Emerson Rosemount 644 User manual

Quick Start Guide
00825-0200-4728, Rev HC
May 2019
Rosemount™ 644 Temperature
Transmitter
with 4–20 mA HART® Protocol (Revision 5
and 7)

Safety messages
NOTICE
This guide provides basic guidelines for installing the Rosemount™ 644 Temperature Transmitter. It
does not provide instructions for detailed configuration, diagnostics, maintenance, service,
troubleshooting, or installation. Refer to the Rosemount 644 Reference Manual for more instruction.
The manual and this guide are also available electronically on Emerson.com/Rosemount.
Important
Read this manual before working with the product. For personal and system safety, and for optimum
product performance, make sure to thoroughly understand the contents before installing, using, or
maintaining this product. The United States has two toll-free assistance numbers and one international
number.
Customer Central: 1-800-999-9307 (7:00 a.m. to 7:00 p.m. Central Standard Time)
National Response Center: 1-800-654-7768 (24 hours a day). Equipment service needs
International: 1-(952)-906-8888
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.
WARNING
Follow instructions
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
WARNING
Explosions
Explosions could result in death or serious injury.
Installation of the transmitters in a hazardous environment must be in accordance with the
appropriate local, national, and international standards, codes, and practices. Please review the
Product Certifications section for any restrictions associated with a safe installation.
Do not remove the connection head cover in explosive atmospheres when the circuit is live.
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.Verify the operating atmosphere of the transmitter is consistent with the appropriate
hazardous locations certifications.
All connection head covers must be fully engaged to meet explosion-proof requirements.
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WARNING
Process leaks
Process leaks could result in death or serious injury.
Do not remove the thermowell while in operation.
Install and tighten thermowells and sensors before applying pressure.
WARNING
Electrical shock
Electrical shock could cause death or serious injury.
Avoid contact with the leads and terminals. High voltage that may be present on leads can cause
electrical shock.
Contents
System readiness......................................................................................................................... 5
Transmitter installation................................................................................................................ 6
Safety instrumented systems..................................................................................................... 24
Product certifications................................................................................................................. 25
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1 System readiness
1.1 Confirm HART® revision capability
•If using HART based control or asset management systems, confirm the
HART capability of those systems prior to transmitter installation. Not all
systems are capable of communicating with HART Revision 7 Protocol.
You can configure thie transmitter for either HART Revision 5 or 7.
1.2 Confirm correct device driver
Procedure
1. Verify the latest Device Driver files are loaded on your systems to
ensure proper communications.
2. Download the latest Device Driver at Emerson.com/Device-Install-
Kits/Device-Install-Kit-Search
Table 1-1 provides the information necessary to ensure the correct
Device Driver files and documentation are being used.
Table 1-1: Device Revisions and Files
Software
date
NAMUR
Software
revision
HART®
Software
revision
HART
Universal
revision(1
)
Device
revision(2
)
Manual
Document
Number
Changes to
Software(3)
June 2012 1.1.1 3 5 8 00809-0100-47
28
See (3) for list of
changes.
7 9
(1) NAMUR software revision is located on the hardware tag of the device. HART software
revision can be read using a HART communication tool.
(2) Device Driver file names use Device and DD Revision, e.g. 10_01. HART Protocol is designed
to enable legacy device driver revisions to continue to communicate with new HART devices.
To access new functionality, download the new Device Driver. Emerson recommends
downloading new Device Driver files to ensure full functionality.
(3) HART Revision 5 and 7 Selectable, Dual Sensor support, Safety Certified, Advanced
Diagnostics (if ordered), Enhanced Accuracy and Stability (if ordered).
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2 Transmitter installation
2.1 Set the alarm switch
Set the alarm switch before putting the device into operation.
Procedure
1. Set the loop to manual (if applicable) and disconnect the power
2. Remove the LCD display by detaching from the transmitter (if
applicable).
3. Set the switch to the desired position.
H indicates High; L indicates Low.
4. Reattach the LCD display to the transmitter (if applicable).
5. Reattach the housing cover. Ensure covers must be fully engaged to
meet explosion-proof requirements.
6. Apply power and set the loop to automatic control (if applicable).
Example
Figure 2-1: Alarm Switch Placement
Rosemount™ 644 Transmitter Rosemount 644 Field Mount
A
A. Alarm switch
Note
If using an LCD display, remove the display by detaching it from the top of
the device, set the switch to the desired position, reattach the LCD display,
and reattach the housing cover. Enclosure covers must be fully engaged to
meet explosion-proof requirements.
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2.2 Verify configuration
Upon receiving your transmitter, verify its configuration using any HART®-
compliant configuration tool. See the Rosemount™ 644 Reference Manual
for configuration instructions using AMS Device Manager.
