Emerson Rosemount 5408 User manual

Reference Manual
00809-0100-4408, Rev CE
March2023
Rosemount™ 5408 and 5408:SIS Level
Transmitters
Non-Contacting Radar with HART® Protocol

Safety messages
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.
Ensure 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 Product
Certifications document and System Control Drawing.
WARNING
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 that 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.
WARNING
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.
Ensure 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.
2

WARNING
Process leaks could result in death or serious injury.
Ensure that the transmitter is handled carefully. If the process seal is damaged, gas might escape from the tank.
WARNING
Any substitution of non-recognized parts may jeopardize safety. Repair (e.g. substitution of components) may
also jeopardize safety and is not allowed under any circumstances.
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.
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 in 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
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause
inaccurate readings.
For information on Rosemount nuclear-qualified products, contact your local Rosemount Sales Representative.
CAUTION
Hot surfaces
The flange and process seal may be hot at high process temperatures. Allow to cool before servicing.
3

4

Contents
Chapter 1 Introduction...............................................................................................................................7
1.1 Using this manual........................................................................................................................7
1.2 NAMUR NE 53 revision history...................................................................................................8
1.3 Product certifications.................................................................................................................. 8
1.4 Product recycling/disposal......................................................................................................... 8
Chapter 2 Transmitter overview............................................................................................................... 9
2.1 Measurement principle...............................................................................................................9
2.2 Process characteristics................................................................................................................9
2.3 Vessel characteristics................................................................................................................11
2.4 Application examples................................................................................................................11
2.5 Components of the transmitter...............................................................................................13
2.6 System integration.................................................................................................................... 14
Chapter 3 Mechanical installation.......................................................................................................... 17
3.1 Safety messages........................................................................................................................17
3.2 Confirm approval type..............................................................................................................18
3.3 Installation considerations.......................................................................................................18
3.4 Mounting preparations............................................................................................................ 27
3.5 Mount the cone antenna..........................................................................................................31
3.6 Mount the process seal antenna.............................................................................................43
3.7 Mount the parabolic antenna.................................................................................................. 47
3.8 Adjust display orientation (optional).......................................................................................64
Chapter 4 Electrical installation..............................................................................................................67
4.1 Safety messages........................................................................................................................67
4.2 Hazardous areas........................................................................................................................68
4.3 Prepare the electrical connections..........................................................................................68
4.4 Connect wiring and power up................................................................................................. 71
4.5 Optional devices........................................................................................................................ 75
Chapter 5 Configuration.......................................................................................................................... 77
5.1 Safety messages........................................................................................................................77
5.2 Overview.....................................................................................................................................77
5.3 Configuration tools................................................................................................................... 77
5.4 Confirm correct device driver.................................................................................................. 78
5.5 Rosemount Radar Master Plus................................................................................................ 78
5.6 Confirm HART® revision capability.......................................................................................... 79
5.7 Configure transmitter using guided setup............................................................................ 79
5.8 Run verify level...........................................................................................................................80
5.9 Multidrop communication....................................................................................................... 80
5.10 Use with the Rosemount 333 HART® Tri-Loop™...................................................................80
5.11 Write protect a transmitter.................................................................................................... 81
Chapter 6 Operation................................................................................................................................. 83
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Rosemount 5408 and 5408:SIS Level Transmitters 5

6.1 LCD display screen messages..................................................................................................83
6.2 Select the display variables...................................................................................................... 84
6.3 View measurement data.......................................................................................................... 85
6.4 Check device status...................................................................................................................85
6.5 Smart echo level test.................................................................................................................88
Chapter 7 Service and troubleshooting................................................................................................. 91
7.1 Safety messages........................................................................................................................91
7.2 Diagnostic messages per NAMUR NE 107............................................................................. 92
7.3 Troubleshooting guides......................................................................................................... 103
7.4 Service and troubleshooting tools........................................................................................ 118
7.5 Application challenges............................................................................................................129
7.6 Replace the transmitter head................................................................................................ 140
7.7 Cleaning or replacing the PTFE sealing................................................................................ 143
7.8 Service support........................................................................................................................147
Appendix A Specifications and reference data...................................................................................... 149
A.1 Performance specifications................................................................................................... 149
A.2 Functional specifications........................................................................................................152
A.3 Physical specifications............................................................................................................ 161
A.4 Spare parts list - transmitter head........................................................................................163
A.5 Spare parts list - antenna.......................................................................................................168
A.6 Availability of process connections.......................................................................................175
A.7 Accessories.............................................................................................................................. 178
A.8 Dimensional drawings............................................................................................................179
Appendix B Configuration parameters................................................................................................... 189
B.1 Menu tree.................................................................................................................................189
B.2 Device setup............................................................................................................................ 190
B.3 Level setup...............................................................................................................................194
B.4 Alert setup................................................................................................................................212
Contents Reference Manual
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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 and 5408:SIS Level Transmitters – 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 for spare parts and accessories.
Configuration parameters provides extended information about the configuration
parameters.
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1.2 NAMUR NE 53 revision history
The Rosemount 5408 meets the NAMUR recommendation NE 53. Table 1-1 provides the
information necessary to ensure you have the correct device driver for your device.
Table 1-1: Identification and Compatibility According to NAMUR NE 53
Release
date
Device identification FDI, DD, and DTM
identification
Release note
NAMUR
hardware
revision(1)
NAMUR
software
revision(1)
Device
software
revision(2)
HART®
universal
revision(3)
Device
revision(4)
March-17 1.0.xx 1.0.xx 1.Axx 6 1 Initial release
7 1
May-19 1.1.xx 1.1.xx 1.Axx 6 1 Updated design of the cone antenna
(PEEK seal) and new device software
to support the change
7 1
September-
21
1.1.xx 1.1.xx 1.Cxx 6 1 Added Smart Echo Level Test
functionality
7 1
(1) NAMUR Revision is located on the transmitter label. Differences in level 3 changes, signified above by xx,
represent minor product changes as defined per NE53. Compatibility and functionality are preserved and
product can be used interchangeably.
(2) Device software revision is located on the transmitter label, e.g. 1.A3. It can also be found in Rosemount
Radar Master Plus (select Overview → Device Information → Revisions).
(3) HART Revision 6 and 7 can be switched in field. Default HART universal revision from factory is located on the
transmitter head label, e.g. PROTOCOL 6.
(4) Device revision is located on the transmitter label, e.g. DEVICE REV 1.
Related information
Confirm correct device driver
1.3 Product certifications
See the Rosemount 5408 Product Certifications document for detailed information on the
existing approvals and certifications.
1.4 Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of
in accordance with local and national legislation or regulations.
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2 Transmitter overview
2.1 Measurement principle
The Rosemount 5408 is a two-wire transmitter for continuous level measurements using
fast-sweep Frequency Modulated Continuous Wave (FMCW) technology.
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.
Figure 2-1: FMCW-method
GILQIPD[IPLQIRXWILQIRXWWI$&'%
Δf∼d=distance
A. Frequency (GHz)
B. Time (s)
C. Transmitted signal
D. Reflected signal
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
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Rosemount 5408 and 5408:SIS Level Transmitters 9

