Emerson Rosemount 5408 User manual

Reference Manual
00809-0300-4408, Rev AA
June 2019
Rosemount™ 5408 Level Transmitter
Non-Contacting Radar with FOUNDATION™ Fieldbus Protocol

Rosemount™ 5408 Level Transmitter – Non-Contacting Radar
NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum product performance, make
sure you thoroughly understand the contents before installing, using, or maintaining this product.
For technical assistance, contacts are listed below:
Customer Central
Technical support, quoting, and order-related questions.
•United States - 1-800-999-9307 (7:00 am to 7:00 pm CST)
•Asia Pacific- 65 777 8211
North American Response Center
Equipment service needs.
•1-800-654-7768 (24 hours a day — includes Canada)
•Outside of these areas, contact your local Emerson representative.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or serious injury.
•Make sure the transmitter is installed by qualified personnel and in accordance with applicable code of practice.
•Use the equipment only as specified in this manual. Failure to do so may impair the protection provided by the equipment.
•For installations in hazardous locations, the transmitter must be installed according to the Rosemount 5408 and 5408:SIS
Product Certifications document and System Control Drawing (D7000002-885).
Explosions could result in death or serious injury.
•Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications.
•Before connecting a handheld communicator in an explosive atmosphere, ensure the instruments are installed in accordance
with intrinsically safe or non-incendive field wiring practices.
•In Explosion-proof/Flameproof and Non-Incendive/Type n installations, do not remove the transmitter covers when power is
applied to the unit.
•Both transmitter covers must be fully engaged to meet Explosion-proof/Flameproof requirements.
Electrical shock could cause death or serious injury.
•In Explosion-proof/Flameproof and Non-Incendive/Type n installations, avoid contact with the leads and terminals. High
voltage that may be present on leads can cause electrical shock.
•Make sure the mains power to the transmitter is off and the lines to any other external power source are disconnected or not
powered while wiring the transmitter.
Process leaks could result in death or serious injury.
•Make sure that the transmitter is handled carefully. If the process seal is damaged, gas might escape from the tank.
Any substitution of non-recognized parts may jeopardize safety. Repair, e.g. substitution of components etc., may also jeopardize
safety and is under no circumstances allowed.
•Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance
and jeopardize safety. Unauthorized changes that interfere with the integrity of the welds or flanges, such as making
additional perforations, compromise product integrity and safety. Equipment ratings and certifications are no longer valid on
any products that have been damaged or modified without the prior written permission of Emerson. Any continued use of
product that has been damaged or modified without the written authorization is at the customer’s sole risk and expense.
2

WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ 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 users’ assets. This is true for all systems used within the facility.
CAUTION
Hot surfaces
The flange and process seal may be hot at high process temperatures. Allow to cool before servicing.
CAUTION
The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified
products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on
Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.
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4

Contents
Chapter 1 Introduction.................................................................................................................. 9
1.1 Using this manual.............................................................................................................................9
1.2 Product recycling/disposal................................................................................................................9
Chapter 2 Transmitter overview...................................................................................................11
2.1 Measurement principle...................................................................................................................11
2.2 Process characteristics....................................................................................................................12
2.3 Vessel characteristics......................................................................................................................14
2.4 Application examples..................................................................................................................... 14
2.5 Components of the transmitter......................................................................................................16
2.6 System integration.........................................................................................................................18
Chapter 3 Mechanical installation................................................................................................ 19
3.1 Safety messages.............................................................................................................................19
3.2 Confirm approval type....................................................................................................................20
3.3 Installation considerations..............................................................................................................20
3.4 Mounting preparations...................................................................................................................30
3.5 Mount the cone antenna................................................................................................................ 34
3.6 Mount the process seal antenna..................................................................................................... 46
3.7 Mount the parabolic antenna......................................................................................................... 49
3.8 Adjust display orientation (optional)...............................................................................................64
Chapter 4 Electrical installation....................................................................................................65
4.1 Safety messages.............................................................................................................................65
4.2 Hazardous areas............................................................................................................................. 66
4.3 Prepare the electrical connections..................................................................................................66
4.4 Connect wiring and power up.........................................................................................................69
Chapter 5 Configuration...............................................................................................................73
5.1 Safety messages.............................................................................................................................73
5.2 Overview........................................................................................................................................ 73
5.3 System readiness............................................................................................................................74
5.4 Get started with your preferred configuration tool......................................................................... 74
5.5 Change device mode......................................................................................................................76
5.6 Configure transmitter using Guided Setup..................................................................................... 77
5.7 Verify level......................................................................................................................................78
5.8 Write protect a transmitter.............................................................................................................79
Chapter 6 Operation.................................................................................................................... 81
6.1 LCD display screen messages..........................................................................................................81
6.2 Set up the LCD display.................................................................................................................... 82