The transmitter communicates using the Field Communicator
(communication requires a loop resistance between 250 and 1100 ohms).
Do not operate when power is below 12 Vdc at the transmitter terminal. See
the Field Communicator Reference Manual for more information.
2.2.1 Verify configuration with a Field Communicator
To verify configuration, you must install a Rosemount™ 644 DD (Device
Descriptor) on the Field Communicator.
Fast Key sequences for the latest DD are shown in Table 2-1. For Fast Key
sequences using legacy DD's, contact your local Emerson representative.
Perform the following steps to determine if an upgrade is required.
Procedure
1. Connect the sensor.
See the wiring diagram located on the device’s top label.
2. Connect the bench power supply to the power terminals (“+” or “–”).
3. Connect a Field Communicator to the loop across a loop resistor or at
the power/signal terminals on the transmitter.
The following message will appear if the communicator has a previous
version of the DDs:
Device Description Not Installed…The Device
Description for manufacturer 0x26 model 0x2618 dev
rev 8/9 is not installed on the System Card…see
Programming Utility for details on Device
Description updates…Do you wish to proceed in
forward compatibility mode?
If this notice does not appear, the latest DD is installed. If the latest version is
not available, the communicator will communicate properly; however, when
the transmitter is configured to utilize advanced transmitter features, there
will be trouble communicating and a prompt to turn off the communicator
will display. To prevent this from happening, upgrade to the latest DD or
answer NO to the question and default to the generic transmitter
functionality.
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Note
Emerson recommends installing the latest DD to access the complete
functionality. Visit Emerson.com/Field-Communicator for information on
updating the DD Library.
2.2.2 Field Communicator user interface
Two user interfaces are available to configure this device.
Figure 2-2 may be used for transmitter configuration and startup.
Figure 2-2: Device Dashboard Field Communicator Interface
Table 2-1: Device Revision 8 and 9 (HART® 5 and 7), DD Revision 1 Fast
Key Sequence
Function HART 5 HART 7
Alarm Values 2, 2, 5, 6 2, 2, 5, 6
Analog Calibration 3, 4, 5 3, 4, 5
Analog Output 2, 2, 5, 1 2, 2, 5, 1
Average Temperature
Setup
2, 2, 3, 3 2, 2, 3, 3
Burst Mode 2, 2, 8, 4 2, 2, 8, 4
Comm Status N/A 1, 2
Configure Additional
Messages
N/A 2, 2, 8, 4, 7
Configure Hot Backup ™2, 2, 4, 1, 3 2, 2, 4, 1, 3
D/A Trim 3, 4, 4, 1 3, 4, 4, 1
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Table 2-1: Device Revision 8 and 9 (HART® 5 and 7), DD Revision 1 Fast
Key Sequence (continued)
Function HART 5 HART 7
Damping Values 2, 2, 1, 5 2, 2, 1, 6
Date 2, 2, 7, 1, 2 2, 2, 7, 1, 3
Display Setup 2, 1, 4 2, 1, 4
Descriptor 2, 2, 7, 1, 4 2, 2, 7, 1, 5
Device Information 1, 8, 1 1, 8, 1
Differential Temperature
Setup
2, 2, 3, 1 2, 2, 3, 1
Drift Alert 2, 2, 4, 2 2, 2, 4, 2
Filter 50/60 Hz 2, 2, 7, 4, 1 2, 2, 7, 4, 1
First Good Temperature
Setup
2, 2, 3, 2 2, 2, 3, 2
Hardware Revision 1, 8, 2, 3 1, 8, 2, 3
HART Lock N/A 2, 2, 9, 2
Intermittent Sensor
Detect
2, 2, 7, 4, 2 2, 2, 7, 4, 2
Loop Test 3, 5, 1 3, 5, 1
Locate Device N/A 3, 4, 6, 2
Lock Status N/A 1, 8, 3, 8
LRV (Lower Range Value) 2, 2, 5, 5, 3 2, 2, 5, 5, 3
LSL (Lower Sensor Limit) 2, 2, 1, 7, 2 2, 2, 1, 8, 2
Message 2, 2, 7, 1, 3 2, 2, 7, 1, 4
Open Sensor Holdoff 2, 2, 7, 3 2, 2, 7, 3
Percent Range 2, 2, 5, 2 2, 2, 5, 2
Sensor 1 Configuration 2, 1, 1 2, 1, 1
Sensor 2 Configuration 2, 1, 1 2, 1, 1
Sensor 1 Serial Number 2, 2, 1, 6 2, 2, 1, 7
Sensor 2 Serial Number 2, 2, 2, 7 2, 2, 2, 8
Sensor 1 Type 2, 2, 1, 2 2, 2, 1, 3
Sensor 2 Type 2, 2, 2, 2 2, 2, 2, 3
Sensor 1 Unit 2, 2, 1, 4 2, 2, 1, 5
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Table 2-1: Device Revision 8 and 9 (HART® 5 and 7), DD Revision 1 Fast
Key Sequence (continued)
Function HART 5 HART 7
Sensor 2 Unit 2, 2, 2, 4 2, 2, 2, 5
Sensor 1 Status N/A 2, 2, 1, 2
Sensor 2 Status N/A 2, 2, 2, 2
Simulate Digital Signal N/A 3, 5, 2
Software Revision 1, 8, 2, 4 1, 8, 2, 4
Tag 2, 2, 7, 1, 1 2, 2, 7, 1, 1
Long Tag N/A 2, 2, 7, 1, 2
Terminal Temperature 2, 2, 7, 1 2, 2, 8, 1
URV (Upper Range Value) 2, 2, 5, 5, 2 2, 2, 5, 5, 2
USL (Upper Sensor Limit) 2, 2, 1, 7, 2 2, 2, 1, 8, 2
Variable Mapping 2, 2, 8, 5 2, 2, 8, 5
2-wire Offset Sensor 1 2, 2, 1, 9 2, 2, 1, 10
2-wire Offset Sensor 2 2, 2, 2, 9 2, 2, 2, 10
2.2.3 Input or verify Callendar Van-Dusen constants
If using sensor matching with this combination of a transmitter and sensor,
verify the constants input.
