Emerson Rosemount 5900 Instruction For Installation, Configuration, And Operation
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Emerson Rosemount 5900 Instruction For Installation, Configuration, And Operation

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Reference Manual
00809-0200-5900, Rev AD
February 2023
Rosemount 5900 Proof Test
Instruction for Installation, Configuration, and Operation
of Proof Test Function with Reference Reflector

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  • Page 1 Reference Manual 00809-0200-5900, Rev AD February 2023 Rosemount 5900 Proof Test Instruction for Installation, Configuration, and Operation of Proof Test Function with Reference Reflector...
  • Page 2 Read this manual before working with the product. For personal and system safety, and for optimum product performance, ensure you thoroughly understand the contents before installing, using, or maintaining this product. For equipment service or support needs, contact your local Emerson Automation Solutions/Rosemount Tank Gauging representative.
  • Page 3  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’...

  • Page 5: Table Of Contents

    Chapter 3  Configuration of reference reflector..................35 3.1 Overview.............................35 3.2 Configuration using TankMaster WinSetup................35 Chapter 4  Operation..........................45 4.1 Proof Test operation......................... 45 4.2 Scheduling..........................49 4.3 History............................51 4.4 Reports............................52 4.5 Removing a Reference Reflector..................... 54 Chapter 5  Service and troubleshooting....................57 5.1 Troubleshooting........................57 5.2 Tank scan............................59 Rosemount 5900...
  • Page 6 Contents Reference Manual February 2023 00809-0200-5900 Emerson.com/Rosemount...

  • Page 7: Chapter 1 Introduction

    1  Introduction The Rosemount 5900 Radar Level Gauge is designed with functionality that lets you proof test high alarms and verify correct product surface measurement. The Rosemount 5900 allows you to combine continuous product level monitoring with proof testing at regular intervals.

  • Page 8: Section Overview

    Rosemount 5900 Proof Test System. The sections are organized as follows: Section 1 Introduction gives a brief introduction to the Rosemount 5900 Proof Test function and the recommended installation procedure.

  • Page 9: Firmware Requirements For Proof Testing

    1.B9 or higher • Rosemount TankMaster 6.E1 or higher For wireless applications the proof test function requires: • Rosemount 5900 and Rosemount 2410 ordered with model code safety certification option "S" • Rosemount TankMaster 6.G0 or higher Rosemount 5900...
  • Page 10 Introduction Reference Manual February 2023 00809-0200-5900 Emerson.com/Rosemount...

