Rosemount 5402 Reference Manual

July 2009 Rosemount 5400 Series Two-Wire Radar Level Transmitter

July 2009 Rosemount 5400 Series www.rosemount.com Rosemount 5400 Series Rosemount 5400 Series Radar Transmitter may be protected by one or more U.S. Patents pending and foreign patents pending. Cover Photo: 5400_08, 5400_Process_Seal.tif, 5400_Rod.tif NOTICE Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product. Within the United States, Emerson Process Management has two toll-free assistance numbers. Customer Central: 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 Emerson Process Management representative. NOTICE There are no health hazards from the Rosemount 5400 Series transmitter. The microwave power density in the tank is only a small fraction of the allowed power density according to international standards. The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on Rosemount nuclear-qualified products, contact your local Emerson Process Management Sales Representative. This product is designed to meet FCC and R&TTE requirements. This device complies with part 15 of the FCC rules. Operation is 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.

July 2009 Rosemount 5400 Series www.rosemount.com Table of Contents SECTION 1 Introduction Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Manual Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Product Recycling/Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SECTION 2 Transmitter Overview Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tanks, vessels, and containers with calm surfaces . . . . . . . . . 2-2 Overfill and underfill detection. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Corrosives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Sticky, viscous and crystallizing products . . . . . . . . . . . . . . . . . 2-2 Sludges and slurries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Reactor vessels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Mounting flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Underground tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Components of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Process Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Dielectric constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Turbulence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Temperature/Pressure/ Density and Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Tank Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Antenna Selection Guide/Measuring Range . . . . . . . . . . . . . . . . . . . . 2-7 SECTION 3 Mechanical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Nozzle Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 5402 with Cone Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 5402 with Process Seal Antenna . . . . . . . . . . . . . . . . . . . . . . . 3-5 5401 with Cone Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 5401 with Rod Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Still-pipes in Metallic Materials . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Nozzle Recommendations and Requirements . . . . . . . . . . . . . . . . 3-7 Service Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Beamwidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Vessel Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Disturbing Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

July 2009 Rosemount 5400 Series TOC-2 Cone Antenna Flange Connection . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Process Seal Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Rod Antenna Threaded Connection. . . . . . . . . . . . . . . . . . . . . . . 3-15 Rod Antenna Flanged Connection . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Bracket Mounting on Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Bracket Mounting on Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Mounting in Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Recommendations for pipe installations . . . . . . . . . . . . . . . . . 3-19 SECTION 4 Electrical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cable/Conduit Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Conduit Electrical Connector Wiring (using Minifast®). . . . . . . . . . 4-4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Cable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Hazardous Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 External Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Connecting the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Non-Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 IS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Optional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Tri-Loop HART to analog converter . . . . . . . . . . . . . . . . . . . . . . . . 4-9 751 Field Signal Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 SECTION 5 Basic Configuration/ Start-Up Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Basic Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Basic Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Tank Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Tank Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Tank Type and Tank Bottom Type . . . . . . . . . . . . . . . . . . . . . . 5-4 Pipe Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Transition Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Process Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Rapid Level Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Turbulent Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Product Dielectric Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Volume Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Standard Tank Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Vertical Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Horizontal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Vertical Bullet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Horizontal Bullet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Sphere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Strapping Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

July 2009 TOC-3 Rosemount 5400 Series Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Output Source/Primary Variable . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Upper/Lower Range Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Alarm Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Echo Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Amplitude Threshold Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Basic Configuration Using Rosemount Radar Master . . . . . . . . . . . . 5-11 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Help in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Installing the RRM software for HART communication . . . . . . . . 5-13 Getting started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Specifying the COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 To set the COM port buffers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Specifying Measurement Units. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Guided Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Using the Setup Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Configuration Using a 375 Field Communicator . . . . . . . . . . . . . . . . 5-21 Basic Configuration Using AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . 5-24 HART Multidrop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 SECTION 6 Operation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Viewing Measurement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Using the Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Specifying Display Panel Variables . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Using a Field Communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Using Rosemount Radar Master (RRM) . . . . . . . . . . . . . . . . . . 6-3 Using AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 LCD Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Viewing Measurement Data in RRM . . . . . . . . . . . . . . . . . . . . . . . 6-6 Viewing Measurement Data in AMS Suite . . . . . . . . . . . . . . . . . . . 6-7 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 LED Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 SECTION 7 Service and Troubleshooting Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Troubleshooting Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Service Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Analyzing the Measurement Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Surface Pulse Not Found. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Registration of False Echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Using the Echo Curve Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 The Configuration Mode Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 The View/Record Mode Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Record Tank Spectra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 File Mode Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

July 2009 Rosemount 5400 Series TOC-4 Using the Echo Curve Analyzer with a 375 Field Communicator. 7-12 Viewing the Echo Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Register False Echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Threshold Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Logging Measurement Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Backing Up the Transmitter Configuration. . . . . . . . . . . . . . . . . . . . . 7-15 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Rosemount Radar Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 AMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 HART command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Viewing Input and Holding Registers. . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Reset to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Surface Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Using the Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Write Protecting a Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Measurement Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Volume Calculation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Analog Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Application Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 APPENDIX A Reference Data Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Temperature and Pressure Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Flange Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Electronics Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Dimensional Drawings and Mechanical Properties . . . . . . . . . . . . . . .A-5 Process Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-18 APPENDIX B Product Certifications Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 EU Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 European ATEX Directive Information. . . . . . . . . . . . . . . . . . . . . . . . .B-3 Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Special Conditions for Safe Use (X) . . . . . . . . . . . . . . . . . . . . .B-3 Flameproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 Special Conditions for Safe Use (X) . . . . . . . . . . . . . . . . . . . . .B-4 Hazardous Locations Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5 Factory Mutual (FM) Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5 Canadian Standards Association (CSA) Approval . . . . . . . . . . . . .B-6 Dual Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6 IECEx Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7 Technology Institution of Industrial Safety (TIIS) Approval. . . . . . .B-9 National Supervision and Inspection Center for Explosion Protection and Safety of Instrumentation (NEPSI) Approvals . . .B-10

July 2009 TOC-5 Rosemount 5400 Series Approval Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11 APPENDIX C Advanced Configuration Tank Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Distance Offset (G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Minimum Level Offset (C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2 Hold Off Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2 Calibration Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2 Advanced Analog Output Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3 Advanced Transmitter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Antenna Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Empty Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Empty Tank Detection Area . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Bottom Echo Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Tank Bottom Projection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Extra Echo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Level Alarm is Not Set When Tank is Empty. . . . . . . . . . . . . . .C-5 Full Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Full Tank Detection Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Level above Hold Off Distance Possible . . . . . . . . . . . . . . . . . .C-5 Level Alarm is Not Set When Tank is Full. . . . . . . . . . . . . . . . .C-5 Double Bounce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Surface Echo Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Slow Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Slow Search Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Double Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Upper Product Dielectric Constant . . . . . . . . . . . . . . . . . . . . . .C-6 Select Lower Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Echo Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Close Distance Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Filter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Damping Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Activate Jump Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Advanced Functions in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7 Empty Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7 Bottom Echo Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7 Empty Tank Detection Area . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8 Extra Echo Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-9 Full Tank Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-10 Double Bounce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-11 Surface Echo Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-12 Hold Off Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13

July 2009 Rosemount 5400 Series www.rosemount.com Section 1 Introduction Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1 Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3 Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4 Product Recycling/Disposal . . . . . . . . . . . . . . . . . . . . . . . page 1-4 SAFETY MESSAGES Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol. Failure to follow safe installation and service guidelines could result in death or serious injury • Make sure only qualified personnel perform installation or service. • Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment. • Any substitution of non-authorized parts or repair, other than exchanging the complete transmitter head or antenna assembly, may jeopardize safety and is prohibited. • Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and jeopardize safety. Unauthorized changes that interfere with the integrity of the welds or flanges, such as making additional perforations, compromise product integrity and safety. Equipment ratings and certifications are no longer valid on any products that have been damaged or modified without the prior written permission of Emerson Process Management. Any continued use of product that has been damaged or modified without prior written authorization is at the customer's sole risk and expense. Explosions could result in death or serious injury • Verify that the operating environment of the transmitter is consistent with the appropriate hazardous locations specifications. • In an Explosion-proof/Flameproof installation, do not remove the transmitter cover when power is applied to the unit. • Before connecting a HART® based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. Electrical shock can result in death or serious injury • Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock. • Make sure the main power to the 5400 Series transmitter is off and the lines to any other external power source are disconnected or not powered while wiring the transmitter.

July 2009 Rosemount 5400 Series 1-2 Antennas with non-conducting surfaces • Antennas with non-conducting surfaces (e.g. Rod antenna and Process Seal antenna) may generate an ignition-capable level of electrostatic charge under extreme condtions. Therefore, when the antenna is used in a potentially explosive atmoshpere, appropriate measures must be taken to prevent electrostatic discharge.

July 2009 1-3 Rosemount 5400 Series MANUAL 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 characteristics Section 3: Mechanical Installation • Mounting considerations • Mounting Section 4: Electrical installation • Cable/conduit entries • Grounding • Cable selection • Hazardous areas • External circuit breaker • Power requirements • Connecting the transmitter • Non-intrinsically safe power supply • Intrinsically safe power supply • Optional devices Section 5: Configuration/Start-Up • Configuration instructions • Configuration using the RRM software • Configuration using a 275/375 Field Communicator Section 6: Operation • Viewing measurement data with a Display panel • Viewing measurement data with Rosemount Radar Master Section 7: Service and Troubleshooting • Troubleshooting • Error and warning codes • Communication errors Appendix A: Reference Data • Specifications • Ordering Information

July 2009 Rosemount 5400 Series 1-4 Appendix B: Product Certifications • Examples of labels • European ATEX Directive information • FM approvals • CSA approvals • IECEx approvals • TIIS approval • NEPSI approvals • Approval drawings Appendix C: Advanced Configuration • Advanced Tank Geometry • Advanced transmitter settings • Advanced functions in RRM SERVICE SUPPORT To expedite the return process outside of the United States, contact the nearest Emerson Process Management representative. Within the United States, call the Emerson Process Management Instrument and Valves Response Center using the 1-800-654-RSMT (7768) toll-free number. This center, available 24 hours a day, will assist you with any needed information or materials. The center will ask for product model and serial numbers, and will provide a Return Material Authorization (RMA) number. The center will also ask for the process material to which the product was last exposed. Emerson Process Management Instrument and Valves Response Center representatives will explain the additional information and procedures necessary to return goods exposed to hazardous substance can avoid injury if they are informed of and understand the hazard. If the product being returned was exposed to a hazardous substance as defined by Occupational Safety and Health Administration (OSHA), a copy of the required Material Safety Data Sheet (MSDS) for each hazardous substance identified must be included with the returned goods. PRODUCT RECYCLING/DISPOSAL Recycling of equipment and packaging should be taken into consideration and disposed of in accordance with local and national legislation/regulations.