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
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 and 5408:SIS are 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).
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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.
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.
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Still pipe and chamber installations
The Rosemount 5408 is a great choice for level measurement in tanks with small diameter
still pipes. It may also be used in chambers, but guided wave radar is generally the best fit
for these applications.
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.
Safety applications
The Rosemount 5408:SIS is the ideal choice for safety functions such as overfill prevention,
level deviation monitoring or dry-run prevention.
SIL 2
2.5 Components of the transmitter
Figure 2-2 shows the different components of the transmitter. There are different antenna
types and sizes available for various applications.
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Figure 2-2: 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
2.6 System integration
The 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. The transmitter can be configured for either HART Revision 6 or 7. The HART
Revision can be switched in field.
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By using the optional Rosemount 333 HART Tri-Loop™, the digital HART signal can be
converted into 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 combined with the Emerson Wireless 775 THUM™ Adapter to
wirelessly communicate HART data with IEC 62591 (WirelessHART®) technology. In addition,
the transmitter can be connected to a Rosemount 751 Field Signal Indicator, or it can be
equipped with an integral display.
Figure 2-3: System Architecture
$%&()*+',
A. Emerson Wireless 775 THUM Adapter
B. Rosemount 5408
C. Rosemount 751
D. Handheld communicator
E. Approved IS barrier (for Intrinsically Safe installations only)
F. Rosemount 333
G. Host/DCS system
H. HART modem
I. PC with Rosemount Radar Master Plus
The Rosemount 5408 is compliant with NAMUR NE 107 Field Diagnostics for standardized
device diagnostic information.
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Transmitter overview Reference Manual
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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.
Ensure 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 Product Certifications document and System Control Drawing.
WARNING
Process leaks could result in death or serious injury.
Ensure that the transmitter is handled carefully. If the process seal is damaged, gas might
escape from the tank.
WARNING
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 and 5408:SIS Level Transmitters 17

3.2 Confirm approval type
For hazardous locations transmitters labeled with multiple approval types:
Procedure
Permanently mark the checkbox of the selected approval type.
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.
•Do not install the transmitter in the center of the tank.
•Do not mount close to or above the inlet stream.
•Multiple Rosemount 5408 transmitters can be used in the same tank without interfering
with each other.
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Figure 3-2: Recommended Mounting Position
/
3.3.2 Free space requirements
If the transmitter is mounted close to a wall or other tank obstruction such as heating
coils and ladders, noise might appear in the measurement signal. See Table 3-1 for
recommended clearance.
For easy access to the transmitter, mount it with sufficient service space (see Table 3-2).
Figure 3-3: Free Space Requirements
$/%
Table 3-1: Distance to Tank Wall (L)
Application Minimum Recommended
Liquids 8 in. (200 mm) ½ of tank radius
Solids 8 in. (200 mm) ⅔ of tank radius
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Table 3-2: Free Space Requirements
Description Distance
Service space width (A) 20 in. (500 mm)
Service space height (B) 24 in. (600 mm)
3.3.3 Antenna size
Choose as large antenna diameter as possible. A larger antenna diameter concentrates the
radar beam and ensures maximum antenna gain. Increased antenna gain permits greater
margin for weak surface echoes.
In addition, a larger antenna diameter results in a smaller beam angle and thereby, less
interference from any internal structures in the tank.
3.3.4 Antenna inclination
Ensure the antenna is aligned perpendicular to the product surface (see Figure 3-4). The
parabolic antenna comes with a swivel connection that adjusts for angled tank roofs.
Note that if the surface echo is weak in solids applications, then a small inclination of the
parabolic antenna toward the surface slope may improve the performance.
Figure 3-4: Inclination
Max. 1.5°
90°
A
B
90°
Max. 3°
A. Cone antenna/process seal antenna
B. Parabolic antenna
3.3.5 Non-metallic tanks
Nearby objects outside the tank may cause disturbing radar echoes. Wherever possible,
the transmitter should be positioned so that objects close to the tank are kept outside the
signal beam.
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