Emerson Rosemount 5900 User guide

Safety Manual
00809-0400-5100, Rev AB
November 2019
Rosemount™5900 Radar Level Gauge and
2410 Tank Hub
Safety Manual for Use in Safety Instrumented Systems
SIL 2 Model Code Option S

Safety Manual
00809-0400-5100, Rev AB
November 2019

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Safety Manual
00809-0400-5100, Rev AB
Contents
November 2019
Contents
Contents
1Section 1: Safety Instrumented System
1.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Purpose of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Assumptions and restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety Instrumented System (SIS) certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.1 Still-pipe Array Antenna with hinged hatch . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety-certified identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Functional specification of the safety function. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5.1 Safety architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2Section 2: Installation and Configuration
2.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Installation in SIS applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3 Configuration in SIS applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 Analog output configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.2 Relay configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.4 Write protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5 Site acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3Section 3: Operation and Maintenance
3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3 Proof test methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4 Comprehensive proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.4.1 Filling and emptying the tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Partial proof test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.5.1 High level alarm test with reference reflector . . . . . . . . . . . . . . . . . . . . . . .19
3.5.2 High level alarm test with simulated reflector. . . . . . . . . . . . . . . . . . . . . . .23
3.5.3 One-point level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.5.4 Relay output verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.5.5 Analog output verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
AAppendix A: Specifications and Reference Data
A.1 SIS reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
A.1.1 Failure rate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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A.1.2 Failure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
A.2 Product life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
BAppendix B: Terms and Definitions
CAppendix C: Dry-run Configuration

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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 which is not made by
Rosemount Tank Radar AB.

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Safety Manual
00809-0400-5100, Rev AB
Safety Instrumented System
November 2019
Safety Instrumented System
Section 1 Safety Instrumented System
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Safety Instrumented System (SIS) certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Safety-certified identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Functional specification of the safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
1.1 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 hand held 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.
Electrical shock could cause death or serious injury
Use extreme caution when making contact with the leads and terminals.
Physical access
Unauthorized personnel may potentially cause significant damage to and/or
misconfiguration of end user’s equipment. This could be intentional or unintentional
and needs to be protected against.
Physical security is an important part of any security program and fundamental to
protecting your system. Restrict physical access by unauthorized personnel to protect
end user’s assets. This is true for all systems used within the facility.

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1.2 Introduction
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.
1.2.1 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. Two relays and one 4-20 mA analog output are available for
alarm indication and overfill and dry run risk. Non safety-related instruments such as level
transmitters, temperature sensors, remote display units, water level sensors, pressure
sensors, and other instruments can be connected.
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.
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 analog 4-20 mA outputs and
relay output and digital communication allowing connection of configuration tools or
safety control system.
1.2.2 Assumptions and restrictions
Note that the Rosemount 5900 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.
False echoes within the radar beam from flat obstructions with a sharp edge may lead to a
situation where the Rosemount 5900 can no longer be used for safety related functions
with the listed failure rates, Safe Failure Fraction and PFDAVG. However, reduced proof test
intervals can help to detect such unwanted causes.

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1.3 Safety Instrumented System (SIS) 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 and High Demand of operation
Systematic Capability: SC 3 (SIL 3 capable)
Random Capability for type B device:
- 1 in 1 SIL 2 @ HFT=0
- 2 in 1 SIL 2 @ HFT=0
Note
Refer to the Rosemount 5900/2410 FMEDA report for failure rate data, assessment details,
and assumptions regarding failure rate analysis.
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, that correspond to the found echoes. Appropriate action has to be taken if the
disturbing echoes affect measurement performed, please contact Emerson Process Man-
agement/Rosemount Tank Gauging for advice.
1.3.1 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 Rosemount 5900 Still-pipe Array
antenna, hinged hatch version during for example manual gauging (hand-dip) or product
sampling.
During hatch opening, system may go to de-energized state (alarm). If needed, alternative
means should be used to ensure process safety during opening of hatch.