July 2009 Rosemount 5400 Series www.rosemount.com Section 2 Transmitter Overview Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1 Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2 Components of the Transmitter . . . . . . . . . . . . . . . . . . . . page 2-4 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5 Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6 Antenna Selection Guide/Measuring Range . . . . . . . . . . page 2-7 THEORY OF OPERATION The Rosemount 5400 Series Radar Transmitter is a smart, two-wire continuous level transmitter. A 5400 transmitter is installed at the top of the tank and emits short microwave pulses towards the product surface in the tank. When a pulse reaches the surface, part of the energy is reflected back to the antenna for subsequent processing by the transmitter electronics. The time difference between the transmitted and reflected pulse is detected by a micro-processor and is converted into a distance, which calculates the level. The product level is related to the tank height and the measured distance by the following expression: Level = Tank Height - Distance. Figure 2-1. Measurement principle for the Rosemount 5400 Series. Time Level Distance Tank Height Signal Amplitude

July 2009 Rosemount 5400 Series 2-2 APPLICATION EXAMPLES Tanks, vessels, and containers with calm surfaces Non-contacting radar can also be used in less challenging applications, such as storage and buffer tanks: • It is easy to mount, maintenance-free, and highly accurate • Gives precise monitoring and control of the process Overfill and underfill detection The Rosemount 5400 Series can be advantageous in risk reduction systems: • Continuous measurement may reduce or simplify proof-tests • Multiple 5400s can be used in the same tank Corrosives Radar measurement is ideal for most corrosive products, such as caustics, acids, solvents and many other chemicals: • Does not contact the process product • Wide material offering such as PTFE, Alloy C-276 and Alloy 400 • Works well in non-metallic tanks also Sticky, viscous and crystallizing products The best-in-class Rosemount 5400 Series provides an accurate and reliable level reading with difficult products, such as resins and adhesives: • Non-contacting is best practice • Almost unaffected by coating and build-up because of the uniquely designed condensation resistant antennas Sludges and slurries Applications like mud, pulp-stock and lime slurries are ideal for non-contacting measurement: • Immune to splashing and solids content • Unaffected by density changes • No re-calibration, no or little maintenance

July 2009 2-3 Rosemount 5400 Series Reactor vessels The innovative design of the Rosemount 5400 Series makes it an excellent choice for the most difficult applications, such as reactor vessels: • Unique circular polarization provides greater mounting flexibility – no tank wall clearance distance is needed • Direct measurement – independent of most variations in process conditions, such as density, dielectric, vapor, temperature, and pressure • Can handle turbulent conditions created by agitation, top-filling, or process reaction Mounting flexibility The versatile Rosemount 5400 Series can be used in mounting configurations other than standard nozzles: • Fits most existing pipes: 2-8 in. (50-200 mm) • Easy to isolate from the process – use a ball-valve Still-pipes reduce the influence of foam, turbulence, and tank obstructions. Ball-valves can be used on both still-pipes and nozzles. Underground tanks The mounting flexibility of the Rosemount 5400 Series makes it an excellent choice for many underground tanks: • Easy top-mounting • Can handle long narrow nozzles, and pipes • Unaffected by dirty products with solids content

July 2009 Rosemount 5400 Series 2-4 COMPONENTS OF THE TRANSMITTER The Rosemount 5400 Series Radar Transmitter is available with a die-cast aluminum or stainless steel housing(1) containing advanced electronics for signal processing. The radar electronics produces an electromagnetic pulse that is emitted through the antenna. There are different antenna types and sizes available for various applications. The transmitter head has separate compartments for electronics and terminals, and can be removed without opening the tank. The head has two entries for conduit/cable connections. The tank connection consists of a Tank Seal and a flange (ANSI, EN (DIN) or JIS). Figure 2-2. Transmitter components. (1) Pending. Cable Entry: ½" NPT. Optional adapters: M20 Transmitter Head with Radar Electronics Antenna Display Panel Terminal side Cable Entry: ½" NPT. Optional adapters: M20 Flange Tank Seal

July 2009 2-5 Rosemount 5400 Series SYSTEM ARCHITECTURE The Rosemount 5400 Series Radar Transmitter is loop-powered, and uses the same two wires for power supply and output signal. The output is a 4-20 mA analog signal superimposed with a digital HART signal. By using the optional HART Tri-loop, the HART signal can be converted up to three additional 4-20 mA analog signals. With the HART protocol multidrop configuration is possible. In this case, communication is restricted to digital, since current is fixed to the 4 mA minimum value. The transmitter can be connected to a Rosemount 751 Field Signal Indicator, or it can be equipped with an integral display. The transmitter can easily be configured using a 375 Field Communicator or a PC with the Rosemount Radar Master software. Rosemount 5400 Series transmitters can also be configured with the AMS® Suite and DeltaV™ software, and other tools that support Electronic Device Description Language (EDDL) functionality. For HART communication a minimum load resistance of 250within the loop is required. Figure 2-3. HART system architecture Integral Display Rosemount Radar Master or AMS Suite HART modem 375 Field Communicator Rosemount 751 Field Signal Indicator 3 x 4-20 mA DCS Rosemount 5400 Series Radar Transmitter Tri-Loop Note! For HART communication a minimum load resistance of 250 within the loop is required.

July 2009 Rosemount 5400 Series 2-6 PROCESS CHARACTERISTICS Dielectric constant A key parameter for measurement performance is reflectivity. A high dielectric constant of the media provides better reflection and enables a longer measuring range. Foam Rosemount 5400 Series Radar Transmitter measurement in foamy applications depends on the foam properties; light and airy or dense and heavy, high or low dielectrics, etc. If the foam is conductive and creamy, the transmitter may measure the surface of the foam. If the foam is less conductive, the microwaves may penetrate the foam, and measure the liquid surface. Turbulence A calm surface gives better reflection than a turbulent surface. For turbulent applications, the maximum range of the radar transmitters is reduced. The range depends on the frequency, the antenna size, the dielectric of the material, and the degree of turbulence. Consult Tables 2-1 and 2-2 on page 2-7 for the expected maximum range with the variables listed. Temperature/Pressure/ Density and Vapor Temperature, pressure, product density and vapor generally have no impact on measurements. Condensation For applications where heavy condensation and vapors may occur, the low frequency version Rosemount 5401 is recommended. Tank Characteristics The conditions inside the tank have a significant impact on measurement performance. For more information see “Vessel Characteristics” on page 3-12.

July 2009 2-7 Rosemount 5400 Series ANTENNA SELECTION GUIDE/MEASURING RANGE The measuring range depends on the microwave frequency, antenna size, the dielectric constant (r) of the liquid, and process conditions. A higher dielectric constant value produces a stronger reflection. The figures in the tables below are guidelines for optimum performance. Larger measuring ranges may be possible. For more information, contact your local Emerson Process Management representative. A. Oil, gasoline or other hydrocarbons, and petrochemicals (r = 1.9-4.0). In pipes or with ideal surface conditions, for some liquefied gases (r = 1.4-4.0) B. Alcohols, concentrated acids, organic solvents, oil/water mixtures, and acetone (r = 4.0-10.0). C. Conductive liquids, e.g. water based solutions, dilute acids, and alkalis (r > 10.0). Table 2-1. Maximum recommended measuring range for the Rosemount 5402 model. Table 2-2. Maximum recommended measuring range for the Rosemount 5401 model. High Frequency Antennas Units: ft (m) Dielectric Constant A B C A B C A B C 2-in. Cone / Process Seal 33 (10) 49 (15) 66 (20) 82 (25) 115 (35) 115 (35) 9.8 (3) 20 (6) 33 (10) 3-in. Cone / Process Seal 49 (15) 66 (20) 98 (30) 82 (25) 115 (35) 115 (35) 13 (4) 30 (9) 39 (12) 4-in. Cone / Process Seal 66 (20) 82 (25) 115 (35) 82 (25) 115 (35) 115 (35) 23 (7) 39 (12) 49 (15) Low Frequency Device Units: ft (m) Dielectric Constant A B C A B C A B C 3-in. Cone(1) NA NA NA 82 (25) 115 (35) 115 (35) NA NA NA 4-in. Cone / Rod(2) 23 (7) 39 (12) 49 (15) 82 (25) 115 (35) 115 (35) 13 (4) 26 (8) 39 (12) 6-in. Cone 43 (13) 66 (20) 82 (25) 82 (25) 115 (35) 115 (35) 20 (6) 33 (10) 46 (14) 8-in. Cone 66 (20) 82 (25) 115 (35) 82 (25) 115 (35) 115 (35) 26 (8) 39 (12) 52 (16) (1) Pipe installations only. NA = not applicable. (2) Pipe installations are not allowed with rod antennas.

July 2009 Rosemount 5400 Series 2-8 Model and Antenna Guide 5402 5401 This table gives guidelines on which model and antenna to select, depending on application. G = Good AD = Application Dependent (consult your local Emerson Process Management representative) NR = Not Recommended Cone (preferred) Process Seal Cone (preferred) Rod Best choice for a broad range of applications, free propagation and pipe installations. Ideal for small tanks and corrosive applications. Also good for heavy antenna condensation/build-up. Suitable for some extreme process conditions. Suitable for small process connections, and corrosive environment. Accuracy ± 0.1 in. (3 mm) ± 0.1 in. (3 mm) ± 0.4 in. (10 mm) ± 0.4 in. (10 mm) Tank Considerations Installation close to smooth tank wall G G G G Internal obstructions, directly in path NR NR AD AD Internal obstructions, avoidance(1) G G NR NR Antenna extends below nozzle G G G G Antenna recessed in smooth nozzle up to 6 ft (2 m) G G AD(2) NR(3) Antenna recessed in nozzle with irregularities, such as bad welds AD(2) AD AD(2) NR(3) Still-pipe mounting G G G NR Valves G G NR NR Pressure/Temperature considerations See page A-4 See page A-4 See page A-4 See page A-4 Measuring range considerations See page A-1 See page A-1 See page A-1 See page A-1 Process Medium Characteristics Vapor (light, medium) G G G G Vapor (heavy) NR AD G G Condensing vapor/product build-up(4) AD G G AD Boiling/Turbulent surface (low/medium) G G G G Boiling/Turbulent surface (heavy) AD AD G(5) NR Boiling/Turbulent surface (still-pipe) G G G NR Foam(6) NR NR AD AD Foam (still-pipe)(6) G G G NR Corrosive products (options available) G(7) G(7) G(7) G(7) Materials with very low dielectric G G G AD Changing density/dielectric/pH/ pressure/temperature G G G G Coating/viscous/crystallizing liquids G G G G Cleanability of antenna AD G AD G (1) The obstruction should not be within the radar beam. Preferred choices due to more narrow radar beam: Model 5402, and cone antenna. (2) An extended cone antenna can be used. (3) The active part must protrude beneath the nozzle. (4) Build-up can often be avoided or reduced by using heat-tracing or cleaning arrangements. (5) Use a 6 or 8 in. (150-200 mm) cone antenna. (6) Foam can either reflect, be invisible, or absorb the radar signal. Pipe mounting is advantageous since it reduces the foaming tendency. (7) See wetted material on page A-6.

July 2009 2-9 Rosemount 5400 Series 5402 (~ 26 GHz) 5401 (~ 6 GHz) Transmitter model and antenna combination Cone Process Seal Cone Rod Wetted Material Antenna options: • 316 / 316 L SST (EN 1.4404) • Alloy C-276 • Alloy 400 • NACE Tank Seal: • PTFE O-ring(2) Antenna option: • PTFE O-ring(2) Antenna options: • 316 / 316 L SST (EN 1.4404) • Alloy C-276 • Alloy 400 • NACE Tank Seal: • PTFE O-ring(2) Antenna options: • PFA(1) • PFA(1) and 316 / 316 L SST (EN 1.4404)(2) Process Connection Flange or Bracket Flange Flange or Bracket Flange, Thread or Bracket (1) PFA is a fluoropolymer with properties similar to PTFE. (2) O-ring options: Viton®, Kalrez®, EPDM and Buna-N.

July 2009 Rosemount 5400 Series www.rosemount.com Section 3 Mechanical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-2 Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-13 SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Please refer to the following safety messages before performing an operation preceded by this symbol. Failure to follow safe installation and service guidelines could result in death or serious injury • Make sure only qualified personnel perform installation or service. • Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment. • Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g. substitution of components etc. may also jeopardize safety and is under no circumstances allowed. Explosions could result in death or serious injury • Verify that the operating environment of the transmitter is consistent with the appropriate hazardous locations specifications. • In an Explosion-proof/Flameproof installation, do not remove the transmitter cover when power is applied to the unit. • Before connecting a HART® based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. Electrical shock can result in death or serious injury • Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock. • Make sure the main power to the 5400 Series transmitter is off and the lines to any other external power source are disconnected or not powered while wiring the transmitter. Antennas with non-conducting surfaces • Antennas with non-conducting surfaces (e.g. Rod antenna and Process Seal antenna) may generate an ignition-capable level of electrostatic charge under extreme conditions. Therefore, when the antenna is used in a potentially explosive atmosphere, appropriate measures must be taken to prevent electrostatic discharge.

