Emerson Rosemount 5900 Instruction Manual

Safety Manual
00809-0200-5100, Rev GB
February 2017
Rosemount™5900 Radar Level Gauge and
2410 Tank Hub
Safety Manual for Use in Safety Instrumented Systems
Certified to relevant
requirements of
IEC 61508:2010 parts 1-7
This manual is valid for model code
Safety Certification (SIS) option 2 and 3

i
Safety Manual
00809-0200-5100, Rev GB
Title Page
February 2017
Title Page
Rosemount™Tank Gauging
NOTICE
Read this manual before working with the product. For personal and system
safety, and for optimum product performance, make sure you thoroughly
understand the contents before installing, using, or maintaining this
product.
For equipment service or support needs, contact your local Emerson Process
Management/Rosemount Tank Gauging representative.
Spare Parts
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.
Rosemount Tank Radar AB will not take any responsibility for faults,
accidents, etc caused by non-recognized spare parts or any repair or
modification which is not made by authorized representative.
NOTICE
Document No. changed from 300540EN to 00809-0200-5100.
The revision no. for this safety manual is included in the SIL certification
although not explicitly stated in the SIL certificates.

ii
Safety Manual
00809-0200-5100, Rev GB
Title Page
February 2017
Title Page

iii
Safety Manual
00809-0200-5100, Rev GB
Contents
February 2017
Contents
Table of Contents
1Section 1: Scope and Purpose of the Safety Manual
2Section 2: Reference Documents
3Section 3: Scope of the Product
3.1 Purpose of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2.1 Assumptions and restrictions for the usage of the product . . . . . . . . . . . . .6
3.2.2 Functional specification of the safety function . . . . . . . . . . . . . . . . . . . . . . . .8
3.2.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4Section 4: Installation and Configuration
4.1 Installation and commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1.1 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.1.2 The Rosemount 5900 terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.1.3 Connecting the Rosemount 2410 to the 5900 . . . . . . . . . . . . . . . . . . . . . . .15
4.1.4 Rosemount 2410 relay output connection . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 Safety alarm setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2.1 Safety measurement performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2.2 Safety alarm parameters and tank geometry . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.3 Amplitude thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2.4 Setting the SIL High Alarm Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.2.5 Setting the SIL Low Alarm Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.2.6 Safety alarm configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.2.7 How to filter out LPG Verification Pin or Reference Reflector. . . . . . . . . . .43
4.2.8 How to adjust the SIL Amplitude Threshold. . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.9 Changing the current alarm configuration . . . . . . . . . . . . . . . . . . . . . . . . . .45
4.2.10How to adjust the SIL Hold Off Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
4.2.11How to enable SIL Low Alarm Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.2.12How to disable SIL Low Alarm Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

iv
Safety Manual
00809-0200-5100, Rev GB
Contents
February 2017
Contents
5Section 5: Proof Test
5.1 Check of surface measurement and verification of the relay function. . . . . . . . .52
5.1.1 Check of surface measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.1.2 Verification of the relay function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.2 System test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.3 SIL High Alarm test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
5.3.1 Viewing a SIL High Alarm Test report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
6Section 6: Terms and Definitions
AAppendix A: Parameters Related to the Safety Function
A.1 5900 and 2410 (SIL 2, 1-in-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
A.2 5900 and 2410 (SIL 3, 2-IN-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
A.3 5900 and 2410 (SIL 2, 2-in-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
A.4 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
BAppendix B: Supported Antennas
CAppendix C: Safety System Identification
C.1 Device Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
C.2 Baselines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
C.3 SIL Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
DAppendix D: SIL Measurement Status
EAppendix E: Disabling the SIL High Alarm
FAppendix F: Cone Pipe Antenna
GAppendix G: Dry-run Configuration

1
Safety Manual
00809-0200-5100, Rev GB
Scope and Purpose of the Safety Manual
February 2017
Scope and Purpose of the Safety Manual
Section 1 Scope and Purpose of the
Safety Manual
The purpose of the safety manual is to document all the information, relating to the Rosemount
Tank Gauging system, which is required to enable integration into a safety-related system, in
compliance with the requirements of IEC 61508.

