed. The 5400 Series supports a set of advanced configuration options as well, which can be used to handle special tank conditions and applications. Basic Configuration The Basic Configuration includes parameters for a standard configuration which is sufficient in most cases. The Basic Configuration comprises the following items:• Measurement Units• Tank Configuration- Tank Geometry- Environment- Volume• Analog OutputEcho Tuning Echo Tuning is used to handle special situations when there are objects in the tank which cause disturbing echoes that are stronger than the surface echo. The following tools are available to handle such situations:• Amplitude Threshold Curve (ATC)• False Echo registrationAdvanced Configuration For some applications further configuration is needed in addition to the Basic Configuration. This may be due to the properties of the product or the shape of the tank. Disturbing objects and turbulent conditions in the tank may also require that advanced measures are taken. See Appendix D: Advanced Configuration for more information.Configuration Tools There are several tools available for basic configuration of a 5400 transmitter:• Rosemount Radar Master (RRM). Note that RRM is required for advanced configuration features. See “Configuration Using Rosemount Radar Master” on page 4-11 for information on how to use RRM for configuration of the 5400 Series.• Rosemount 275/375 Field Communicator.See “Configuration using a 275/375 Handheld Communicator” on page 4-20 for Field Communicator Menu Tree.• AMS Suite software. RRM is a user-friendly, Windows based software package including waveform plots, off-line/on-line configuration Wizard, logging, and extensive on-line help. To communicate with the transmitter using RRM, a HART® modem (part number 03300-7004-0001) is required.

Reference Manual 00809-0100-4026, Rev ABAugust 20044-3Rosemount 5400 SeriesBASIC CONFIGURATION This chapter describes the basic parameters that need to be configured for a Rosemount 5400 transmitter. If the transmitter is pre-configured at factory according to the ordering specifications in the Configuration Data Sheet, no further basic configuration is needed unless conditions have changed since the ordering date. At the end of this section different configuration tools are described.Measurement Units Measurement units can be specified for presentation of Level, Level Rate, Volume and Temperature values.Tank Geometry Tank HeightThe Tank Height is the distance between the Upper Reference Point at the underside of the transmitter flange, and the Lower Reference Point close to or at the bottom of the tank. The transmitter measures the distance to the product surface and subtracts this value from the Tank Height to determine the level.Figure 4-1. Tank GeometryTank Type and Tank Bottom TypeThe 5400 transmitter is optimized according to the Tank Type and Tank Bottom Type configuration by automatically setting some parameters to pre-defined default values. Select Tank Bottom Type Flat Inclined if the bottom inclination is between 10 and 30 degrees. If the inclination is less than 10 degrees but there are disturbing objects on the tank floor (like heating coils) within the radar beam, this selection should also be used. If inclination is greater than 30 degrees use Tank Bottom Type Cone.Tank Height (R)Product LevelUpper Reference PointTANKGEOMETRY_STANDARD.EPSUpper Reference PointLower Reference Point(Level=0)Hold Off/UNZ

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-4Figure 4-2. The transmitter can be optimized for different tank types and bottom shapes.Pipe DiameterWhen the transmitter is mounted in a still pipe the inner diameter of the pipe must be specified. The Pipe Diameter is used to compensate for the lower microwave propagation speed inside the pipe. An incorrect value will give a scale factor error. If locally supplied still-pipes are used, make sure the inner diameter is noted before the pipe is installed.Hold Off DistanceThis parameter should only be changed if there are disturbing objects close to the antenna. No valid measurements are possible above the Hold Off Distance. By increasing the Hold Off Distance the measuring range is reduced.Process Conditions Describe the conditions in your tank according to the Tank Environment parameters for Process Conditions listed below. For best performance, choose only if applicable and not more than two options.Rapid Level ChangesOptimize the transmitter for measurement conditions where the level changes quickly due to filling and emptying of the tank. As a default standard a 5400 transmitter is able to track level changes of up to 1.5 inch/s (40 mm/s). When the Rapid Level Changes check box is marked, the transmitter can track level changes of up to 8 inch/s (200 mm/s).Turbulent SurfaceThis parameter should be used if the tank shows a turbulent surface. The reason for the turbulence might be splash loading, agitators, mixers, or boiling product. Normally the waves in a tank are quite small and cause local rapid level changes. By setting this parameter the performance of the transmitter will be improved when there are small and quickly changing amplitudes and levels.Table 4-1. Tank Type and Tank Bottom TypeTank Type Tank Bottom TypeVertical Cylinder Flat, Dome, Cone, Flat inclinedHorizontal Cylinder Not usedSpherical Not usedCubical Flat, Dome, Cone, Flat inclinedTANKTYPE.EPSFlat Dome ConeFlat inclined Spherical