July 2009 Rosemount 5400 Series 3-2 INSTALLATION PROCEDURE Follow these steps for proper installation: Review Installation Considerations (see page 3-3) Mount the transmitter (see page 3-13) Wire the transmitter (see page 4-3) Make sure covers and cable/conduit connections are tight Power up the transmitter Configure the transmitter (see page 5-1) Verify measurements

July 2009 3-3 Rosemount 5400 Series MOUNTING CONSIDERATIONS Before installing a Rosemount 5400 Series transmitter, consider specific mounting requirements, vessel, and process characteristics. Mounting Location For optimal performance, the transmitter should be installed in locations with a clear and unobstructed view of the level surface (A): • Filling inlets creating turbulence (B), and stationary metallic objects with horizontal surfaces (C) should be kept outside the signal beam – see page 3-10 for beamwidth information • Agitators with large horizontal blades may reduce the performance of the transmitter, so install the transmitter in a location where this effect is minimized. Vertical or slanted blades are often invisible to radar, but create turbulence (D) • Do not install the transmitter in the center of the tank (E) • Because of circular polarization, there is no clearance distance requirement from the tank wall if it is flat and free of obstructions such as heating coils and ladders (F). Usually, the optimal location is 1/4 of the diameter from the tank wall Figure 3-1. It is important to consider the proper mounting position. • The antenna is normally aligned vertically (D) (A) (E) (B) (F) (C)

July 2009 Rosemount 5400 Series 3-4 • A metal still-pipe can be used to avoid disturbing objects, turbulence, and foam (G) Figure 3-2. Mounting in still-pipe • The walls in non-metallic tanks are invisible to the radar signal, so nearby objects outside of the tank may be detected • Choose the largest possible antenna diameter for installation. A larger antenna concentrates the radar beam, and will be less susceptible to obstruction interference, and assures maximum antenna gain • Multiple 5400 transmitters can be used in the same tank without interfering with each other (H) Figure 3-3. Multiple 5400 transmitters in the same tank (G) (H)

July 2009 3-5 Rosemount 5400 Series Nozzle Considerations Special considerations may have to be taken because of the nozzle, depending on the selection of transmitter model and antenna. 5402 with Cone Antenna The antenna can be recessed in smooth nozzles up to 6 ft (2 m). If the inside of the nozzle contains disturbing objects, use the extended cone (I). Figure 3-4. Nozzle considerations for 5402 with Cone Antenna. 5402 with Process Seal Antenna The antenna can be used on nozzles up to 6 ft (2 m), (J). Disturbing objects inside the nozzle (K) may impact the measurement, and should therefore be avoided. The flange on the tank should have a flat or raised face. Other tank flanges may be possible, please consult your local Emerson Process Management representative for advice. Figure 3-5. Nozzle considerations for 5402 with Process Seal Antenna. Spray nozzle (I) Smooth nozzle Bad weldings (K) Bad welding (J)

July 2009 Rosemount 5400 Series 3-6 5401 with Cone Antenna The antenna should extend 0.4 in. (10 mm), or more, below the nozzle (L). If required, use the extended cone solution. Figure 3-6. Nozzle considerations for 5401 with Cone Antenna. 5401 with Rod Antenna The active part of the rod antenna should protrude below the nozzle (M). Figure 3-7. Nozzle considerations for 5401 with Rod Antenna (L) 0.4 in. (10 mm) or more Active part starts here (M) Max. 4 or 10 in. (100 or 250 mm) for short and long version respectively

July 2009 3-7 Rosemount 5400 Series Still-pipes in Metallic Materials If used correctly, pipe measurement can be advantageous in many applications: • Use cone or process seal antennas – not the rod antenna • The gap between the cone antenna and the still-pipe is limited to 0.2 in. (5 mm). If required, order an oversized antenna and cut on location (N). Only applicable to 5401 cone antennas and cone antennas with wetted flange plate (i.e. straight antennas) Figure 3-8. Nozzle considerations for Still-pipes in Metallic Materials Nozzle Recommendations and Requirements The Rosemount 5400 Series is mounted on a nozzle by using appropriate flanges. For best performance, it is recommended that the nozzle meets the following recommendations for height (L) and diameter: Figure 3-9. Mounting of the 5400 Series transmitter. (N) Max. 0.2 in. (5 mm) L Minimum Diameter >0.4 in. (10 mm) Minimum Diameter L L Minimum Diameter Minimum Diameter L Process Seal Antenna Rod Antenna Cone Antenna Extended Cone Antenna >0.4 in. (10 mm)

July 2009 Rosemount 5400 Series 3-8 Table 3-1. Minimum nozzle diameter and maximum nozzle height for cone antennas. Table 3-2. Minimum nozzle diameter and maximum nozzle height for rod antennas. Table 3-3. Minimum nozzle diameter and maximum nozzle height for process seal antennas. Table 3-4. Minimum nozzle diameter and maximum nozzle height for extended cone antennas. Model Antenna/Material L max in. (mm) Min. Diameter in. (mm) 5402(1) (1) For Rosemount 5402, the values for maximum nozzle height are recommendations. Cone 2 in. (50 mm) SST 6.1 (155) 2.2 (55) Cone 3 in. (75 mm) SST 5.5 (140) 2.8 (72) Cone 4 in. (100 mm) SST 8.5 (215) 3.8 (97) Cone 2 in. (50 mm) Alloy C-276, Alloy 400 5.5 (140) 2.2 (55) Cone 3 in. (75 mm) Alloy C-276, Alloy 400 6.5 (165) 2.8 (72) Cone 4 in. (100 mm) Alloy C-276, Alloy 400 9.6 (240) 3.8 (97) 5401 Cone 3 in. (75 mm) SST Pipe installations only Cone 4 in. (100 mm) SST 5.5 (140) 3.8 (97) Cone 6 in. (150 mm) SST 6.9 (175) 5.7 (145) Cone 8 in. (200 mm) SST 10.2 (260) 7.6 (193) Cone 3 in. (75 mm) Alloy C-276, Alloy 400 Pipe installations only Cone 4 in. (100 mm) Alloy C-276, Alloy 400 5.5 (140) 3.8 (97) Cone 6 in. (150 mm) Alloy C-276, Alloy 400 6.9 (175) 5.7 (145) Cone 8 in. (200 mm) Alloy C-276, Alloy 400 10.2 (260) 7.6 (193) Model Antenna L max in. (mm) Min. Diameter in. (mm) 5401(1) (1) For Rosemount 5401, the values for minimum nozzle diameter and maximum nozzle height are requirements. Rod (short) 4.0 (100) 1.5 (38) Rod (long) 10 (250) 1.5 (38) Model Antenna L max in. (mm) Min. Diameter in. (mm) 5402(1) (1) For Rosemount 5402, the values for maximum nozzle height are recommendations. Process Seal 2 in. (50 mm) 19.7 (500) 2.0 (51) Process Seal 3 in. (75 mm) 19.7 (500) 3.0 (77) Process Seal 4 in. (100 mm) 19.7 (500) 4.0 (102) Model Antenna L max in. (mm) Min. Diameter in. (mm) 5402(1) (1) For Rosemount 5402, the values for maximum nozzle height are recommendations. Extended Cone Antenna, S3(2) (2) The extended cone antennas are available in 5 in. (125 mm) step increments from 10 to 50 in. (250-1250 mm). Consult your local Emerson Process Management representative for more information. Expect long lead times for sizes other than the 20 in. (500 mm) version. 20 in. (500 mm) See Table 3-1 5401 Extended Cone Antenna, S3(2) 20 in. (500 mm) See Table 3-1

July 2009 3-9 Rosemount 5400 Series Install the transmitter as follows: • Align the antenna vertically • Choose the largest antenna diameter possible. A larger receiving area concentrates the radar beam and ensures maximum antenna gain. Increased antenna gain permits greater margin for weak surface echoes. A larger antenna also results in smaller beam angle and thereby, less interference from any internal structures in the tank • For best measurement performance, the antenna should extend below the nozzle 0.4 in. (10 mm) or more For more information, see “Nozzle Considerations” on page 3-5. Service Space For easy access to the transmitter, mount it with sufficient service space. There is no requirement on clearance distance from the tank wall, provided it is flat and free of obstructions such as heating coils and ladders. The optimal location is often 1/4 of the tank diameter. Figure 3-10. Service space recommendations. A B C Rod Antenna Cone Antenna A B C C B A Process Seal Antenna Service space Distance inch (mm) A Cone, Rod, Process Seal 20 (500) B Cone, Rod 24 (600) Process Seal 33 (850) Inclination Maximum angle C Cone, Rod, Process Seal 3°

July 2009 Rosemount 5400 Series 3-10 Beamwidth The following recommendations should be considered when mounting the transmitter: • The transmitter should be mounted with as few internal structures as possible within the beam angle • The flat tank wall can be located within the antenna beam angle if there is a minimum distance from the transmitter to the tank wall (see Figure 3-10 for preferred installation) Figure 3-11. Beamwidth at various distances from the flange. Table 3-5. Beamwidth for the Rosemount 5402 model. Table 3-6. Beamwidth for the Rosemount 5401 model. Distance 5401 (low frequency) 5402 (high frequency) 16 ft (5 m) 33 ft (10 m) 49 ft (15 m) 66 ft (20 m) Beamwidth Distance Antenna 2 in. (DN 50) Cone/ Process Seal 3 in. (DN 80) Cone/ Process Seal 4 in. (DN 100) Cone/ Process Seal Beamwidth, ft (m) 16 ft (5 m) 4.9 (1.5) 3.3 (1.0) 3.3 (1.0) 33 ft (10 m) 9.8 (3.0) 6.6 (2.0) 4.9 (1.5) 49 ft (15 m) 14.8 (4.5) 9.8 (3.0) 8.2 (2.5) 66 ft (20 m) 19.7 (6.0) 13.1 (4.0) 9.8 (3.0) Distance Antenna 4 in. (DN 100) Cone /Rod 6 in. (DN 150) Cone 8 in. (DN 200) Cone Beamwidth, ft (m) 16 ft (5 m) 9.8 (3..0) 6.6 (2.0) 4.9 (1.5) 33 ft (10 m) 21.3 (6.5) 13.1 (4.0) 9.8 (3.0) 49 ft (15 m) 32.8 (10) 19.7 (6.0) 14.8 (4.5) 66 ft (20 m) 41 (12.5) 26.2 (8.0) 19.7 (6.0)

July 2009 3-11 Rosemount 5400 Series Figure 3-12. Beam Angle. Table 3-7. Beam Angle for the Rosemount 5402. Table 3-8. Beam Angle for the Rosemount 5401. Beam Angle Antenna Beam Angle Cone 2 in. (50 mm) / Process Seal 17° Cone 3 in. (75 mm) / Process Seal 11° Cone 4 in. (100 mm) / Process Seal 9° Antenna Beam Angle 3 in. (75 mm) Cone Pipe installations only 4 in. (100 mm) Cone / Rod 35° 6 in. (150 mm) Cone 23° 8 in. (200 mm) Cone 17°

July 2009 Rosemount 5400 Series 3-12 Vessel Characteristics Heating coils, agitators and other objects in the tank may lead to disturbing echoes and noise in the measurement signal. Vertical structures cause minimal effect since the radar signal is scattered rather than directed back to the antenna. The shape of the tank bottom affects the measurement signal when the product surface is close to the tank bottom. The Rosemount 5400 Series has built-in functions which optimize measurement performance for various bottom shapes (see “Tank Type and Tank Bottom Type” on page 5-4). Disturbing Objects The Rosemount 5400 Series transmitter should be mounted so that objects such as heating coils, ladders, etc. are not in the radar signal path. These objects may cause false echoes resulting in reduced measurement performance. However, the transmitter has built-in functions designed to reduce the influence from disturbing objects where such objects cannot be totally avoided. The Rosemount 5402 has a more narrow radar beam that is particularly suitable in installations with tall or narrow nozzles, or nozzles close to the tank wall. It may also be used to avoid disturbing objects in the tank. Valves The 5400 Series transmitter can be isolated from the process by using a valve: • Use a full-port ball valve • The 5402 is required, and the Process Seal Antenna is the preferred choice, since it does not require a spool piece. The cone antenna can also be used • Ensure there is no edge between the ball valve and the nozzle/pipe, the inside should be smooth Valves can be combined with pipes.