  • Page 11: Chapter 2 Installation

    The Reference Reflector is installed under the antenna. It is attached to a wire fixed to the Parabolic Antenna. The Reference Reflector introduces a radar echo that is used for proof testing the Rosemount 5900 Radar Level Gauge. Proof testing can be performed without the need to open the tank.
  • Page 12 A. Nut M8 B. Spring washer C. Washer D. M8 terminal E. Wire diameter 4 mm (0.16 in.) Length 5 m (16.4 ft.) F. Nut M12 G. Weight H. M6 screw (x2) Allen key size 3 Figure 2-2: Reference Reflector Emerson.com/Rosemount...
  • Page 13 Reference Manual Installation 00809-0200-5900 February 2023 Figure 2-3: Clamp Ring A. M6 cylinder nut B. M6 screw C. Clamping ring Rosemount 5900...
  • Page 14 Installation Reference Manual February 2023 00809-0200-5900 2.3.2  Tank geometry parabolic antenna Figure 2-4: Tank geometry for Rosemount 5900 with Parabolic Antenna and Proof Test Reference Reflector A. Reference Reflector (RR). Maximum inclination 2.5°. B. Weight C. Clamping ring D. Parabolic antenna E.
  • Page 15 G. Gauge Reference Point In the Rosemount 5900 and 2410 Safety Manual (Document No. 00809-0200-5100) you will find more information on how to install and configure the Rosemount 5900 Radar Level Gauge and 2410 Tank Hub in a Safety Instrumented System. Rosemount 5900...
  • Page 16 600 to 2000 (24 to 79) 250 (10) 2000 to 3000 (79 to 118) 200 (7.9) 3000 to 4000 (118 to 157) 135 (5.3) 4000 to 5000 (157 to 197) 90 (3.5) 3. Mount the appropriate Reference Reflector on the weight. Emerson.com/Rosemount...
  • Page 17 4. Tighten the M12 nut to a torque value of 18 Nm. A. Reference Reflector (RR) B. M12 nut. Torque=18 Nm. C. Spring washer D. Weight 5. Calculate the required Wire Distance. See Wire Distance calculation Figure 2-7. Rosemount 5900...
  • Page 18 7. Place the weight in the calculated Wire Distance position. 8. Tighten the two screws (size M6) to a torque value of 2.5 Nm. 9. Cut the wire. You may leave 0 to 150 mm (0 to 6 in.) of the wire below the weight. Emerson.com/Rosemount...
  • Page 19 12. Tighten the M8 nut to the specified torque of 8 Nm. A. Nut M8 Torque=8 Nm B. Spring washer C. Washer D. Nut M8 E. M8 terminal F. Wire G. Antenna H. Clamping ring I. Tank center Rosemount 5900...
  • Page 20 Reference Reflector is correctly aligned towards the center of the tank • inclination of Reference Reflector is less than 2.5° Figure 2-6: Align the Reference Reflector A. Reference Reflector (RR) B. Tank center C. Parabolic antenna D. Tank wall Related information Tank geometry parabolic antenna Wire Distance calculation Emerson.com/Rosemount...
  • Page 21 Wire Distance in order to obtain the correct position (Reference Reflector Distance) of the Reference Reflector. Figure 2-7: Wire Distance A. Wire distance B. Reference reflector C. Weight Rosemount 5900...
  • Page 22 Use the following formula to calculate the required Wire Distance for a welded connection: Wire Distance=RR + Ga -W - 194 (mm) where: Figure 2-8 thickness of the flange gasket (see Figure 2-8) Reference Reflector Distance (see Figure 2-4) Figure 2-8: Welded Connection A. Flange B. 60 mm (2.4 in.) C. Antenna Emerson.com/Rosemount...
  • Page 23 Use the following formula to calculate the required Wire Distance for clamped connection: Wire Distance=RR + Ga +T - 243 (mm) where: flange thickness (see Figure 2-9) thickness of the flange gasket (see Figure 2-9) Reference Reflector Distance (see Figure 2-4) Figure 2-9: Clamped Connection Rosemount 5900...

  • Page 24: Install The Reference Reflector For Array Antenna

    Install the Reference Reflector for Array antenna 2.4.1  Reference Reflector kit The Reference Reflector is delivered with all parts needed for proper installation on a Rosemount 5900 with Array Antenna. The Reference Reflector kit includes the following parts: • Wire assembly •...
  • Page 25 A Safety Wire should be use to secure the Reference Reflector during installation in a Still-Pipe. Figure 2-13: Flexible Ring A. M6 nut B. Rod attachment The Flexible Ring provides an attachment point in the Still-Pipe for the wire and weight assembly. Rosemount 5900...
  • Page 26 Reference Manual February 2023 00809-0200-5900 2.4.2  Tank geometry array antenna Fixed version Figure 2-14: Tank Geometry for Rosemount 5900 with Array Antenna Fixed Version and Proof Test Reference Reflector A. Gauge Reference Point B. Array antenna C. Flexible ring D. Bronze rod E.
  • Page 27 Safety Instrumented System (SIS) for installation requirements in Safety Instrumented Systems (SIS). Hatched version Figure 2-15: Tank Geometry for Rosemount 5900 with Array Antenna Hatched Version and Proof Test Reference Reflector A. Gauge Reference Point B. Array antenna hatched version C.
  • Page 28 1. Decide position of SIL High Alarm. In the Rosemount 5900 and 2410 Safety Manual (Document No. 00809-0200-5100) you will find more information on how to install and configure the Rosemount 5900 Radar Level Gauge and 2410 Tank Hub in a Safety Instrumented System. Emerson.com/Rosemount...
  • Page 29 Distance RR - Gauge Reference Point: 600 to 5000 mm (see Table 2-2) c. Minimum 500 mm to maximum product level Figure 2-16: Tank geometry for Rosemount 5900 with Array Antenna and Proof Test Reference Reflector in Safety Instrumented System. A. SIL Surface Distance B. SIL High Alarm Limit C.
  • Page 30 3. Mount the Reference Reflector on the weight. 4. Tighten the M12 nut to a torque value of 18 Nm. A. M12 nut Torque=18 Nm B. Reference Reflector (RR) C. Spring washer D. Weight 5. Calculate the Wire Distance as described in Wire Distance calculation. Emerson.com/Rosemount...
  • Page 31 10. Install the Flexible Ring at the top of the Still-pipe. The ring can be adjusted to fit a wide range of Still-Pipe inner diameters according to Table 2-3. 11. Ensure that the Flexible Ring fits tightly inside the pipe. Rosemount 5900...
  • Page 32 (11.75 - 12.52 in.) 13. Fasten one end of the Safety Wire to the Bronze Rod and the other end to the tank. 14. Lower the weight and reflector into the Still-pipe to the full length of the wire. Emerson.com/Rosemount...
  • Page 33 Reference Manual Installation 00809-0200-5900 February 2023 15. Put the wire into the rod attachment through the slot. 16. Lower the Bronze Rod until it stops as illustrated below. 17. Remove the Safety Wire from the Bronze Rod. Rosemount 5900...
  • Page 34 Use the following formula to calculate the required Wire Distance for clamped connection: Array Antenna hatched version Wire Distance=RR - Ga - 362 (mm) where: thickness of the flange gasket Reference Reflector Distance Array Antenna fixed version Wire Distance=RR - 324 (mm) where: Reference Reflector Distance Emerson.com/Rosemount...