6.3 View measurement data.................................................................................................................83
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6.4 Device status.................................................................................................................................. 85
Chapter 7 Service and troubleshooting........................................................................................ 89
7.1 Safety messages............................................................................................................................. 89
7.2 Diagnostic messages...................................................................................................................... 89
7.3 FOUNDATION™ Fieldbus error messages.............................................................................................96
7.4 Troubleshooting guides..................................................................................................................99
7.5 Service and troubleshooting tools................................................................................................ 105
7.6 Application challenges................................................................................................................. 119
7.7 Replace the transmitter head....................................................................................................... 127
7.8 Cleaning or replacing the PTFE sealing..........................................................................................129
7.9 Service support............................................................................................................................ 133
Appendix A Specifications and reference data............................................................................... 135
A.1 Performance specifications.......................................................................................................... 135
A.2 Functional specifications.............................................................................................................. 138
A.3 Physical specifications.................................................................................................................. 148
A.4 Ordering Information................................................................................................................... 151
A.5 Availability of process connections............................................................................................... 156
A.6 Spare parts and accessories..........................................................................................................157
A.7 Dimensional drawings..................................................................................................................164
Appendix B Product Certifications................................................................................................ 173
B.1 European directive information.................................................................................................... 173
B.2 Ordinary location certification...................................................................................................... 173
B.3 Telecommunication compliance.................................................................................................. 173
B.4 FCC...............................................................................................................................................173
B.5 IC..................................................................................................................................................174
B.6 Radio Equipment Directive (RED) 2014/53/EU..............................................................................175
B.7 Installing equipment in North America......................................................................................... 175
B.8 USA.............................................................................................................................................. 175
B.9 Canada......................................................................................................................................... 181
B.10 Europe........................................................................................................................................187
B.11 International.............................................................................................................................. 192
B.12 Additional certifications............................................................................................................. 196
B.13 Installation drawings.................................................................................................................. 197
Appendix C Configuration parameters..........................................................................................207
C.1 Menu tree.................................................................................................................................... 207
C.2 Device setup................................................................................................................................ 208
C.3 Level setup................................................................................................................................... 211
C.4 Alert setup................................................................................................................................... 228
Appendix D FOUNDATION™ Fieldbus Block Information................................................................ 233
D.1 Resource block.............................................................................................................................233
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D.2 Analog Input block.......................................................................................................................239
D.3 Measurement Transducer block................................................................................................... 248
D.4 Register Transducer block............................................................................................................252
D.5 Supported units........................................................................................................................... 254
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1 Introduction
1.1 Using this manual
The sections in this manual provide information on installing, operating, and maintaining
the Rosemount™ 5408 Level Transmitter – Non-Contacting Radar.
The sections are organized as follows:
Transmitter overview provides an introduction to theory of operation, a description of the
transmitter, information on typical applications, and process characteristics.
Mechanical installation contains mechanical installation instructions.
Electrical installation contains electrical installation instructions.
Configuration provides instructions on configuration of the transmitter.
Operation contains operation and maintenance techniques.
Service and troubleshooting provides troubleshooting techniques for the most common
operating problems.
Specifications and reference data supplies reference and specification data, as well as
ordering information.
Product Certifications contains safety approval information and approval drawings.
Configuration parameters provides extended information about the configuration
parameters.
FOUNDATION Fieldbus Block Information provides information regarding the function
blocks.
1.2 Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of
in accordance with local and national legislation/regulations.
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Introduction Reference Manual
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2 Transmitter overview
2.1 Measurement principle
The Rosemount™ 5408 is a two-wire transmitter for continuous level measurements over a
broad range of liquids, slurries, and solids. The measurement principle is fast-sweep
Frequency Modulated Continuous Wave (FMCW).
The transmitter continuously emits signal sweeps with a constantly varying frequency
towards the product surface. Since the transmitter continuously changes the frequency of
the transmitted signal, there will be a difference in frequency between the transmitted
and the reflected signals (see Figure 2-1).
The frequency of the reflected signal is subtracted from the frequency of the signal
transmitted at that moment, resulting in a low frequency signal which is proportional to
the distance to the product surface. This signal is further processed to obtain fast, reliable,
and highly accurate level measurements. See Figure 2-2 for a schematic overview of the
signal processing.