July 2009 3-13 Rosemount 5400 Series MOUNTING Mount the transmitter on a nozzle on top of the tank making sure only qualified personnel perform the installation. The transmitter housing must not be opened. If the transmitter housing must be removed for service, make sure that the PTFE sealing is carefully protected against dust and water. Cone Antenna Flange Connection Figure 3-13. Mounting the 5400 with cone antenna and flange. 1. Place a gasket on top of the tank flange. 2. Lower the transmitter with antenna and flange into the tank nozzle. 3. Tighten the bolts and nuts with sufficient torque for the flange and gasket choice. Transmitter housing Bolt Gasket Flange Tank flange Cone antenna Nut Nozzle Locking screw (ATEX) Nut, 60 Nm (44 Lbft)

July 2009 Rosemount 5400 Series 3-14 Process Seal Antenna Figure 3-14. Mounting the 5400 with Process Seal. Table 3-9. Tightening torque for Process Seal flanges. 1. Place the O-ring in the groove on the underside of the antenna process window. See page A-8 for information on temperature ranges for the O-ring. 2. Place the antenna on top of the nozzle. 3. Mount the flange and tighten the bolts cross-wise. For torque information, see Table 3-9. 4. Mount the transmitter head and tighten the nut to 60 Nm (44 Lbft). 5. Re-tighten the flange bolts after 24 hours. O-ring (no gasket required) Process Seal window Bolt O-rings (one customer mounted, and one integrated) Flange Transmitter housing Nut, 60 Nm (44 Lbft) Locking screw (ATEX) Process Seal antenna Nozzle Tank flange Nut Flange Torque (Nm) Torque (Lbft) 2 in. (50 mm), 150lbs 80 59 2 in. (50 mm), 300lbs 80 59 3 in. (75 mm), 150lbs 80 59 3 in. (75 mm), 300lbs 125 92 4 in. (100 mm), 150 lbs 80 59 4 in. (100 mm), 300 lbs 125 92 DN 50 PN 40 109 80 DN 80 PN 40 109 80 DN 100 PN 16 109 80 DN 100 PN 40 135 100 50A 10K 109 80 80A 10K 109 80 100A 10K 109 80 150A 10K 135 100

July 2009 3-15 Rosemount 5400 Series Rod Antenna Threaded Connection Figure 3-15. Mounting the 5400 with rod antenna and threaded tank connection. 1. Lower the transmitter and antenna into the tank. 2. Turn the transmitter until it is properly secured in the process connection. NOTE! Tank connections with NPT threads require a sealant for pressure-tight joints. Rod antenna Sealant on threads Locking screw (ATEX) Transmitter housing Nut, 60 Nm (44 Lbft)

July 2009 Rosemount 5400 Series 3-16 Rod Antenna Flanged Connection Figure 3-16. Mounting the 5400 with rod antenna and flange. 1. Place a gasket on top of the tank flange(1). The gasket thickness and material must be suitable for the process. 2. Lower the transmitter with antenna and flange into the tank nozzle. 3. Tighten the bolts and nuts with sufficient torque for the flange and gasket choice. (1) Gasket is optional for the All-PFA version of the rod antenna. Gasket (optional for the All PFA version) Flange Tank flange Rod antenna PFA plate (only All PFA version, 1R, 2R) Transmitter housing Bolt Nut Locking screw (ATEX) Nozzle

July 2009 3-17 Rosemount 5400 Series Bracket Mounting on Wall Figure 3-17. Bracket Mounting the 5400, on wall. 1. Mount the bracket directly to the wall with screws suitable for the purpose. 2. Mount the transmitter with antenna to the bracket, then secure the installation with the three supplied screws. Transmitter housing Bracket Antenna

July 2009 Rosemount 5400 Series 3-18 Bracket Mounting on Pipe Figure 3-18. Bracket Mounting the 5400, on pipe. 1. Put the two U-bolts through the holes of the bracket. Holes are available for both vertical and horizontal pipe mounting. 2. Put the clamping brackets on the U-bolts and around the pipe. 3. Fasten the bracket to the pipe with the four supplied nuts. 4. Mount the transmitter with antenna to the bracket, and secure with the three supplied screws. Clamping Bracket Antenna Transmitter housing Bracket U-bolt Screws Screw

July 2009 3-19 Rosemount 5400 Series Mounting in Pipes Still-pipe mounting is recommended for tanks with extremely turbulent surface conditions. All cone antenna sizes for the Rosemount 5400 Series of transmitters can be used for Still-pipe installations. The 3 in. (75 mm) antenna for the 5401 is designed for use in Still-pipes only. Rod antennas are not recommended for Still-pipes. When the transmitter is mounted on a Still-pipe, the inclination should be within 1°. The gap between the antenna and the Still-pipe may be up to 0.2 in. (5 mm). Figure 3-19. Mount the transmitter vertically. Recommendations for pipe installations • The pipe interior must be smooth • Not suitable for adhesive products • At least one hole is above the product surface • The hole diameter Ø should not exceed 10% of the pipe diameter D • Holes should only be drilled on one side Max. 0.2 in (5 mm) max. 1 °

July 2009 Rosemount 5400 Series 3-20 Figure 3-20. Recommended hole size for pipe installations. min. 6 in. (150 mm) max. Ø: D/10. D

July 2009 Rosemount 5400 Series www.rosemount.com Section 4 Electrical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1 Cable/Conduit Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 Cable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 Hazardous Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 External Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 Connecting the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . page 4-6 Non-Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . page 4-7 Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . page 4-8 Optional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-9 SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Please refer to the following safety messages before performing an operation preceded by this symbol.

July 2009 Rosemount 5400 Series 4-2 Failure to follow safe installation and service guidelines could result in death or serious injury • Make sure only qualified personnel perform installation or service. • Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment. • Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g. substitution of components etc. may also jeopardize safety and is under no circumstances allowed. Explosions could result in death or serious injury • Verify that the operating environment of the transmitter is consistent with the appropriate hazardous locations specifications. • In an Explosion-proof/Flameproof installation, do not remove the transmitter cover when power is applied to the unit. • Before connecting a HART® based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. Electrical shock can result in death or serious injury • Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock. • Make sure the main power to the 5400 Series transmitter is off and the lines to any other external power source are disconnected or not powered while wiring the transmitter. Antennas with non-conducting surfaces • Antennas with non-conducting surfaces (e.g. Rod antenna and Process Seal antenna) may generate an ignition-capable level of electrostatic charge under extreme conditions. Therefore, when the antenna is used in a potentially explosive atmosphere, appropriate measures must be taken to prevent electrostatic discharge.

July 2009 4-3 Rosemount 5400 Series CABLE/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 according to national, local and plant electrical codes. Properly seal unused ports to prevent moisture or other contamination from entering the terminal compartment of the electronics housing. Install wiring with a drip loop with the bottom of the loop lower than the cable/conduit entry. Figure 4-1. Cable Entries. NOTE! Use the enclosed metal plug to seal the unused port. The temporary orange plastic plugs used at delivery are not sufficient seals! Failure to use the metal plug to seal the unused port invalidates product certification. Remove the orange protective plastic plugs, used for transportation. Seal any unused port with the enclosed metal plug. Cable Entry Cable Entry

July 2009 Rosemount 5400 Series 4-4 Conduit Electrical Connector Wiring (using Minifast®) Figure 4-2. Quick Connect Housing Pin-Out. For wiring details, refer to pin-out drawing and the cordset manufacturer’s installation instructions. For 5400 transmitters with conduit electrical connector M, refer to the cordset manufacturer’s installation instructions for wiring details. “+” “-” No Connection Ground

July 2009 4-5 Rosemount 5400 Series GROUNDING The housing should always be grounded according to 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! Using the threaded conduit connection for grounding may not be sufficient! NOTE! After installation and commissioning, make sure that no ground currents exist from 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., explosion-proof conduits must be used in the vicinity of the vessel. For the ATEX flameproof approval version of the Rosemount 5400 Series, suitable conduits with sealing device or flameproof (EEx d) cable glands must be used depending on local requirements. Use 18 AWG to 12 AWG wiring to minimize the voltage drop to the transmitter. HAZARDOUS AREAS When the Rosemount 5400 Series transmitter is installed in a hazardous area, all national and local regulations and specifications in applicable certificates must be observed. EXTERNAL CIRCUIT BREAKER For complicance with Low Voltage Directive 73/23/EEG, an external circuit breaker should be installed. POWER REQUIREMENTS Terminals in the transmitter housing provide connections for signal wiring. The 5400 transmitter operates with the following power supplies: Table 4-1. Minimum input voltage (UI) at different currents. Hazardous approval Current 3.75 mA 21.75 mA Minimum input voltage (UI) Non-Hazardous Installations and Intrinsically Safe Installations 16 Vdc 11 Vdc Explosion-proof / Flameproof Installations 20 Vdc 15.5 Vdc

July 2009 Rosemount 5400 Series 4-6 CONNECTING THE TRANSMITTER The Rosemount 5400 Series accepts power supplies ranging from 16 Vdc to 42.4 Vdc. It uses 4-20 mA power superimposed with a HART signal. To connect the transmitter: 1. Make sure the housing is grounded (including IS ground inside the Terminal compartment) according to Hazardous Locations Certifications, national, and local electrical codes. 2. Make sure the power supply is disconnected. 3. Remove the terminal block cover. 4. Pull the cable through the cable gland/conduit. For Explosion-proof/ Flameproof installations, use cable glands or conduit entry devices certified Explosion-proof or Flameproof. Install the wiring with a drip loop, with the bottom of the loop lower than the cable/conduit entry. 5. Connect the wires according to Figure 4-4 for non-intrinsically safe power supplies, and according to Figure 4-7 for intrinsically safe power supplies. 6. Remove the orange protective plastic plugs used for transportation and seal any unused port with the enclosed metal plug. 7. Mount the cover and tighten the cable gland, making sure the cover is secure to meet explosion-proof requirements. For ATEX, IECEx, NEPSI and TIIS installations, lock the cover with the Locking screw . 8. Connect the power supply. NOTE! Use PTFE tape or other sealant at the NPT threads in the Cable Entries. Figure 4-3. Terminal compartment and external ground screw. 5 1 1 3 2 4 Cable entries. Internal Ground screw. Terminals for signal and power supply. Locking screw. External Ground screw.