  • Page 35: Configuration Of Reference Reflector

    Manual for more information on using the TankMaster WinSetup program to configure a Rosemount Tank Gauging system. See also the Rosemount 5900 Radar Level Gauge and Rosemount 2410 Tank Hub Safety Manual Option S for more information on proof testing in Safety Instrumented Systems (SIS).
  • Page 36 Factor) and allowed deviations from the calibrated reflector position (Distance Tolerance). This step needs to be done for physical as well as simulated reference reflectors. Prerequisites Ensure that a standard configuration of the Rosemount 5900 is performed prior to the proof test configuration. Procedure 1.
  • Page 37 Configuration of reference reflector 00809-0200-5900 February 2023 3. The Proof Test window appears. It lets you perform proof tests, view previous tests, and schedule future tests. There are two different versions: Option Proof Test window SIL2 Model Code S and non-SIL SIL3 Rosemount 5900...
  • Page 38 8. Specify the desired Distance Tolerance value. This is the region around the specified RR Distance within which the level gauge searches for a radar echo when calibrating the Reference Reflector (see Figure 3-2). The default value is 0.3 m. 9. Click the Calibrate button. Emerson.com/Rosemount...
  • Page 39 • Rosemount 5900 with Parabolic antenna: 600 to 1200 mV • Rosemount 5900 with Array antenna (Still-Pipe): 1000 to 3500 mV • Rosemount 5900 with simulated antenna: approximately 600 mV 13. Click the Save button to store the current calibration.
  • Page 40 Reference Reflector Settings pane. Click the Apply button to store the parameters. 3. Specify the desired Default Test Time. This value will be used as the default value in the Level Sensor Test window. The actual test time can be changed when running the test. Emerson.com/Rosemount...
  • Page 41 Related information Configuration procedure 3.2.5  Proof test configuration example An example of proof test configuration for a Rosemount 5900 Radar Level Gauge with Reference Reflector is shown in Table 3-1. The actual distance and amplitude as measured by the Rosemount 5900 gauge is shown in Table 3-2.
  • Page 42 Reference Reflector during calibration. Calibrated Distance Distance to the Reference Reflector measured by the gauge during calibration. Distance Tolerance The region around the specified RR Distance within which the Rosemount 5900 searches for a radar echo when calibrating the Reference Reflector. Emerson.com/Rosemount...
  • Page 43 Approved range of signal amplitudes during a proof test. Min./Max. Amplitude Minimum and maximum amplitude values that will be allowed during a proof test. RR Distance Distance from the Gauge Reference Point to the reference reflector (RR). Related information Configuration procedure Rosemount 5900...
  • Page 44 Configuration of reference reflector Reference Manual February 2023 00809-0200-5900 Emerson.com/Rosemount...