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1.4 Safety-certified identification
All Rosemount 5900 Radar Level Gauges and Rosemount 2410 Tank Hubs must be identified
as safety-certified before installing into SIS systems. Table 1-1 lists the versions of the
Rosemount 5900/2410 Series devices that have been considered for the functional safety
assessment, to which this manual applies.
Models with the S option code are IEC 61508 certified by an accredited 3rd party
agency for use in safety instrumented systems up to SIL 2.
Table 1-1. Rosemount Tank Gauging System (4-20 mA Analog Output)
Table 1-2. Rosemount Tank Gauging System (Standard K1/K2 Relay Output)
To identify a Rosemount 5900 and Rosemount 2410 safety-certified device:
Verify the option code Sin the model code, on the label affixed to the outside of the
transmitter head.
Check if a yellow label is affixed to the transmitter head for option code S.
Before doing any configuration, write down the Device Id from the label, and make
sure you are connected to the correct transmitter by verifying the same Device Id
in your communication device.
Hardware
Rosemount 5900 Radar Level Gauge
(type B) Model Code S
Rosemount 2410 Tank Hub Model Code S
Primary Field Bus Model Code B
Secondary Field Bus Model Code A, B, C, D
Software/Firmware
Rosemount 5900 Radar Level Gauge
(type B) Sw 1.B5 and further
Rosemount 2410 Tank Hub Sw 1.B1 and further
Hardware
Rosemount 5900 Radar Level Gauge
(type B) Model Code S
Rosemount 2410 Tank Hub Model Code S
Relay Option 1xSPST Model Code 1
Relay Option 2xSPST Model Code 2
Software/Firmware
Rosemount 5900 Radar Level Gauge
(type B) Sw 1.B5 and further
Rosemount 2410 Tank Hub Sw 1.B1 and further

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1.5 Functional specification of the safety function
The safety function is based on the analog output 4-20 mA or K1/K2 relay outputs.
If a measured value goes beyond the measurement range, the transmitter enters saturation
mode (limit alarm is disabled) or alarm mode, depending on the current configuration.
The Rosemount Tank Gauging Safety System provides either:
one or two relay outputs, and/or
one 4-20 mA output
and measures the distance from the Gauge reference point to the surface of a liquid in a
tank.
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.
1.5.1 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 Rosemount 5900 Radar Level Gauge, one antenna, and one
Rosemount 2410 Tank Hub.
SIL 2 2-in-1 (1oo1D)
Single channel architecture (1oo1D) complying with SIL 2. This version includes
one “2-in-1” Rosemount 5900 Radar Level Gauge, one antenna, and one
Rosemount 2410 Tank Hub.

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Installation and Configuration
Section 2 Installation and Configuration
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Installation in SIS applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Configuration in SIS applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Write protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Site acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
2.1 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 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 hand held 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.
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.

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Installation and Configuration
2.2 Installation in SIS applications
The Rosemount™5900 Radar Level Gauge and Rosemount 2410 Tank Hub should be
installed and configured as described in the reference manual. The materials must be
compatible with process conditions and process fluids. No special installation is required in
addition to the standard installation practices outlined in the reference manuals:
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)
Rosemount Tank Gauging System Configuration Manual
(Document No. 00809-0300-5100)
Note
Installation drawings must be considered for installation of devices in a Rosemount Tank
Gauging Safety System.
Note
The Rosemount 5900 Radar Level Gauge and Rosemount 2410 Tank Hub are 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.

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2.3 Configuration in SIS applications
2.3.1 Analog output configuration
Alarm and saturation levels
DCS or safety logic solver should be configured to handle both High alarm and Low alarm. It
is also required that the transmitter is configured for High or Low alarm. Figure 2-1
identifies the alarm levels available and their operation values.
Figure 2-1. Alarm Levels and Operation Values
It is assumed that the current output signal is fed to a SIL 2-compliant analog input board of
a safety logic solver.
Note
Only the High or Low Alarm Mode can be used for the safety function. Do not choose Freeze
Current.
Note
A Low Alarm will be triggered in case of a hardware fault on the Analog Output card.
Rosemount Alarm Level
Normal Operation
3.75 mA(1)
1. Transmitter Failure, hardware or software alarm in Low position.
4 mA 20 mA 21.75 mA(2)
3.9 mA
low saturation
20.8 mA
high saturation
Namur Alarm Level
Normal Operation
3.6 mA(1) 4 mA 20 mA 22.5 mA(2)
2. Transmitter Failure, hardware or software alarm in High position.
3.8 mA
low saturation
20.5 mA
high saturation