July 2009 4-7 Rosemount 5400 Series NON-INTRINSICALLY SAFE POWER SUPPLY With a non-intrinsically safe power supply in non-hazardous installations or Explosion-proof/Flameproof installations, wire the transmitter as shown in Figure 4-4. NOTE! Make sure that the power supply is off when connecting the transmitter. Figure 4-4. Wiring for non-intrinsically safe power supply. The 375 Field Communicator and the HART Modem require a minimum load resistance of 250within the loop to function properly. For maximum loop resistance, see Figure 4-5. Figure 4-5. Maximum load resistance for Non-hazardous installation. See Figure 4-4 for wiring information. NOTE! The diagram is valid only if the HART load resistance is at the + side and if the - side is grounded, otherwise the load resistance value is limited to 435. Power supply Rosemount 375 Field Communicator Load resistance HART Modem Rosemount 5400 Series Radar Level Transmitter PC 250  Operating Region Maximum Load Resistance External Power Supply Voltage

July 2009 Rosemount 5400 Series 4-8 Figure 4-6. Maximum load resistance for Explosion-Proof/ Flameproof installation. See Figure 4-7 for wiring information. NOTE! For Explosion-proof/Flameproof installations make sure the transmitter is grounded to the I.S. ground terminal inside the terminal compartment in accordance with national and local electrical codes. INTRINSICALLY SAFE POWER SUPPLY With an intrinsically safe power supply, wire the transmitter as shown in Figure 4-7. NOTE! Make sure the instruments in the loop are installed according to intrinsically safe field wiring practices. Figure 4-7. Wiring diagram for intrinsically safe power supply. The 375 Field Communicator and the HART Modem require a minimum load resistance within the loop of 250 to function properly. For maximum load resistance see Figure 4-8. NOTE This diagram is valid only if the HART load resistance is at the + side and if the - side is grounded, otherwise the maximum load resistance is limited to 435. Operating Region Maximum Load Resistance External Power Supply Voltage Power supply Rosemount 375 Field Communicator HART Modem Rosemount 5400 Series Radar Level Transmitter Approved IS Barrier Load resistance 250  PC

July 2009 4-9 Rosemount 5400 Series IS parameters Ui=30 V. Ii=130 mA. Pi=1 W. Ci=7.26 nF. Li=0 H. Figure 4-8. Maximum load resistance for Intrinsically Safe installation. OPTIONAL DEVICES Tri-Loop HART to analog converter The Rosemount 5400 transmitter outputs a HART signal with four process variables. The Model 333 HART Tri-Loop provides up to three additional analog 4-20 mA outputs. Figure 4-9. Wiring diagram for HART Tri-Loop. Operating Region Maximum Load Resistance External Power Supply Voltage Ch. 3 Ch. 2 Ch. 1 Each Tri-Loop Channel recieves power from Control Room Channel 1 must be powered for the Tri-Loop to operate Device recieves power from Control Room RL 250 HART Burst Command 3/ Analog Output Intrinsically Safe Barrier DIN Rail Mounted HART Tri-Loop Control Room Burst Input to Tri-Loop

July 2009 Rosemount 5400 Series 4-10 Configure Channels 1, 2, and 3 to reflect the units in addition to Upper Range Values and Lower Range Values for secondary, tertiary, and fourth variables (variable assignment is configured in the Model 5400). It is also possible to enable or disable a channel from this menu. 751 Field Signal Indicator Figure 4-10. Wiring diagram for a Rosemount 5400 transmitter with a 751 Field Signal Indicator. Power supply Rosemount 5400 Radar Transmitter Model 751 Field Signal Indicator

July 2009 Rosemount 5400 Series www.rosemount.com Section 5 Basic Configuration/Start-Up Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-2 Basic Configuration Parameters . . . . . . . . . . . . . . . . . . . . page 5-3 Basic Configuration Using Rosemount Radar Master . . page 5-11 Configuration Using a 375 Field Communicator . . . . . . . page 5-21 Basic Configuration Using AMS Suite . . . . . . . . . . . . . . . page 5-24 HART Multidrop Configuration . . . . . . . . . . . . . . . . . . . . . page 5-25 SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol. Explosions could result in death or serious injury: Verify that the operating environment of the gauge is consistent with the appropriate hazardous locations certifications. Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. Do not remove the gauge cover in explosive atmospheres when the circuit is alive. All connection head covers must be fully engaged to meet explosion-proof requirements. Failure to follow safe installation and servicing guidelines could result in death or serious injury: Make sure only qualified personnel perform the installation. Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment. Do not perform any service other than those contained in this manual unless you are qualified.

July 2009 Rosemount 5400 Series 5-2 OVERVIEW Configuration of a Rosemount 5400 transmitter is normally a simple and straight-forward task. If the transmitter is pre-configured at the factory according to ordering specifications in the Configuration Data Sheet, no further Basic Configuration is required, unless tank conditions have changed. The 5400 Series supports a set of advanced configuration options that can be used to handle special tank conditions and applications. For further information on advanced configuration options, see “Advanced Configuration” on page C-1. Basic Configuration Parameters The Basic Configuration includes parameters for a standard configuration which is sufficient in most cases. The Basic Configuration comprises the following items: • Measurement Units • Tank Configuration - Tank Geometry - Environment - Volume • Analog Output • Echo Tuning: see page 5-10 for more information on the ATC, and “Registration of False Echoes” on page 7-7 for more information on False Echo Registration 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 “Basic Configuration Using Rosemount Radar Master” on page 5-11 for information on using RRM to configure the 5400 Series. • Rosemount 375 Field Communicator. See “Configuration Using a 375 Field Communicator” on page 5-21 for the Field Communicator Menu Tree. • AMS Suite software. See “Basic Configuration Using AMS Suite” on page 5-24 for information on configuring AMS Suite. RRM is a user-friendly, Windows® based software package that includes waveform plots, off-line/on-line configuration Wizard, logging, and extensive on-line help. To communicate with the transmitter using RRM, a MACTek Viator HART modem (see “Other Accessories” on page A-24) is recommended.

July 2009 5-3 Rosemount 5400 Series BASIC CONFIGURATION PARAMETERS This chapter describes the basic parameters that need to be configured for a Rosemount 5400 transmitter. If the transmitter is factory-configured according to the ordering specifications in the Configuration Data Sheet, no further basic configuration is needed unless conditions have changed since the ordering date. Different configuration tools are described at the end of this section. Measurement Units Measurement units can be specified for presentation of Level, Level Rate, Volume and Temperature values. Tank Geometry Tank Height The Tank Height is the distance between the Upper Reference Point at the underside of the transmitter flange or the threaded adapter, and the Lower Reference Point close to or at the bottom of the tank (see Figure 5-2 for further information on Upper Reference Points for various tank connections). The transmitter measures the distance to the product surface and subtracts this value from the Tank Height to determine the product level. Figure 5-1. Tank Geometry. Tank Height (R) Product Level Upper Reference Point Lower Reference Point (Level=0) Transition Zone

July 2009 Rosemount 5400 Series 5-4 Figure 5-2. Upper Reference Point. Tank Type and Tank Bottom Type The 5400 transmitter is optimized according to the Tank Type and Tank Bottom Type configuration by automatically setting some parameters to predefined default values. Select Tank Bottom Type Flat Inclined if the bottom inclination is between 10 and 30 degrees. If the inclination is less than 10 degrees, but there are disturbing objects on the tank floor (like heating coils) within the radar beam, this selection should also be used. If the inclination is greater than 30 degrees, use the Cone Tank Bottom Type. Table 5-1. Tank Type and Tank Bottom Type Figure 5-3. The transmitter can be optimized for different tank types and bottom shapes. Cone antenna Rod antenna with flange Rod antenna with threaded tank connection UPPER REFERENCE POINT Adapter Flange Process Seal antenna Tank Type Tank Bottom Type Vertical Cylinder Flat, Dome, Cone, Flat inclined/Obstructed Horizontal Cylinder Not used Spherical Not used Cubical Flat, Dome, Cone, Flat inclined/Obstructed Flat Dome Cone Flat inclined Spherical

July 2009 5-5 Rosemount 5400 Series Pipe Diameter When the transmitter is mounted in a still-pipe, the inner diameter of the pipe must be specified. The Pipe Diameter is used to compensate for the lower microwave propagation speed inside the pipe. An incorrect value gives a scale factor error. If locally supplied still-pipes are used, make sure the inner diameter is noted before the pipe is installed. Transition Zone The measurement accuracy is reduced within the Transition Zone region 6 in. (150 mm) from the lower end of the antenna. It is recommended that the Upper Range Value (20 mA) be set outside the Transition Zone, areas where measurements are not recommended. Process Conditions Describe the conditions of the tank according to the Tank Environment parameters for Process Conditions listed below. For best performance, choose only if applicable, and no more than two options. Rapid Level Changes Optimize the transmitter for measurement conditions where the level changes quickly from the filling and emptying of the tank. As a default standard, a 5400 transmitter is able to track level changes of up to 1.5 in./s (40 mm/s). When the Rapid Level Changes check-box is selected, the transmitter can track level changes of up to 8 in./s (200 mm/s). Turbulent Surface This parameter should be used if the tank has a turbulent surface. The reason for the turbulence might be splash loading, agitators, mixers, or boiling product. Normally, the waves in a tank are quite small and cause local rapid level changes. By setting this parameter, the performance of the transmitter will improve when there are small and quickly changing amplitudes and levels. Foam Setting this parameter optimizes the gauge for conditions with weak and varying surface echo amplitudes, such as foam. When the foam is light and airy, the actual product level is measured. For heavy and dense foam, the transmitter measures the level of the foam’s upper surface. Product Dielectric Range The Dielectric Constant is related to the reflectivity of the product. By setting this parameter, measurement performance can be optimized. However, the transmitter will still be able to perform properly, even if the actual Dielectric Constant differs from the configured value.

July 2009 Rosemount 5400 Series 5-6 Volume Configuration For volume calculations, choose one of the standard tank shapes or the strapping option. Select None if volume calculation is not used. For the standard tanks, a Volume Offset parameter can be specified which can be used for a non-zero volume that corresponds to the zero level. This may be useful, for example, if the user wants to include the product volume below the zero level. Volume calculation is performed by using a predefined tank shape or a strapping table. One of the following standard tank shapes can be chosen: • Sphere • Vertical Cylinder • Horizontal Cylinder • Vertical Bullet • Horizontal Bullet The following parameters must be entered for a standard tank shape: • Tank diameter • Tank height (not for spherical tanks) • Volume Offset

July 2009 5-7 Rosemount 5400 Series Standard Tank Shapes Figure 5-4. Standard tank shapes Vertical Cylinder Vertical Cylinder tanks are specified by Diameter, Height, and Volume Offset. Horizontal Cylinder Horizontal Cylinder tanks are specified by Diameter, Height, and Volume Offset. Vertical Bullet Vertical Bullet tanks are specified by Diameter, Height, and Volume Offset. The volume calculation model for this tank shape estimates that the radius of the bullet end is equal to the Diameter/2. Horizontal Bullet Horizontal Bullet tanks are specified by Diameter, Height, and Volume Offset. The volume calculation model for this tank shape estimates that the radius of the bullet end is equal to the Diameter/2. Sphere Spherical tanks are specified by Diameter and Volume Offset. Diameter Height Diameter Height Diameter Height Diameter Height Diameter

July 2009 Rosemount 5400 Series 5-8 Strapping Table The Strapping Table option is used when the tank shape deviates significantly from an ideal sphere or cylinder, or when high volume accuracy is required. The Strapping Table divides the tank into segments. Level values and corresponding volumes are entered at the bottom of the tank. These figures can typically be obtained from tank drawings or from a certificate provided by the tank manufacturer. A maximum of 20 strapping points can be entered. For each level value the corresponding total volume up to the specified level is entered. The volume value is interpolated if the product surface is between two level values in the table. Figure 5-5. Strapping points Actual tank bottom may look like this. Using only 3 strapping points results in a level-to-volume profile that is more angular than the actual shape. Using 10-15 of the points at the bottom of the tank yields a level-to-volume profile that is similar to the actual tank bottom.