Figure 2-1: FMCW-method
GILQIPD[IPLQIRXWILQIRXWWI$&'%
Δf≈d=distance
A. Frequency (GHz)
B. Time (s)
C. Transmitted signal
D. Reflected signal
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Figure 2-2: Flowchart of the Signal Processing
$%&'()*+,-.
A. Microwave module
B. A/D converter
C. Fast Fourier transform (FFT)
D. Peak search
E. Peak interpolation
F. Echo tracker
G. Echo identifier
H. Distance filtering
I. Variable calculation
J. LCD handler
K. FOUNDATION™ Fieldbus
2.2 Process characteristics
2.2.1 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.
2.2.2 Foam and turbulence
Foaming liquids or turbulence may cause weak and varying surface echo amplitudes. The
effects of turbulence are usually minor, but in the most challenging conditions, the
transmitter may be mounted in a still pipe. In addition, measurement performance can be
optimized by configuring the appropriate process conditions settings.
Measurement in foamy applications depends largely on the foam properties. When the
foam is light and airy, the actual product level is measured. For heavy and dense foam, the
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transmitter may measure the level of the foam’s upper surface. The Double Surface
Handling function allows the user to select if the foam layer or product surface should be
used as output.
Related information
Process conditions
Double surface handling
2.2.3 Dust
Dust is often present in solids applications, and even if the non-contacting radar is not
affected by the dust in the vapor space, dust can be sticky and create a layer on the
antenna. If this layer becomes too thick, it may affect the measurement. This is best
managed by using air purging.
2.2.4 Solid surface
Solids have some common characteristics which may cause weak and varying surface
reflections. The surface is rarely flat or horizontal, the angle of the sloping surface differs
during filling and emptying, and the dielectric constant of many solids is fairly low. Table
2-1 presents common characteristics of some solids applications.
The parabolic antenna is ideal for applications with weak surface reflections. A larger
diameter concentrates the radar beam and ensures maximum antenna gain. The parabolic
antenna comes with a swivel connection that adjusts for angled tank roofs.
Table 2-1: Common Characteristics of Solids Applications
Applications Common characteristics
Particle size Vapor space
Dust or
powder
Small (<1 in.) Larger (>1 in.) Dust Steam or
condensation
Wood chip bins Yes Yes Yes Yes Possible
Grain silo - small kernel grains Yes Yes No Yes No
Grain silo - large kernel grains No Yes No No No
Lime stone silo No Yes Yes Possible No
Cement - raw mill silo Yes Yes No Yes No
Cement - finished product silo Yes Yes No Yes No
Coal bin Yes Yes Yes Yes Yes
Saw dust Yes Yes No Yes No
High consistency - pulp stock No No No No Yes
Alumina Yes Yes No Yes No
Salt No Yes Yes No No
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2.3 Vessel characteristics
2.3.1 In-tank obstructions
The transmitter should be mounted so that objects such as heating coils, ladders, and
agitators are not in the radar signal path. These objects may cause false echoes resulting in
reduced measurement performance. However, the transmitter has built-in functions
designed to reduce the influence from disturbing objects where such objects cannot be
totally avoided.
Vertical and inclined structures cause minimal effect since the radar signal is scattered
rather than directed back to the antenna.
2.3.2 Tank shape
The shape of the tank bottom affects the measurement signal when the product surface is
close to the tank bottom. The transmitter has built-in functions which optimize
measurement performance for various bottom shapes.
2.4 Application examples
The Rosemount 5408 is ideal for level measurements over a broad range of liquid and
solids applications. The transmitters are virtually unaffected by changing density,
temperature, pressure, media dielectric, pH, and viscosity. Non-contacting radar level is
ideal for harsh conditions such as corrosive and sticky media, or when internal tank
obstructions are a limiting factor.
Storage and buffer tanks
The Rosemount 5408 provides accurate and reliable level measurement for both metallic
or non-metallic vessels containing almost any liquid (e.g. oil, gas condensate, water,
chemicals).
Reactors
The Rosemount 5408 is ideal for the most challenging applications, including reactors
where there can be agitation, foaming, and condensation, as well as high temperatures
and pressures.
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Blenders and mixers
The Rosemount 5408 can help you withstand the rigors of blenders and mixing tanks. Easy
to install and commission, it is also unaffected by virtually any fluid property change.
