Rosemount 5402 User manual

www.rosemount.com
Reference Manual
00809-0100-4026, Rev FA
July 2009
Rosemount 5400 Series
Two-Wire Radar Level Transmitter

Reference Manual
00809-0100-4026, Rev FA
July 2009 Rosemount 5400 Series
www.rosemount.com
Rosemount 5400 Series
Rosemount 5400 Series Radar Transmitter may be protected by one or more U.S. Patents pending and foreign
patents pending.
Cover Photo: 5400_08, 5400_Process_Seal.tif, 5400_Rod.tif
NOTICE
Read this manual before working with the product. For personal and system safety, and for
optimum product performance, make sure you thoroughly understand the contents before
installing, using, or maintaining this product.
Within the United States, Emerson Process Management has two toll-free assistance
numbers.
Customer Central: 1-800-999-9307(7:00 a.m. to 7:00 p.m. CST)
Technical support, quoting, and order-related questions.
North American Response Center:
Equipment service needs.
1-800-654-7768 (24 hours a day – Includes Canada)
For equipment service or support needs outside the United States, contact your local
Emerson Process Management representative.
NOTICE
There are no health hazards from the Rosemount 5400 Series transmitter. The microwave
power density in the tank is only a small fraction of the allowed power density according to
international standards.
The products described in this document are NOT designed for nuclear-qualified
applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware
or products may cause inaccurate readings.
For information on Rosemount nuclear-qualified products, contact your local Emerson
Process Management Sales Representative.
This product is designed to meet FCC and R&TTE requirements.
This device complies with part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired
operation.