Reference Manual 00809-0100-4026, Rev ABAugust 20044-5Rosemount 5400 SeriesFoamSetting this parameter optimizes the gauge for conditions with weak and varying surface echo amplitudes such as foam. When the foam is light and airy the actual product level is measured. For heavy and dense foam the transmitter measures the level of the upper surface of the foam.Solid Products (Future)Setting this parameter optimizes the transmitter for solid products, for example concrete or grains, which are not transparent for radar signals. For instance, this parameter can be used when the application is a silo with product build-up.Product Dielectric RangeThe Dielectric Constant is related to the reflectivity of the product. By setting this parameter measurement performance can be optimized. However, the transmitter will still be able to perform well even if the actual Dielectric Constant differs from the configured value.Volume To configure the Rosemount 5400 transmitter for volume calculations you have to choose the desired calculation method.Volume calculation is performed by using a strapping table or a predefined tank shape. You can choose one of the following standard tank shapes:Sphere, Horizontal Cylinder, Vertical Cylinder, Horizontal Bullet or Vertical Bullet.The following parameters must be entered for a standard tank shape:• Tank diameter.• Tank height (not for spherical tanks).• Volume Offset: use this parameter if you do not want zero volume and zero level to match (for example if you want to include volume below the zero level).Strapping TableThe Strapping Table option should be used when the tank shape deviates significantly from an ideal sphere or cylinder, or when high volume accuracy is required.The Strapping Table divides the tank into segments. Level values and corresponding volumes are entered starting at the bottom of the tank. These figures can typically be obtained from tank drawings or from a certificate provided by the tank manufacturer. A maximum of 20 strapping points can be entered. For each level value the corresponding total volume up to the specified level is entered.The volume value is interpolated if the product surface is between two level values in the table.

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-6Analog Output For the analog output the Output Source (Primary Value), Range Values and Alarm Mode are specified.Figure 4-3. Standard Range Value settings.Output Source/Primary VariableSpecify the source to control the analog output. Typically the Primary Value is configured to be Product Level.Upper/Lower Range ValueEnter the range values that correspond to the analog output values 4 and 20 mA. If a measured value goes beyond the measurement range, the transmitter enters saturation mode (limit alarm is disabled) or alarm mode depending on the current configuration.Alarm ModeChoose the desired Alarm mode to specify the analog output state when there is a failure or a measurement error.High: the output current is set to the High Alarm Limit.Low: the output current is set to the Low Alarm Limit.Freeze Current: the output current is set to the last valid value at the time when the error occurs.Default settings for alarm mode:• Measurement errors: Output current=High. • Measured value out of range: transmitter enters saturation mode (if Limit Alarm is disabled).20 mA Upper Range Value (URV)Product Level4 mA Lower Range Value (LRV)Range 0-100 %ANALOGOUT_SATNDARD.EPSLower Reference Point(Level=0)Upper Reference PointHold Off

Reference Manual 00809-0100-4026, Rev ABAugust 20044-7Rosemount 5400 SeriesTable 4-2. Analog Output: Standard Alarm Values vs. Saturation Values.Table 4-3. Analog Output: NAMUR-Compliant Alarm Values vs. Saturation ValuesLevel 4–20 mA Saturation Values 4–20 mA Alarm ValueLow 3.9 mA 3.75 mAHigh 20.8 mA 21.75 mALevel 4–20 mA Saturation Values 4–20 mA Alarm ValueLow 3.8 mA 3.6 mAHigh 20.5 mA 22.5 mA

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-8ECHO TUNING When the Basic Configuration is performed the transmitter may need to be tuned to handle disturbing objects in the tank. There are different methods available for disturbance echo handling with the Rosemount 5400 Series Transmitter:• Amplitude Threshold Curve (ATC)• False Echo registrationThe Guided Setup in the configuration program Rosemount Radar Master includes a Measure and Learn function which automatically registers false echoes and creates an ATC (see “Guided Setup” on page 4-14).Amplitude Threshold CurveSetting up an Amplitude Threshold Curve makes tracking of the product surface more robust in the presence of noise and weak disturbing echoes. The ATC is normally used for filtering out disturbances with an amplitude that is smaller than the amplitude of the product surface echo.Figure 4-4. Weak disturbing echoes can be filtered out by creating an amplitude threshold.The Amplitude Threshold Curve function is available in the Rosemount Radar Master (RRM) program.SPECTRUM_ATC.EPSAmplitude Threshold CurveMeasurement signalAmplitude, mVDistance, m