Open atmospheric applications
The Rosemount 5408 measures reliably in open applications, from short range sumps or
ponds to long range dams.
Still pipe and chamber installations
The Rosemount 5408 is an excellent choice for level measurement in tanks with still pipes.
It may also be used in chambers, but guided wave radar is generally the best fit for these
applications. See Still pipe/chamber installations for installation guidelines.
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Bulk solids
The Rosemount 5408 is the ideal solution for small to medium sized silos with rapid level
changes. The narrow beam avoids internal obstructions while still keeping good level
measurement.
2.5 Components of the transmitter
Figure 2-3 shows the different components of the transmitter. There are different antenna
types and sizes available for various applications.
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Figure 2-3: Components
$%&'(*.*-,)/0+1sr23
A. Terminal compartment
B. Transmitter housing (aluminum or stainless steel)
C. Sensor module with signal processing electronics
D. External ground screw
E. Flanged process connection
F. Cone antenna
G. Two cable/conduit entries (½-14 NPT, M20 x 1.5, or G½); Optional adapters: eurofast™
and minifast™
H. LCD display (optional)
I. Alignment marker (one per side)
J. Threaded process connection (NPT or BSPP (G))
K. Air purge ring (option code PC1 for cone antenna)
L. Integrated air purge connection
M. Parabolic antenna
N. Parabolic antenna with swivel mount
O. Process seal antenna
P. Tri-Clamp® process connection
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2.6 System integration
The transmitter is loop-powered, and uses the same two wires for power supply and
output signal. FOUNDATION™ Fieldbus is an all-digital communication.
The transmitter can be connected to a Rosemount 752 Remote Indicator, or it can be
equipped with an integral display.
The transmitter can easily be configured by using a PC with the Rosemount Radar Master
Plus software (running in the Instrument Inspector™ Application), a handheld
communicator, the AMS Device Manager, or any other Device Descriptor (DD) or Field
Device Integration (FDI) compatible host system.
The Rosemount 5408 is compliant with NAMUR NE 107 Field Diagnostics for standardized
device diagnostic information.
Figure 2-4: System Architecture
*))(+$%&,'.
A. Host/DCS system (e.g. DeltaV)
B. Maintenance
C. H2 - High speed field bus
D. Handheld communicator
E. Rosemount 5408 Level Transmitter
F. Rosemount 5300 Level Transmitter
G. Rosemount 752 Remote Indicator
H. PC with Rosemount Radar Master Plus
I. Fieldbus modem
J. H1 - Low speed fieldbus
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3 Mechanical installation
3.1 Safety messages
Instructions and procedures in this section may require special precautions to ensure the
safety of the personnel performing the operations. Information that potentially raises
safety issues is indicated by a warning symbol ( ). Refer to the following safety messages
before performing an operation preceded by this symbol.
WARNING
Failure to follow safe installation and servicing guidelines could result in death or serious
injury.
•Make sure the transmitter is installed by qualified personnel and in accordance with
applicable code of practice.
•Use the equipment only as specified in this manual. Failure to do so may impair the
protection provided by the equipment.
•For installations in hazardous locations, the transmitter must be installed according to
the Rosemount 5408 and 5408:SIS Product Certifications document and System
Control Drawing (D7000002-885).
Process leaks could result in death or serious injury.
•Make sure that the transmitter is handled carefully. If the process seal is damaged, gas
might escape from the tank.
Explosions could result in death or serious injury.
•Verify that the operating atmosphere of the transmitter is consistent with the
appropriate hazardous locations certifications.
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Rosemount 5408 Level Transmitter 19

3.2 Confirm approval type
For hazardous locations transmitters labeled with multiple approval types:
Procedure
Permanently mark the checkbox of the selected approval type(s).
Figure 3-1: Label with Multiple Approval Types
3.3 Installation considerations
Before installing the transmitter, follow recommendations for mounting position,
sufficient free space, nozzle requirements, etc.
3.3.1 Mounting position
When finding an appropriate location on the tank for the transmitter, the conditions of the
tank must be carefully considered.
Consider the following guidelines when mounting the transmitter:
•For optimal performance, the transmitter should be installed in locations with a clear
and unobstructed view of the product surface.
•The transmitter should be mounted with as few internal structures as possible within
the signal beam, see Beam width and beam angle.
•Do not install the transmitter in the center of the tank.
•Do not mount close to or above the inlet stream.
•Multiple Rosemount 5408 Level Transmitters can be used in the same tank without
interfering with each other.
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