July 2009 5-9 Rosemount 5400 Series Analog Output For the analog output. the Output Source (Primary Value), Range Values, and Alarm Mode are specified. Figure 5-6. Standard Range Value settings. Output Source/Primary Variable Specify the source to control the analog output. Typically, the Primary Value is configured to be the Product Level. Upper/Lower Range Value Enter the range values that correspond to the analog output values 4 and 20 mA. The 20 mA point should be set below the Transition Zone, since the measurement accuracy is reduced in this region. For information on the Transition Zone, see “Specifications” on page A-1. If a measured value goes beyond the measurement range, the transmitter enters saturation mode (if limit alarm is disabled) or alarm mode, depending on the current configuration. Alarm Mode Choose the desired Alarm mode to specify the analog output state when there is a failure or a measurement error. High: the output current is set to the High Alarm Limit. Low: the output current is set to the Low Alarm Limit. Freeze Current: the output current is set to the last valid value at the time when the error occurs. 20 mA Upper Range Value (URV) Product Level 4 mA Lower Range Value (LRV) Range 0-100% Lower Reference Point (Level=0) Upper Reference Point Transition Zone

July 2009 Rosemount 5400 Series 5-10 Default settings for alarm mode: • Measurement errors: Output current = High • Measured value out of range: transmitter enters saturation mode (if Limit Alarm is disabled) Table 5-2. Analog Output: Standard Alarm Values vs. Saturation Values. In saturation mode, if the primary variable is not in low alarm mode, the minimum output is 3.9 mA. If the primary variable is not in high alarm mode, the maximum output is 20.8 mA. Table 5-3. Analog Output: NAMUR-Compliant Alarm Values vs. Saturation Values Echo Tuning When Basic Configuration is performed, the transmitter may need to be tuned to handle disturbing objects in the tank. There are different methods available for handling disturbance echoes with the Rosemount 5400 Series Transmitter: • Amplitude Threshold Curve (ATC) • False Echo registration, see “Registration of False Echoes” on page 7-7 The Guided Setup in the Rosemount Radar Master configuration program includes a Measure and Learn function which automatically registers false echoes and creates an ATC (see “Guided Setup” on page 5-15). The created ATC is based on the present tank spectra and process condition settings. Disturbances below the product surface might not be handled by the Measure and Learn function. Level 4–20 mA Saturation Values 4–20 mA Alarm Value Low 3.9 mA 3.75 mA High 20.8 mA 21.75 mA Level 4–20 mA Saturation Values 4–20 mA Alarm Value High 20.5 mA 22.5 mA

July 2009 5-11 Rosemount 5400 Series Amplitude Threshold Curve Setting up an ATC makes tracking of the product surface more robust in the presence of noise and weak disturbing echoes. The ATC is normally used for filtering out disturbances with an amplitude smaller than the amplitude of the product surface echo. The ATC is designed as a number of individually adjustable amplitude threshold points. Figure 5-7. 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. BASIC CONFIGURATION USING ROSEMOUNT RADAR MASTER The Rosemount Radar Master (RRM) is a user-friendly software tool that allows configuration of the Rosemount 5400 transmitter. Choose either of the following methods to configure a Rosemount 5400 transmitter with RRM: • Guided Setup if you are unfamiliar with the 5400 transmitter (see page 5-15) • Setup functions if you are already familiar with the configuration process or for changes to the current settings (see page 5-20) System Requirements Hardware Processor (minimum/recommended): Pentium 200 MHz/1 GHz Memory (minimum/recommended): 64/128 MB RAM COM Port: 1 serial COM port or 1 USB port Graphical Card (minimum/recommended): screen resolution 800 x 600/1024 x 768. Hard drive space: 100 MB Amplitude Threshold Curve Measurement signal Amplitude, mV Distance, m

July 2009 Rosemount 5400 Series 5-12 Software Operating Systems supported: Windows 2000 - Service Pack 3 Windows XP - Service Pack 2 Help in RRM Help is accessed by selecting the Contents option from the Help menu. Help is also available from a Help button in most windows.

July 2009 5-13 Rosemount 5400 Series Installing the RRM software for HART communication To install the Rosemount Radar Master: 1. Insert the installation CD into the CD-ROM drive. 2. If the installation program is not started automatically, 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. Make sure that HART is chosen as default protocol. 6. Set COM Port Buffers to 1, see page 5-14. Getting started 1. From the Start menu, click Programs > Rosemount > Rosemount Radar Master or click the RRM icon in the Windows workspace. 2. If the Search Device window did not appear automatically, choose menu option Device > Search. 3. In the Search Device window, choose communication protocol HART and click the Start Scan button (click the Advanced button to specify start and stop address). Now RRM searches for the transmitter. 4. The Search Device window presents a list of found transmitters. 5. Select the desired transmitter and press OK to connect. If communication does not work, check that the correct COM port is configured correctly and is connected to the computer. See “Specifying the COM Port” on page 5-14. Verify from the Communication Preferences window that HART communication is enabled. 6. The RRM Status Bar can be used to verify that RRM is communicating with the transmitter: RRM communicates with the transmitter No communication with the transmitter

July 2009 Rosemount 5400 Series 5-14 Specifying the COM Port If communication is not established, open the Communication Preferences window and check that the correct COM Port is selected: 1. From the View menu, select Communication Preferences in RRM. Figure 5-8. Communication Settings. 2. Make sure that HART communication is enabled. 3. Check which COM port is connected to the modem. 4. Choose the COM port option matching the actual COM port on the PC that is connected to the transmitter. To set the COM port buffers The COM port Receive Buffer and Transmit Buffer need to be set to 1 by doing the following: 1. In the MS Windows Control Panel, open the System option. 2. Choose the Hardware tab and click the Device Manager button. 3. Expand the Ports node in the tree view. 4. Click the right mouse button on the selected COM port and choose Properties. 5. Select the Port Settings tab and click the Advanced button. 6. Drag the Receive Buffer and Transmit Buffer slides to 1. 7. Click the OK button. 8. Reboot the computer. Specifying Measurement Units Measurement units for data presentation in RRM can be specified when the RRM program is installed. Units can also be changed as follows: 1. Choose the Application Preferences option from the View menu. 2. Select the Measurement Units tab. 3. Choose the desired units for Length, Level Rate, Volume and Temperature.

July 2009 5-15 Rosemount 5400 Series Guided Setup The following description tells how to use the RRM Guided Setup. The corresponding HART commands (275/375 Handheld Communicator Fast Key Sequence) are also shown. The Guided Setup is useful for those unfamiliar with the 5400 transmitter. Guided Setup and Configuration Wizard 1. Start the RRM program. RRM automatically presents a list of available transmitters. Select the desired transmitter. The transmitter is now connected and the Guided Setup window appears. 2. In the Guided Setup window , click the Run Wizard... button and follow the instructions through a short transmitter installation procedure. Note! The Guided Setup is an extended installation guide including more than just the configuration Wizard. It can be disabled by deselecting the Open Guided Setup dialog after Connect check-box in the Application Preferences window (menu option View > Application Preferences). Device Properties 3. The first window in the configuration wizard presents general information that is stored in the transmitter database, such as device model, serial number, antenna type, communication protocol, and device address. Verify that the information matches the ordering information. Device Information 4. The Tag, Message, Descriptor, and Date information is entered in this window. This information is not required for the operation of the transmitter and may be left out, if desired. HART command: [2, 2, 1]. Run Wizard

July 2009 Rosemount 5400 Series 5-16 Tank Geometry 5. Choose the Tank Type corresponding to the actual tank. If none of the available options matches the tank, choose Unknown. HART command: [2, 1, 2, 1]. Tank Bottom Type is important for the measurement performance close to the tank bottom. HART command: [2, 1, 2, 2]. Tank Height is the distance from the Upper Reference Point to the Lower Reference Point (see “Tank Geometry” on page 5-3). This number needs to be as accurate as possible. HART command: [2, 1, 2, 3]. Select the Enable Still-Pipe/Bridle Measurement check-box and enter the Pipe Inner Diameter if the transmitter is mounted on a Still-Pipe. HART command: [2, 1, 2, 4] / [2, 1, 2, 5]. For more information, see “Tank Geometry” on page 5-3. Tank Environment 6. In the Process Condition box, select the check-boxes that correspond to the conditions of the tank. Select as few options as possible and no more than two. See “Process Conditions” on page 5-5 for more information. The Dielectric Chart lists the dielectric constants of a large number of products and can be opened by selecting View > Dielectric Constant Chart menu option. Choose the Product Dielectric Range that corresponds to the current product. If the correct range value for this parameter is unknown, or the contents in the tank are continually changing, choose Unknown. HART command: [2, 1, 3, 2]. Enter inner diameter of the pipe

July 2009 5-17 Rosemount 5400 Series Volume 7. For volume calculation, choose a pre-defined calculation method based on a tank shape that corresponds to the actual tank. Choose None if volume calculation is not needed. The Strapping Table option is used if the actual tank does not match any of the available options for pre-defined tanks or if higher calculation accuracy is desired. HART command: [2, 1, 4, 1]. For more information, see “Volume Configuration” on page 5-6. Analog Output 8. Typically, the Primary Variable (PV) is configured to be Product Level or Volume. Set the analog output range by inputting the Lower Range Value (4 mA) and the Upper Range Value (20 mA) to the desired values. The Alarm Mode specifies the output state when a measurement error occurs. HART command: [2, 1, 5]. See “Analog Output” on page 5-9 for more information on Analog Output configuration and Alarm Mode settings. Finish Configuration Wizard 9. This is the last window in the Configuration Wizard. The configuration can be changed at any time by using the Setup windows (General, Tank, Output etc., see “Using the Setup Functions” on page 5-20), which contain further options not available in the configuration wizard. Click the Finish button and continue with the next step in the Guided Setup.

July 2009 Rosemount 5400 Series 5-18 Echo Tuning 10. Step 2 in the Guided Setup allows automatic configuration of the Amplitude Threshold Curve and registration of false echoes by running the Measure and Learn function. See “Echo Tuning” on page 5-10 for more information on amplitude thresholds and false echoes. Click button 2 to start the Measure and Learn function. (If Echo Tuning is not needed, or is done at a later stage, go on to step 3 in the Guided Setup). Measure and Learn Function 11. Click the Yes button to run the Measure and Learn function. If No is clicked, this function can be run at a later stage using the Spectrum Analyzer in RRM. Make sure there is no filling or emptying occurring when the Measure and Learn function is used. Tank Precondition Settings 12. The Measure and Learn function creates an Amplitude Threshold Curve (ATC) automatically and suggests False Echo Areas. See “Echo Tuning” on page 5-10. (By clicking the Advanced button, one or both of the options can be selected in the corresponding check-box). Verify the Tank Precondition settings, verify that the Distance to Surface value is correct. If not, it may be due to a disturbing object in the tank). Choose Empty Tank if the tank is empty. Spectrum Plot 13. The automatically created Amplitude Threshold Curve (ATC) and False Echo Areas are shown in the Spectrum Plot. False Echo Areas are presented as shaded areas, and represent tank levels where RRM found interfering echoes to be blocked out. False Echo Areas can be moved or removed before storing to the transmitter database. Verify that each False Echo Area is identified as an object in the tank that gives rise to a disturbing echo. See “Echo Tuning” on page 5-10 for more information. Click the Store button to save the ATC and the registered disturbance echoes.

July 2009 5-19 Rosemount 5400 Series Restart the Transmitter 14. Restart the transmitter to activate all of the configuration changes. It may take up to 60 seconds after the restart button is pressed before measurement values are updated. View Measured Values 15. Step 4 shows measurement values to verify that the transmitter is working correctly. If the measured values seem incorrect, configuration settings may need to be adjusted. Configuration Backup 16. When configuration is complete, the configuration should be saved to a backup file. This information is useful for: - installing another 5400 in a similar tank, since the file can be directly uploaded to a new device. - restoring the configuration, if configuration data is lost or accidentally modified, making the device inoperable. The Configuration Report window automatically appears when the backup is complete. Guided Setup Complete 17. The Guided Setup is now complete. To exit the Guided Setup, click the Close button.