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Analog output configuration in TankMaster
To configure the Rosemount 2410 Tank Hub analog output:
1. In the WinSetup workspace click the right mouse button on the tank hub icon and
choose the Properties option.
2. Select the Configuration tab.
3. Click the Analog Output button to open the Analog Output Configuration
window(1).
4. Check the Enable box to activate the analog output option.
5. Configure Source Parameter, Value Range, and Alarm Mode. See Appendix C in the
Rosemount 2410 Tank Hub Reference Manual(2) for more information on how to
configure the analog output.
Note
In case a Proof Test Reference Reflector is used, make sure that the Value at 20 mA is set
above the position of the reflector.
1. Note that this button is available if the Analog Output option is activated for the Rosemount 2410 Tank Hub.
2. Document No 00809-0100-2410
Enable

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2.3.2 Relay configuration
To configure Rosemount 2410 Tank Hub relays:
1. In the WinSetup workspace click the right mouse button on the tank hub icon,
choose Properties and select the Configuration tab.
2. Click one of the Virtual Relay No. buttons. See Appendix C in the Rosemount 2410
Tank Hub Reference Manual(1) for more information on how to configure relays.
Normally Open/Normally Closed
Normally Open (NO) is the default setting for the Rosemount 5900 and Rosemount 2410 in
Safety Instrumented Systems (SIS). Verify the relay configuration by, for example, using the
proof test function Relays K1/K2 Verification Test. See “Maintenance” on page 29 for more
information.
See the Rosemount 2410 Tank Hub Reference Manual(1) for more information on the
Rosemount 2410 relays.
Note
In case a Proof Test Reference Reflector is used, make sure that the relay set point is set
below the position of the reflector.
1. Document No 00809-0100-2410

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2.4 Write protection
A Rosemount Tank Gauging safety-certified system should always be write protected in
order to avoid unintentional configuration changes. The Rosemount 5900 Radar Level
Gauge as well as the Rosemount 2410 Tank Hub should be write protected.
It is recommended to use one of the following write protection options:
Hardware switch
Software password protected function
See the appropriate reference manuals listed in “Installation in SIS applications” on page 8
for more information on how to enable write protection.
2.5 Site acceptance
After installation and/or configuration, proper operation of the transmitter (including
verification of all configuration changes) must be verified. A site acceptancetest is therefore
required. The proof test outlined in this document can be used for this.

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Operation and Maintenance
Section 3 Operation and Maintenance
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
Proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
Proof test methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Comprehensive proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Partial proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
3.1 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 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 hand held 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.
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.

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Operation and Maintenance
3.2 Proof test
The purpose of proof testing is to identify dangerous undetected failures. Proof testing may
be divided into comprehensive and partial testing. For the Rosemount™5900 Radar Level
Gauge and the Rosemount 2410 Tank Hub, a comprehensive proof test includes the
following functional elements:
Output circuitry (relay, analog output)
Measurement electronics (digital signal processing)
Sensing element (antenna, microwave unit)
A partial test may include one or more of these elements.
The Rosemount TankMaster software supports proof testing of the Rosemount 5900 Level
Gauge and the Rosemount 2410 Tank Hub.
The Rosemount Tank Gauging Safety System should be checked at regular intervals in order
to detect Dangerous Undetected (DU) failures. The time periods depend on the PFDavg
value.
Note
Proof test for PFDavg calculations is only applicable for Low Demand mode.
One or more of the proof tests described below are recommended.
Make sure to enable write protection as soon as you are finished.
Note
The Rosemount 5900 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.
Note
Before every test, make sure you are connected to the correct transmitter by verifying Sin
the model code on the label and your software version. Also verify that the Device Id on the
label matches the one in your configuration tool.