Reference Manual 00809-0100-4026, Rev ABAugust 20044-9Rosemount 5400 SeriesRegistration of False EchoesThe False Echo function is used to improve the performance of the gauge when the surface is close to a horizontal surface of a stationary object in the tank. The object causes an echo when it is above the surface. When the echoes from the surface and the object are close to each other, they might interfere and cause a decrease in performance.Figure 4-5. The Rosemount 5400 can handle disturbing radar echoes.The False Echo function allows you to register disturbing echoes caused by objects in the tank. When the surface is passing by a disturbing object, the gauge can measure with higher reliability, when the position of the object is registered. This makes it possible to detect a product surface close to a disturbance echo even if the surface echo is weaker than the disturbing echo. See the following recommendations before you register new interfering echoes:• Make sure that a correct amplitude threshold curve is set before you register any disturbance echoes (see “Amplitude Threshold Curve” on page 4-8).• Compare the list of interfering echoes with the tank drawing or by visual inspection of the tank. Note if there are objects like beams, heating coils, agitators etc. which correspond to the found echoes. Only register echoes above the Amplitude Threshold Curve which can be clearly identified as objects in the tank, keeping the number of registered echoes to a minimum.• Make sure the level is stable before you register a disturbance echo. A fluctuating level may indicate a temporary disturbance which is not due to an interfering object.• Do not register False Echoes located below the product surface. It is recommended that registration is done when the tank is empty.FALSE_ECHOES.EPSFalse echoSurface echoDisturbing objects

Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-10Figure 4-6. Disturbing echoes can be filtered out by registration as False Echoes.The False Echo Registration function is available in the Rosemount Radar Master (RRM) program, in the AMS Suite as well as for the 275/375 Handheld Communicator.Registered False EchoFALSEECHO_REGISTRATION.EPSAmplitude, mVDistance, m

Reference Manual 00809-0100-4026, Rev ABAugust 20044-11Rosemount 5400 SeriesCONFIGURATION USING ROSEMOUNT RADAR MASTERThe Rosemount Radar Master (RRM) is a user-friendly software tool that allows you to configure the Rosemount 5400 transmitter. You can choose either of the following two methods to configure a Rosemount 5400 transmitter with RRM: • Guided Setup Start if you are unfamiliar with the 5400 transmitter (see page 4-14).• Use the Setup function if you are already familiar with the configuration process or if you just want to change the current settings (see page 4-19).System Requirements HardwareProcessor (minimum/recommended): Pentium 200 MHz/1 GHzMemory (minimum/recommended): 64/128 MB RAMCOM Port: 1 serial COM portGraphical Card (minimum/recommended): screen resolution 800 x 600/1024 x 768.Hard drive space: 100 MBSoftwareOperating Systems supported:Windows 98 - service pack 3 and aboveWindows NT 4 - service pack 6 and above Windows 2000Windows XPHelp In RRM Help is accessed by selecting the Contents option from the Help menu. Help is also available via a Help button in most windows.

$Reference Manual00809-0100-4026, Rev ABAugust 2004Rosemount 5400 Series4-12Installing the RRM software To install the Rosemount Radar Master:1. Insert the installation CD into your CD-ROM drive.2. If the installation program is not automatically started, choose Run from the Windows Start bar.3. Type D:\RRM\Setup.exe where D is the CD-ROM drive.4. Follow the instructions on the screen.5. For Windows 2000/XP set COM Port Buffers to 1, see page 4-13.To start the RRM:1. From the Start menu click Programs>Saab Rosemount>Rosemount Radar Master or click the RRM icon in the Windows workspace. Now RRM searches for the transmitter.2. When the transmitter is found press Yes to connect. If communication does not work check that the correct COM port is connected on the computer and that the COM port is properly configured, see “Specifying the COM Port” on page 4-13.3. In the RRM Status Bar verify that RRM communicates with the transmitter.RRM/START_BAR_RUN.TIFRRM communicates with the transmitterNo communication with the transmitterRRM/STATUSBAR.TIF/STATUSBAR_OFFLINE.TIF$

Rosemount Tank Radar 5402 Radar Level Gauge User Manual Book 5400 RevAB

Rosemount Tank Radar AB Radar Level Gauge Book 5400 RevAB

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