July 2009 Rosemount 5400 Series 5-20 Using the Setup Functions Use the Setup function if you are already familiar with the configuration process for the 5400 transmitter or to change the current settings: Figure 5-9. Setup functions in RRM. 1. Start the RRM software. 2. In the RRM workspace, choose the appropriate icon for configuring transmitter parameters: • Wizard: guides the user through the basic configuration procedure of the Rosemount 5400 transmitter • General: configures general settings, such as measurement units and communication parameters, and which LCD variables to display • Tank: configures Tank Geometry, Tank Environment, and Volume • Output: configures Analog Output • Echo Curve: disturbance echo handling • Advanced: advanced configuration General Tank Geometry, Environment, Volume Analog Output Echo Curve Advanced Wizard

July 2009 5-21 Rosemount 5400 Series CONFIGURATION USING A 375 FIELD COMMUNICATOR This section describes the configuration of a 5400 transmitter with a 375 Field Communicator. The menu tree with the various configuration parameters is shown in Figure 5-11 on page 5-22. Section “Basic Configuration Parameters” on page 5-3 describes the basic configuration parameters. See sections “Echo Tuning” on page 5-10 and “Advanced Configuration” on page C-1 for information on disturbance echo handling and advanced configuration. For information on all capabilities, refer to 375 Field Communicator Product Manual (Document No. 00809-0100-4276). Figure 5-10. The 375 Field Communicator. To make a basic setup of the transmitter, do the following: 1. Check that the desired Measurement Units are selected. HART command: [2, 1, 1, 5]. 2. Enter configuration parameters for the following: • Device info. HART command: [2, 2, 1] • Geometry. HART command: [2, 1, 2] • Environment. HART command: [2, 1, 3] • Volume. HART command: [2, 1, 4] • Analog Out. HART command: [2, 1, 5] 3. Run Measure and Learn. HART command: [2, 1, 6, 2]. This function creates an Amplitude Threshold Curve (ATC). 4. Restart the transmitter. HART command: [2, 1, 6, 4]. To view the Echo Curve and adjust threshold settings, see “Using the Echo Curve Analyzer with a 375 Field Communicator” on page 7-12. Function Key Navigation Keys Alphanumeric Keys Backlight adjustment key Tab Key Enter Key

July 2009 Rosemount 5400 Series 5-22 Figure 5-11. HART Communicator Menu Tree corresponding to Device Revision 2. Process Variables 1 Process Variables 2 Setup 3 Diagnostics 4 Level 5 Analog Out 6 Distance 7 Signal Strength 1 Primary Variable 2 2nd 3 3rd 4 4th 5 All variables 6 Identification 1 Basic Setup 2 Device 3 Tank 4 Analog output 5 Echo Curve 6 Advanced 7 Calibration 1 Diagnostics 2 Tools 1 Variable Mapping 2 Geometry 3 Environment 4 Volume 5 Analog Out 6 Finish 1 Identification 2 Variable Mapping 3 LCD 4 Communication 5 Alarm/Sat. Limits 1 Identification 2 Variable Mapping 3 LCD 4 Communication 5 Alarm/Sat. Limits 1 Geometry 2 Environment 3 Volume 4 Antenna 1 Analog Out 2 Alarm/Sat. Limits 1 Echo Peaks 2 Echo Curve 1 Empty Tank 2 Echo Tracking 3 Double Bounce 4 Bottom Projection 5 Double Surface 6 Filter Settings 7 Full Tank 1 Analog Output Setup Diagnostics 1 Primary Variable 2 2nd 3 3rd 4 4th 5 HART Digital Units 6 Damping Value 7 Device Status 1 Tank Type 2 Tank Bottom Type 3 Tank Height 4 Still-pipe/Bridle Meas 5 Drawing 1 Process Condition 2 Product Dielectric Range 1 Volume Calculation Method 2 Drawing 1 Primary Variable 2 Range Values 3 Alarm Mode 4 Sensor Limit 5 Alarm Mode Definition 2 Measure and Learn 4 Restart Device 1 Found Echo Peaks 2 Measurement Output 3 Register False Echoes 4 Add False Echo 5 Remove False Echo 1 Measure and Learn 2 Set Threshold 3 Echo Curve

July 2009 5-23 Rosemount 5400 Series Table 5-4. HART Fast Key Sequences Function HART Fast Key Alarm Mode 2, 1, 5, 3 Antenna Type 2, 3, 4 Device Information 2, 2, 1 LCD Language 2, 2, 3 LCD Variables 2, 2, 3 Length Unit 2, 1, 1, 5 Lower Range Value (LRV) (4 mA) 2, 1, 5, 2 Pipe Diameter 2, 1, 2, 4 Primary Variable 2, 1, 1, 1 Product Dielectric Constant 2, 1, 3, 2 Range Values (LRV/URV) 2, 1, 5, 2 Tag 2, 2, 1 Tank Bottom Type 2, 1, 2, 2 Tank Height 2, 1, 2, 3 Tank Type 2, 1, 2, 1 Temperature Unit 2, 1, 1, 5 Hold Off Distance/Upper Null Zone 2, 3, 4 Upper Range Value (URV) (20 mA) 2, 1, 5, 2 Volume Configuration 2, 1, 4, 1 Volume Unit 2, 1, 1, 5

July 2009 Rosemount 5400 Series 5-24 BASIC CONFIGURATION USING AMS SUITE The Rosemount 5400 Series transmitter can be configured using the AMS Suite software: 1. Start the AMS Device Manager making sure the transmitter is connected. The transmitter is displayed in the Device Connection View window (pictures correspond to AMS version 9.0). 2. In the Device Connection View, right click the transmitter icon. 3. Choose the Configure/Setup option. 4. Choose the Basic Setup option. 5. Configure the transmitter by selecting the appropriate tab. For information on the various configuration parameters, see “Basic Configuration Parameters” on page 5-3 . Configure/Setup

July 2009 5-25 Rosemount 5400 Series HART MULTIDROP CONFIGURATION The 5400 transmitter can be run in multidrop mode where each transmitter has a unique HART address. Figure 5-12. Multidrop connection The poll address can be changed using a 375 Field Communicator or using the Rosemount Radar Master software. To change the poll address using a 375 Field Communicator, choose HART command [2, 2, 4, 1]. To change the poll address using the Rosemount Radar Master (RRM) software: 1. Choose the Setup > General option. 2. Select the Communication tab. 3. Set the desired address (between 1 and 15 for multidrop operation). 4. Click the Store button to save the new address.

July 2009 Rosemount 5400 Series www.rosemount.com Section 6 Operation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-1 Viewing Measurement Data . . . . . . . . . . . . . . . . . . . . . . . . page 6-2 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-8 LED Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-9 SAFETY MESSAGES Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol. 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 HART®-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. Electrical shock 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.

July 2009 Rosemount 5400 Series 6-2 VIEWING MEASUREMENT DATA Using the Display Panel The Rosemount 5400 transmitter uses an optional Display Panel to present measurement data. When the transmitter is switched on, the Display Panel presents information such as transmitter model, measurement frequency, software version, communication type (HART, FF), serial number, HART identification tag, setting of write protection switch, and Analog Output settings. When the transmitter is operating, the Display Panel presents Level, Signal Amplitude, Volume and other measurement data, depending on the Display Panel configuration (see “Specifying Display Panel Variables” on page 6-3). The display has two rows, with the upper row showing the measured value and the bottom row showing the parameter name and measurement unit. The display toggles between the different variables every 2 seconds. Variables can be selected to be presented by using a 275/375 Handheld Communicator, the AMS Suite, or the Rosemount Radar Master (RRM) software. Figure 6-1. The 5400 Display Panel. Error messages are listed in sections “LCD Error Messages” on page 6-8 and “LED Error Messages” on page 6-9. NOTE! A malfunctioning display panel may only be replaced by service personnel at Emerson Process Management Service Department and must not be replaced while the transmitter is in operation. Toggling between measurement parameter and measurement unit Measurement value

July 2009 6-3 Rosemount 5400 Series Specifying Display Panel Variables It is possible to specify the variables to be presented on the Display Panel (LCD). Using a Field Communicator For a 275/375 Handheld Communicator, the LCD settings are available with HART command [2, 2, 3]. Using Rosemount Radar Master (RRM) The LCD tab in the General window allows variables to be specified for view on the Display Panel screen: 1. Choose the General option from the Setup menu, or click the General icon in the Device Configuration window. 2. Select the LCD tab. Figure 6-2. RRM lets you specify variables for the 5400 Display Panel. 3. Select the variables to appear on the Display Panel. The LCD will alternate between the selected items. 4. Click the Store button to save the LCD settings in the transmitter database. Device Config General

July 2009 Rosemount 5400 Series 6-4 Using AMS The LCD tab in the Configure/Setup window specifies which variables will be shown on the Display Panel screen: 1. Select the transmitter icon in the AMS Suite Device Connection View window. 2. Click the right mouse button and choose the Configure/Setup/Device option. 3. Select the LCD tab and choose the desired LCD parameters and LCD measurement units. The available LCD parameters are listed in Table 6-1 on page 6-5. 4. Click the OK button to save the configuration. 5. Close the window. Figure 6-3. Configure parameters to be presented on the Display Panel. LCD tab Device

July 2009 6-5 Rosemount 5400 Series LCD Parameters Table 6-1. LCD parameters and presentation on display. Parameter Presentation on display Description Level LVL Product level. Distance DST Distance from the upper reference point to the product surface. Level Rate LR The speed of level movement up or down. Signal Strength AMP The signal amplitude of the surface echo. Volume Only measurement unit is shown. Total product volume. Internal Temperature ITEMP Temperature inside the transmitter housing. AOut Current ANOUT Analog Output 4 -20 mA current. Percent of Range % RNG Level value in percent of total measurement range. Comm Quality COM Q

July 2009 Rosemount 5400 Series 6-6 Viewing Measurement Data in RRM To view measurements such as Level, Signal Strength, etc. in Rosemount Radar Master, choose the Tools > Device Display option and select the Level tab: Figure 6-4. Presentation of measurement data in RRM. To view Analog Output signal, choose the Tools > Device Display option and select the Analog Out tab: Figure 6-5. Presentation of Analog Output value in RRM.

July 2009 6-7 Rosemount 5400 Series Viewing Measurement Data in AMS Suite To view measurements such as Level, Signal Strength, etc. in the AMS Suite: 1. Select the transmitter icon in the AMS Suite Device Connection View window. 2. Click the right mouse button and choose the Process Variables option. Figure 6-6. Presentation of measurement data in AMS Suite.

July 2009 Rosemount 5400 Series 6-8 LCD ERROR MESSAGES Figure 6-7. The 5400 Display Panel displaying an error message. Table 6-2. Error messages displayed on the 5400 Display Panel. For more information on errors, see “Errors” on page 7-22. Error Message Error Message Description RAM FAIL An error in the gauge data memory (RAM) has been detected during the startup tests. Note: this resets the gauge automatically. FPROM FAIL An error in the gauge program memory (FPROM) has been detected during the startup tests. Note: this resets the gauge automatically. HREG FAIL An error in the transmitter configuration memory (EEPROM) has been detected. The error is either a checksum error that can be solved by loading the default database or a hardware error. NOTE: the default values are used until the problem is solved. OMEM FAIL MWM FAIL An error in the microwave module. DPLY FAIL An error in the LCD. MODEM FAIL Modem hardware failure. AOUT FAIL An error in the Analog Out Module. OHW FAIL An unspecified hardware error has been detected. ITEMP FAIL An error in the internal temperature measurement. MEAS FAIL A serious measurement error has been detected. CONFIG FAIL At least one configuration parameter is outside the allowed range. NOTE: the default values are used until the problem is solved. SW FAIL An error has been detected in the transmitter software.