  • Page 45: Chapter 4 Operation

    00809-0200-5900 February 2023 4  Operation 4.1  Proof Test operation This is a description of how to perform proof tests with a Rosemount 5900 using the Rosemount TankMaster WinSetup program. Supported proof tests: • High level alarm Note Not for wireless applications •...
  • Page 46 4. To perform a High Level Alarm proof test: • Select the check box for Reference Reflector test, and click the Start Guided Proof Test button. • For SIL3 gauges; in the Level Sensor (ATG) pane click the Test button. Emerson.com/Rosemount...
  • Page 47 30 seconds and 60 minutes. The default value is 120 seconds. 8. Ensure that device status is OK. See different status messages that may appear according to Table 4-1. 9. Click the Start Proof Test button to perform the test for the specified Proof Test Time. Rosemount 5900...
  • Page 48 Proof test status Table 4-1: Proof Test Status Options Status options Proof Test Active Test Finished Test Ended by User RR Not Found RR not Calibrated Level Surface Too Close Proof Test Status not Available Related information Service and troubleshooting Emerson.com/Rosemount...

  • Page 49: Scheduling

    4.2.1  Pop-up message The Reminder pop-up message will appear at the scheduled time. In case you choose to accept, you will be directed to the Proof Test window in order to start the proof test procedure. Rosemount 5900...
  • Page 50 WinSetup remind you later by choosing one of the options in the Remind In drop-down list: 1 Day, 1 Week, or 1 Month. Figure 4-2: If proof test is skipped you may choose to be reminded later Related information Proof Test operation Emerson.com/Rosemount...

  • Page 51: History

    RR Status • Proof Test Status • Echo Distance • Echo Amplitudes • Date • Performed By • Approved By • Note Test reports are available by pressing the Show Test Report button. Related information Viewing a report Rosemount 5900...

  • Page 52: Reports

    Reports in Adobe Acrobat pdf format are available via the Proof Test History window. Procedure 1. In TankMaster WinSetup, click the Rosemount 5900 icon and select the Proof Test option to open the Proof Test window. 2. Click the History button.
  • Page 53 The report includes device information and device status. There is also information regarding the result of the proof test, for example whether alarms did sound or if emergency shutdown was activated. Table 4-3: Proof Test Report SIL2 model code "S" and non-SIL SIL3 Rosemount 5900...

  • Page 54: Removing A Reference Reflector

    There may be a situation when you would like to remove the Reference Reflector and disable the Proof Test function. Then you can use the Reset function to remove all Proof Test calibration data. This ensures that there is no data stored in the Rosemount 5900 database that may interfere with the current measurements.
  • Page 55 3. In the Reference Reflector Configuration window, click the Reset button to open the Reset window. 4. The Reset window shows the current Reference Reflector calibration data for the Rosemount 5900 Radar Level Gauge. 5. Click the Reset button to clear all calibration data. Status will be changed to Not Calibrated.
  • Page 56 Operation Reference Manual February 2023 00809-0200-5900 Emerson.com/Rosemount...

  • Page 57: Service And Troubleshooting

    Gauge Reference Point is located at the flange of the tank nozzle. Possible cause RR Calibration could not be performed. Recommended actions • RR calibration could not be performed. 5.1.2  Proof test could not be started Possible cause Product surface too close to the reference reflector. Rosemount 5900...
  • Page 58 Disable write protection. 5.1.5  Reference Reflector does not appear in Tank Scan Possible cause Tank Signal Mean (TSM) function (near-zone improvement) filters away the Reference Reflector. Recommended actions • Enable Peak Labels by checking the box. Related information Tank scan Emerson.com/Rosemount...

  • Page 59: Tank Scan

    5.2  Tank scan The Tank Scan function is a useful tool to verify that the Rosemount 5900 level gauge is able to locate the product surface and the reference reflector. It lets you locate possible disturbing objects, and you may also check that amplitude thresholds are properly set so that the Reference Reflector echo is not filtered away.
  • Page 60 Service and troubleshooting Reference Manual February 2023 00809-0200-5900 2. Select the Properties option. 3. Select the Advanced Configuration tab an click the Tank Scan button. Emerson.com/Rosemount...
  • Page 61 Reference Manual Service and troubleshooting 00809-0200-5900 February 2023 4. The Tank Scan window appears allowing you to analyze the various echoes in the tank. Rosemount 5900...
  • Page 62 Emerson Terms and Conditions of Sale are available upon request. The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of one of the Emerson family of companies. All other marks are the property of their respective owners.

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