2
Safety Manual
00809-0200-5100, Rev GB
Scope and Purpose of the Safety Manual
February 2017
Scope and Purpose of the Safety Manual

3
Safety Manual
00809-0200-5100, Rev GB
Reference Documents
February 2017
Reference Documents
Section 2 Reference Documents
IEC 61508
IEC 61511
Rosemount Tank Gauging System Configuration Manual,
Ref. no. 00809-0300-5100
Rosemount 2410 Tank Hub Reference Manual,
Ref. no. 00809-0100-2410
Rosemount 5900S Radar Level Gauge Reference Manual,
Ref. no. 00809-0100-5900
Rosemount 5900C Radar Level Gauge Reference Manual,
Ref. no. 00809-0100-5901
Rosemount Tank Gauging System Data Sheet,
Ref. no. 00813-0100-5100.

4
Safety Manual
00809-0200-5100, Rev GB
Reference Documents
February 2017
Reference Documents

5
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product
Section 3 Scope of the Product
3.1 Purpose of the product
The Rosemount™Tank Gauging Safety System is designed for high performance level gauging in
various types of storage tanks. It measures the distance to a liquid in a tank for Safety
Instrumented Systems. The SIL Alarm Relay output is used for alarm indication of overfill and
dry-run risk. Non safety-related instruments such as temperature sensors, remote display units,
water level sensors, pressure sensors, and other instruments can be connected. The non-safety
related instruments must not be used in Safety Instrumented Systems but can be connected
independently to the same system without affecting the safety function.
The Rosemount Tank Gauging Safety System is intended for use as a level measurement sensor
in safety instrumented functions (SIF) designed per IEC 61511. It is comprised of the following
main elements:
Rosemount 5900
The Rosemount 5900 is a radar level gauge developed for a wide range of applications at bulk
liquid storage facilities. Different antennas can be used in order to meet the requirements of
different applications. The 2-in-1 version of the Rosemount 5900 has two independent and
galvanically isolated radar modules in the same transmitter enclosure using a single antenna.
The Rosemount 5900 outputs an intrinsically safe SIL Alarm signal which is connected to the
Rosemount 2410.
Rosemount 2410
The Rosemount 2410 acts as a power supply to the connected Rosemount 5900 using the
intrinsically safe Tankbus. The Rosemount 2410 provides the SIL Alarm relay output and digital
communication allowing connection of configuration tools or safety control system.

6
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product
3.2 Certification
The Rosemount Tank Gauging Safety System is designed for applications in high demand mode
operation (demand rate of 1 per week).
The Rosemount Tank Gauging Safety System is certified to:
Low/High Demand of operation
Systematic Capability: SIL 3 capable
Random Capability for type B device:
- 1 in 1 SIL2: SIL 3 @ HFT=1, SIL 2 @ HFT=0
- 2 in 1 SIL2: SIL 3 @ HFT=1, SIL 2 @ HFT=0
- 2 in 1 SIL3: SIL 3 @ HFT=0, SIL 2 @ HFT=0
3.2.1 Assumptions and restrictions for the usage of the product
Install the Rosemount Tank Gauging Safety System according to the instructions in this manual
(Rosemount 5900 Radar Level Gauge and 2410 Tank Hub Safety Manual, Document No.
00809-0200-5100).
The following documents provide further instructions for a safe installation:
Rosemount Tank Gauging System Configuration Reference Manual (Document No.
00809-0300-5100)
Rosemount 2410 Tank Hub Reference Manual
(Document No. 00809-0100-2410)
Rosemount 5900S Radar Level Gauge Reference Manual
(Document No. 00809-0100-5900)
Rosemount 5900C Radar Level Gauge Reference Manual
(Document No. 00809-0100-5901)
Note
The Rosemount 5900 Radar Level Gauge is not safety-rated during maintenance work,
configuration changes, or other activity that affects the Safety Function. Alternative means
should be used to ensure process safety during such activities.
It is important that the Rosemount Tank Gauging Safety System is installed and used in
appropriate applications as described in relevant installation instructions. Otherwise the
required functional safety may not be maintained.
The instruments in a Rosemount Tank Gauging System must be operated within specified
environmental conditions. Operating conditions are available in the Rosemount Tank Gauging
System Data Sheet, Document No. 00813-0100-5100.
If there are any echoes measured by the Rosemount 5900 which cannot be traced back to the
product surface, note if there are any objects such as beams, heating coils etc. in the tank
corresponding to the found echoes. Appropriate action has to be taken if the disturbing echoes
affect measurement performed, please contact Emerson Process Management/Rosemount
Tank Gauging for advice.