July 2009 6-9 Rosemount 5400 Series LED ERROR MESSAGES For Rosemount 5400 transmitters without a display, a flashing Light Emitting Diode (LED) is used to present error messages. Figure 6-8. Rosemount 5400 transmitters without display use a LED for presentation of error messages. In normal operation, the LED flashes orange once every other second. When an error occurs, the LED flashes a sequence that corresponds to the Code number followed by a five second pause, and this sequence is continuously repeated. The following errors can be displayed: Table 6-3. LED error codes. Example Modem error (code 6) is displayed as the following flash sequence: Flashing LED Code Error 0 Ram Failure 1 FPROM 2 HREG 4 Microwave Module 5 Display 6 Modem 7 Analog Out 8 Internal Temperature 11 Hardware 12 Measurement 14 Configuration 15 Software Seconds

July 2009 Rosemount 5400 Series www.rosemount.com Section 7 Service and Troubleshooting Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . page 7-3 Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-4 Analyzing the Measurement Signal . . . . . . . . . . . . . . . . . page 7-4 Surface Pulse Not Found . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-5 Using the Echo Curve Analyzer . . . . . . . . . . . . . . . . . . . . page 7-9 Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . page 7-14 Logging Measurement Data . . . . . . . . . . . . . . . . . . . . . . . . page 7-14 Backing Up the Transmitter Configuration . . . . . . . . . . . page 7-15 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-17 Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-18 Viewing Input and Holding Registers . . . . . . . . . . . . . . . . page 7-18 Reset to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . page 7-19 Surface Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-20 Using the Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . page 7-20 Write Protecting a Transmitter . . . . . . . . . . . . . . . . . . . . . page 7-20 Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-21 SAFETY MESSAGES Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol. NOTE! The antenna seal assembly, under no circumstances, should be disassembled.

July 2009 Rosemount 5400 Series 7-2 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 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. • 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. • Substitution of components may impair Intrinsic Safety. Electrical shock could cause death or serious injury. • Use extreme caution when making contact with the leads and terminals. • To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing. 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.

July 2009 7-3 Rosemount 5400 Series TROUBLESHOOTING OVERVIEW Table 7-1 below gives information on the possible causes of system malfunctions. It also lists the symptoms and necessary actions to be taken. Table 7-1. Troubleshooting chart Symptom Possible cause Action No level reading • Power disconnected • Data communication cables disconnected • Check the power supply • Check the cables for serial data communication • Check LED/Display No HART communication • COM Port configuration does not match the connected COM Port • Cables may be disconnected • Wrong HART address is used • Hardware failure • HART resistor • Check that correct COM Port is selected in the HART server (see “Specifying the COM Port” on page 5-14) • Check the COM port buffer, “Specifying the COM Port” on page 5-14 • Check wiring diagram • Verify that the 250 Ohm resistor is in the loop, see Figure 4-10 on page 4-10 • Check cables • Make sure that correct HART short address is used. Try address=0 • Check the COM Port Buffer setting, see page 5-14 • Check Analog Output current value to verify that transmitter hardware works Analog Out is set in Alarm • Measurement Failure or Transmitter Failure • Open the Diagnostics window in RRM to check active errors and alarms, see “Diagnostics” on page 7-17 • See also “Analyzing the Measurement Signal” on page 7-4 and “Analog Output Status” on page 7-26 Incorrect level reading • Configuration error • Disturbing objects in the tank • See “Application Errors” on page 7-27 • Check the Tank Height parameter; RRM>Setup>Tank • Check status information and diagnostics information, see “Diagnostics” on page 7-17 • Check that the transmitter has not locked on an interfering object • See “Analyzing the Measurement Signal” on page 7-4 Integral display does not work • Check the display configuration in Rosemount Radar Master (open menu Setup>General) • Diagnostics • Contact Emerson Process Management Service Department(1) Temperature Measurement Failure • Check ambient temperature(2) • Restart gauge • Contact Emerson Process Management Service Department Level Measurement Failure • Check Power Supply • Check the gauge configuration • Check that the mechanical installation is correct Volume Measurement Failure • Restart gauge • Check gauge configuration using PC Based configuration tool No surface echo • Check signal strength • Restart transmitter • See “Analyzing the Measurement Signal” on page 7-4 (1) A malfunctioning display panel may only be replaced by service personnel at Emerson Process Management Service Department. (2) If the 5400 transmitter has been exposed to temperatures outside the specified limits, the device may stop its normal operation.

July 2009 Rosemount 5400 Series 7-4 SERVICE OVERVIEW The functions mentioned in this section are available in the Rosemount Radar Master (RRM) configuration program. ANALYZING THE MEASUREMENT SIGNAL Rosemount Radar Master (RRM), and other tools using enhanced Electronic Device Description Language (EDDL), has powerful functions for advanced troubleshooting. By using the Echo Curve plot function, an instant view of the tank signal is displayed. Measurement problems can be resolved by studying the position and amplitude of the different pulses. Figure 7-1. The Echo Curve presents all visible echoes. In a typical measurement situation, the following pulses appear in the diagram: Reference. This pulse is caused by the transition between transmitter head and antenna and it is used by the transmitter as a reference at level measurements. A missing reference pulse might be a symptom of a malfunctioning transmitter. Contact your local Emerson Process Management representative for assistance. Product surface. This pulse is caused by a reflection on the product surface. Different amplitude thresholds are used to filter out unwanted signals and pick up different pulses. The transmitter uses certain criteria to decide which type of pulse that is detected. Echoes found above the Surface Threshold might be considered the product surface. Surface Threshold. The amplitude threshold used for detecting the Product level peak. The amplitude threshold is designed as a number of individually adjustable amplitude threshold points, the Amplitude Threshold Curve (ATC). See “Amplitude Threshold Curve” on page 5-11. The ATC is set during the Measure and Learn function and can be adjusted manually. The ATC is used for filtering out disturbances with an amplitude smaller than the product surface echo. Reference Product Surface Unknown Hold Off distance Tank Bottom False Echo Surface Threshold / ATC

July 2009 7-5 Rosemount 5400 Series The surface thresholds should be set to approximately 20% of the measured signal amplitude of the product surface. False Echo Area. False Echo Areas are set during the Measure and Learn function (see “Guided Setup” on page 5-15), when the disturbing object is larger than the surface echo. The False Echo Area can be adjusted manually. Hold Off Distance - Upper Null Zone. Measurements are not performed within the Hold Off Distance. By setting the Hold Off Distance to zero, measurements can be performed close to the flange. Consider near zone accuracy. See “Near Zone Accuracy” on page A-1. Tank Bottom. Measurements are not performed after the Tank Bottom limit. SURFACE PULSE NOT FOUND The amplitude thresholds are adjusted manually or during the Measure and Learn function to appropriate values to filter out noise and other non-valid measurements from the measurement signal. The amplitude of the measurement signal, i.e. the amplitude of the signal reflected by the product surface, is related to the actual dielectric constant of the product. Rosemount Radar Master (RRM) has a plot function that allows viewing of the reflections in the tank. If the amplitude threshold is too high, the product level will not be detected, as illustrated in Figure 7-2. In a situation like this, the amplitude threshold is lowered so that the Surface peak is not filtered out. Figure 7-2. Example 1: surface threshold is too high. If there are disturbing objects in the tank, the threshold must be set carefully to avoid locking on the wrong amplitude peak. In Figure 7-3, the transmitter has locked on a peak above the actual product surface, i.e. a disturbance was interpreted as the product surface. Amplitude, mV The Surface Threshold is above the Surface peak Surface Threshold= Amplitude Threshold Curve (ATC) Distance, m Reference

July 2009 Rosemount 5400 Series 7-6 Figure 7-3. Example 2: surface threshold is too low. By adjusting the surface threshold, the product surface is properly detected, as illustrated in Figure 7-4: Figure 7-4. Echo Curve after surface threshold was adjusted To adjust the amplitude thresholds, see “Using the Echo Curve Analyzer” on page 7-9. In the Echo Curve Analyzer in RRM, the amplitude threshold points can easily be dragged to the desired values. Amplitude, mV Actual surface Surface Threshold= Amplitude Threshold Curve (ATC) Distance, m P1 - Disturbing echo misinterpreted as product surface Reference Amplitude, mV Distance, m After Surface Threshold is adjusted, the product surface is correctly detected Surface Threshold= Amplitude Threshold Curve (ATC) Reference

July 2009 7-7 Rosemount 5400 Series Registration of False Echoes The False Echo function improves the performance of the gauge when the surface is close to a horizontal surface of a static 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 may interfere and cause a decrease in performance. Figure 7-5. The Rosemount 5400 can handle disturbing radar echoes. The False Echo function allows registration of disturbing echoes caused by objects in the tank. When the surface is passing a disturbing object, the transmitter measures with higher reliability if 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. Follow these recommendations before registering new interfering echoes: • Make sure a correct amplitude threshold curve is set before registering any disturbance echoes (see “Amplitude Threshold Curve” on page 5-11) • Compare the list of interfering echoes with the tank drawing or visual inspection of the tank. Note any 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 registering a disturbance echo. A fluctuating level may indicate a temporary disturbance that is not from an interfering object • Do not register False Echoes located below the product surface. It is recommended that registration be done when the tank is empty False echo Surface echo Disturbing objects

July 2009 Rosemount 5400 Series 7-8 Figure 7-6. 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 Echo Amplitude, mV Distance, m

July 2009 7-9 Rosemount 5400 Series USING THE ECHO CURVE ANALYZER The Echo Curve in Rosemount Radar Master (RRM) shows the measurement signal amplitude in the tank and includes the Echo Tuning functionality (see “Echo Tuning” on page 5-10 for more information on false echo handling). To plot the measurement signal: 1. Start the Rosemount Radar Master program. 2. Open Device Config/Tools (or Device Config/Setup). 3. Click the Echo Curve icon (see Figure 7-7). Figure 7-7. The Echo Curve function is a useful tool for signal analysis. 4. The Echo Curve Analyzer window appears with the View/Record Mode tab (or the Configuration Mode tab) selected. Device Config Device Config Tools

July 2009 Rosemount 5400 Series 7-10 The Configuration Mode Tab The Configuration Mode tab allows for adjustment of the different amplitude thresholds. When clicking the Echo Curve icon under Device Config/Setup, the Echo Curve Analyzer window appears with the Configuration Mode tab selected: Figure 7-8. Echo Curve Analyzer plot in Configuration mode. The Measure and Learn function in Rosemount Radar Master automatically creates an Amplitude Threshold Curve (ATC) used by the 5400 transmitter to find the surface pulse. The ATC is adapted to the shape of the measurement signal as described in “Echo Tuning” on page 5-10. To create an Amplitude Threshold Curve (ATC), click the Learn button in the Echo Curve Analyzer/Configuration Mode window. By clicking the Learn button, the Measure and Learn function is activated and creates an ATC that filters out all disturbing echoes. The ATC can also be edited manually if further fine tuning is needed. The Configuration Mode window also allows the changing of the amplitude thresholds manually, simply by dragging the corresponding anchoring points in the plot to the desired positions. Note that by changing the amplitude thresholds in the Echo Curve plot manually, the Automatic mode is disabled for the corresponding threshold. The Set Thresholds button sets the ATC to a fixed value based on the configured Dielectric Constant of the product. To register a false echo, right-click and select Register as false echo. Set Threshold Measure and Learn