Reference Manual
00809-0100-4026, Rev FA
July 2009 Rosemount 5400 Series
www.rosemount.com
Table of Contents
SECTION 1
Introduction Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Product Recycling/Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2
Transmitter Overview Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tanks, vessels, and containers with calm surfaces . . . . . . . . . 2-2
Overfill and underfill detection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Corrosives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sticky, viscous and crystallizing products . . . . . . . . . . . . . . . . . 2-2
Sludges and slurries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Reactor vessels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Underground tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Components of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Dielectric constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Turbulence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Temperature/Pressure/
Density and Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Tank Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Antenna Selection Guide/Measuring Range . . . . . . . . . . . . . . . . . . . . 2-7
SECTION 3
Mechanical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Nozzle Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5402 with Cone Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5402 with Process Seal Antenna . . . . . . . . . . . . . . . . . . . . . . . 3-5
5401 with Cone Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
5401 with Rod Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Still-pipes in Metallic Materials . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Nozzle Recommendations and Requirements . . . . . . . . . . . . . . . . 3-7
Service Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Beamwidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Vessel Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Disturbing Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Reference Manual
00809-0100-4026, Rev FA
July 2009
Rosemount 5400 Series
TOC-2
Cone Antenna Flange Connection . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Process Seal Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Rod Antenna Threaded Connection . . . . . . . . . . . . . . . . . . . . . . . 3-15
Rod Antenna Flanged Connection . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Bracket Mounting on Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Bracket Mounting on Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Mounting in Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Recommendations for pipe installations . . . . . . . . . . . . . . . . . 3-19
SECTION 4
Electrical Installation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable/Conduit Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Conduit Electrical Connector Wiring (using Minifast®). . . . . . . . . . 4-4
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hazardous Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
External Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Connecting the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Non-Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Intrinsically Safe Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
IS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Optional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Tri-Loop HART to analog converter . . . . . . . . . . . . . . . . . . . . . . . . 4-9
751 Field Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
SECTION 5
Basic Configuration/
Start-Up
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Basic Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Basic Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tank Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tank Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tank Type and Tank Bottom Type . . . . . . . . . . . . . . . . . . . . . . 5-4
Pipe Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Transition Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Process Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Rapid Level Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Turbulent Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Product Dielectric Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Volume Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Standard Tank Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Vertical Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Horizontal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Vertical Bullet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Horizontal Bullet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Sphere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Strapping Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Reference Manual
00809-0100-4026, Rev FA
July 2009
TOC-3
Rosemount 5400 Series
Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Output Source/Primary Variable . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Upper/Lower Range Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Alarm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Echo Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Amplitude Threshold Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Basic Configuration Using Rosemount Radar Master . . . . . . . . . . . . 5-11
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Help in RRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Installing the RRM software for HART communication . . . . . . . . 5-13
Getting started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Specifying the COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
To set the COM port buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Specifying Measurement Units. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Guided Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Using the Setup Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Configuration Using a 375 Field Communicator . . . . . . . . . . . . . . . . 5-21
Basic Configuration Using AMS Suite . . . . . . . . . . . . . . . . . . . . . . . . 5-24
HART Multidrop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
SECTION 6
Operation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Viewing Measurement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Specifying Display Panel Variables . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using a Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using Rosemount Radar Master (RRM) . . . . . . . . . . . . . . . . . . 6-3
Using AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
LCD Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Viewing Measurement Data in RRM . . . . . . . . . . . . . . . . . . . . . . . 6-6
Viewing Measurement Data in AMS Suite . . . . . . . . . . . . . . . . . . . 6-7
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
LED Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
SECTION 7
Service and
Troubleshooting
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Service Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Analyzing the Measurement Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Surface Pulse Not Found. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Registration of False Echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Using the Echo Curve Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
The Configuration Mode Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
The View/Record Mode Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Record Tank Spectra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
File Mode Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Reference Manual
00809-0100-4026, Rev FA
July 2009
Rosemount 5400 Series
TOC-4
Using the Echo Curve Analyzer with a 375 Field Communicator . 7-12
Viewing the Echo Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Register False Echoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Threshold Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Logging Measurement Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Backing Up the Transmitter Configuration. . . . . . . . . . . . . . . . . . . . . 7-15
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Rosemount Radar Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
AMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
HART command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Viewing Input and Holding Registers. . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Reset to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Surface Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Using the Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Write Protecting a Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Measurement Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Volume Calculation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Analog Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Application Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
APPENDIX A
Reference Data Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Temperature and Pressure Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Flange Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Electronics Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Dimensional Drawings and Mechanical Properties . . . . . . . . . . . . . . . A-5
Process Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
APPENDIX B
Product Certifications Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
EU Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
European ATEX Directive Information. . . . . . . . . . . . . . . . . . . . . . . . . B-3
Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Special Conditions for Safe Use (X) . . . . . . . . . . . . . . . . . . . . . B-3
Flameproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Special Conditions for Safe Use (X) . . . . . . . . . . . . . . . . . . . . . B-4
Hazardous Locations Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Factory Mutual (FM) Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Canadian Standards Association (CSA) Approval . . . . . . . . . . . . . B-6
Dual Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
IECEx Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Technology Institution of Industrial Safety (TIIS) Approval. . . . . . . B-9
National Supervision and Inspection Center for Explosion
Protection and Safety of Instrumentation (NEPSI) Approvals . . . B-10

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

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

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

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Rosemount 5400 Series
MANUAL OVERVIEW This manual provides installation, configuration and maintenance information
for the Rosemount 5400 Series Radar Transmitter.
Section 2: Transmitter Overview
• Theory of operation
• Descripton of the transmitter
• Process and vessel characteristics
Section 3: Mechanical Installation
• Mounting considerations
• Mounting
Section 4: Electrical installation
• Cable/conduit entries
• Grounding
• Cable selection
• Hazardous areas
• External circuit breaker
• Power requirements
• Connecting the transmitter
• Non-intrinsically safe power supply
• Intrinsically safe power supply
• Optional devices
Section 5: Configuration/Start-Up
• Configuration instructions
• Configuration using the RRM software
• Configuration using a 275/375 Field Communicator
Section 6: Operation
• Viewing measurement data with a Display panel
• Viewing measurement data with Rosemount Radar Master
Section 7: Service and Troubleshooting
• Troubleshooting
• Error and warning codes
• Communication errors
Appendix A: Reference Data
• Specifications
• Ordering Information

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

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

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

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

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

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

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