7
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product
Disturbing echoes within the radar beam from flat obstructions with a sharp edge may lead to a
situation where the Rosemount Tank Gauging Safety System can no longer be used for safety
related functions.
The Rosemount Tank Gauging Safety System is designed for a level rate of up to 50 mm (2
inches) per second.
In addition to the requirements mentioned above, the following constraints apply for the
Rosemount Tank Gauging Safety System:
Turbulent product surface is not permitted
Foam on top of the product surface is not permitted
Solid products are not permitted
Level rate may not exceed 50 mm/s (2 in./s)
Still-pipe Array Antenna with hinged hatch
The Rosemount 5900 Radar Level Gauge including the SIL alarm output is not safety-rated
during maintenance work. This includes opening of the 5900 still-pipe array antenna, hinged
hatch version during for example manual gauging (hand-dip) or product sampling.
During hatch opening, system will go to de-energized state (alarm). If needed, alternative
means should be used to ensure process safety during opening of hatch.

8
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product
3.2.2 Functional specification of the safety function
The Rosemount Tank Gauging Safety System provides a SIL Alarm Relay output to indicate
overfill or dry-run risk. No other output is related to the safety function.
The Rosemount Tank Gauging Safety System provides the following safety functions:
Measures the distance from the SIL Reference Point to the surface of a liquid in a tank
De-energizes (alarm) a safety critical output signal upon passing the configured SIL
High or Low Alarm Limits, where these limits are defined as distances from the SIL
Reference Point
The Rosemount Tank Gauging Safety System contains advanced self-diagnostics; internal
monitoring features, and is programmed to go to de-energized state (alarm) upon detection of
an internal failure.
Safety architecture
The Rosemount Tank Gauging Safety System offers various models in order to support different
system configurations.
SIL 2 1-in-1 (1oo1D)
Single channel architecture (1oo1D) complying with SIL 2. This version includes one
5900 Radar Level Gauge, one antenna, and one 2410 Tank Hub.
SIL 2 2-in-1 (1oo1D)
Single channel architecture (1oo1D) complying with SIL 2. This version includes one
“2-in-1” 5900 Radar Level Gauge, one antenna, and one 2410 Tank Hub.
SIL 3 2-in-1 (1oo2D)
Dual channel architecture (internal 1oo2D) complying with SIL 3 - high reliability
version. Voting is performed in terminal block of 5900 Radar level gauge. This version
includes one “2-in-1” 5900 Radar Level Gauge, one antenna, and one 2410 Tank Hub.
In addition to the options described above, the customer can implement a system that
complies with SIL 3 by having voting (1oo2D) performed in a safety logic solver. This
version includes two Rosemount Tank Gauging Safety Systems with single channel
architecture complying with SIL 2 (two 5900 Radar Level Gauges, two antennas, and
two 2410 Tank Hubs).

9
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product
3.2.3 Maintenance
The proof test procedure should be carried out at regular intervals as described in Section 5:
Proof Test.
Some applications may require periodic cleaning to ensure antenna contamination does not
affect the measurement performance.
The devices in the Rosemount Tank Gauging Safety System may only be repaired or modified by
authorized personnel trained by Emerson Process Management / Rosemount Tank Gauging.
For upgrade of firmware, use the procedure in the Rosemount 5900S Radar Level Gauge
Reference Manual (00809-0100-5900). Check release notes prior to upgrade, see the
Rosemount Tank Gauging web site www.rosemount-tg.com.

10
Safety Manual
00809-0200-5100, Rev GB
Scope of the Product
February 2017
Scope of the Product

11
Safety Manual
00809-0200-5100, Rev GB
Installation and Configuration
February 2017
Installation and Configuration
Section 4 Installation and Configuration
4.1 Installation and commissioning
Before the actual safety configuration takes place, the Rosemount™Tank Gauging Safety System
shall be installed and configured as described in the following manuals:
Rosemount 2410 Reference Manual
(Document No. 00809-0100-2410)
Rosemount 5900S Reference Manual
(Document No. 00809-0100-5900)
Rosemount 5900C Reference Manual
(Document No. 00809-0100-5901)
Rosemount Tank Gauging System Configuration Manual (Document No.
00809-0300-5100)
Rosemount 5900 Instruction for Installation, Configuration, and Operation of Proof
Test Function with Reference Reflector (Document No. 00809-0200-5900)
When the devices are up and running proceed with the Safety Alarm configuration as described
in “Safety alarm setup” on page 19.
Note
Installation drawings must be considered for installation of devices in a Rosemount Tank
Gauging Safety System.

12
Safety Manual
00809-0200-5100, Rev GB
Installation and Configuration
February 2017
Installation and Configuration
4.1.1 Wiring diagram
Figure 4-1. Wiring diagram for Rosemount 2410 and Rosemount 5900 with SIL option
See installation drawings as specified in Table 4-1 on page 13 for more information on wiring the
2410 Tank Hub and the 5900 Radar Level Gauge.
Rosemount 5900
Radar Level Gauge
Rosemount 2410
Tank Hub
SIL Alarm Relay Output
SIL Alarm
Tankbus
Intrinsically Safe (Exi)Non-Intrinsically Safe
(Exd/Exe)
Power
Supply
Configuration (not
part of the safety
function)

13
Safety Manual
00809-0200-5100, Rev GB
Installation and Configuration
February 2017
Installation and Configuration
Table 4-1. Installation drawings for the Rosemount 5900 and 2410 Safety Instrumented
System
Drawing Issue Title
D9240041-963 3Electrical Installation Drawing 5900 Series 1-in-1
(1oo1D) SIL 2
D9240041-964 2Electrical Installation Drawing 5900 Series 2-in-1
(1oo2D) SIL 3
D9240041-965 4Electrical Installation Drawing SIL 2 1-in-1 (1oo1D)
D9240041-966 3Electrical Installation Drawing SIL 3 2-in-1 System
D9240041-967 2Electrical Installation Drawing Dual SIL 2 Single Gauges
D9240041-968 4Electrical Installation Drawing 2410 Tank Hub SIL
Version
D7000002-167 1Electrical Installation Drawing SIL 2 2-in-1 (1oo1D)
System
D7000002-168 1Electrical Installation Drawing 5900 Series 2-in-1
(1oo1D) SIL 2
D7000001-598 2Reference Reflector for Array Antenna
D7000001-610 1Reference Reflector for Parabolic Antenna

14
Safety Manual
00809-0200-5100, Rev GB
Installation and Configuration
February 2017
Installation and Configuration
4.1.2 The Rosemount 5900 terminal block
Terminal block connections for the Rosemount 5900 with SIL option:
Figure 4-2. 5900 terminal compartment
Table 4-2. 5900 terminal block connections with SIL alarm output
See “Wiring diagram” on page 12 for information on how to connect a Rosemount 5900 Radar
Level Gauge to a Rosemount 2410 Tank Hub in a Rosemount Tank Gauging Safety System.
Connection SIL Safety System
X1: Primary Tankbus in Intrinsically safe Tankbus input, power and communication
X2: Alarm SIL alarm output
(connect to Exi terminal block on Rosemount 2410 Tank Hub)
Note! There are different terminal blocks for SIL 2 and SIL 3.
X3: Primary Tankbus out Optional jumpers between X3 and X4 for connection to second level
gauge when using the 2-in-1 version of the Rosemount 5900 for SIL 3
installations. No jumpers are used for SIL 2.
X4: Secondary Tankbus in
Test terminals Test terminals for temporary connection of a handheld communicator
such as the Rosemount 475 Field Communicator
Ground terminals, internal
SIL Alarm
Tankbus
Rosemount 5900 Radar Level Gauge
Test terminals
FB+
FB-
2-in-1: jumpers between X3
and X4 for connection to
second level gauge
Label that indicates SIL Level SIL 3 or SIL 2