Procedure
1. From the HOME screen, select2 Configure → 2 Manual Setup → 1
Sensor.
2. Set the control loop to manual and select OK.
3. At the ENTER SENSOR TYPE prompt, select Cal VanDusen.
4. At the ENTER SENSOR CONNECTION prompt, select the
appropriate number of wires.
5. Enter the Ro, Alpha, Delta, and Beta values from the stainless steel
tag attached to the special-order sensor when prompted.
6. Return the control loop to automatic control and select OK.
7. To disable the transmitter-sensor matching feature from the HOME
screen select 2 Configure → 2 Manual Setup → 1 Sensor → 10
Sensor Matching-CVD.
8. Choose the appropriate sensor type from the ENTER SENSOR
TYPE prompt.
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2.2.4 Verify configuration with local operator interface (LOI)
The optional LOI can be used for commissioning the device. The LOI is a two-
button design. To activate the LOI, push any button.
LOI button functionality is shown on the bottom corners of the display. See
Table 2-2 and Figure 2-4 for button operation and menu information.
Figure 2-3: Local Operator Interface
Table 2-2: LOI Button Operation
Button
Left No SCROLL
Right Yes ENTER
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Figure 2-4: LOI Menu
2.2.5 Switch HART® Revision mode
Not all systems are capable of communicating with HART Revision 7
Protocol. You can configure this transmitter for either HART Revision 5 or 7
using a HART capable configuration tool.
Updated configuration menus include a HART Universal Revision parameter
that can be configured to 5 or 7 if accessible by your system. See Table 2-1
for the Fast Key sequence.
If the HART configuration tool is not capable of communicating with HART
Revision 7, the configuration menus in Table 2-1 will not be available. To
switch the HART Universal Revision parameter from generic mode, follow
the instructions below.
Procedure
Go to Configure → Manual Setup → Device Information → Identification
→ Message.
a) To change your device to HART Revision 7, enter HART7 in the
Message field.
b) To change your device to HART Revision 5, enter HART5 in the
Message field.
Note
See Table 2-1 to change HART Revision when the correct Device Driver is
loaded.
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2.3 Mount the transmitter
Mount the transmitter at a high point in the conduit run to prevent moisture
from draining into the transmitter housing.
2.3.1 Head mount transmitter with DIN plate style sensor installation
Procedure
1. Attach the thermowell to the pipe or process container wall.
2. Install and tighten the thermowell before applying process pressure.
3. Verify the transmitter failure mode switch position.
4. Assemble the transmitter to the sensor. Push the transmitter
mounting screws through the sensor mounting plate.
5. Wire the sensor to the transmitter.
6. Insert the transmitter-sensor assembly into the connection head.
a) Thread the transmitter mounting screw into the connection
head mounting holes.
b) Assemble the extension to the connection head.
c) Insert the assembly into the thermowell.
7. If using a cable gland, properly attach the cable gland to a housing
conduit entry.
8. Insert the shielded cable leads into the connection head through the
cable entry.
9. Connect the shielded power cable leads to the transmitter power
terminals.
Avoid contact with sensor leads and sensor connections.
10. Connect and tighten the cable gland.
11. Install and tighten the connection head cover.
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
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A. Connection head cover
B. Connection head
C. Thermowell
D. Transmitter mounting screws
E. Integral mount sensor with flying leads
F. Extension
2.3.2 Head mount transmitter with threaded sensor installation (two or
three conduit entries)
Procedure
1. Attach the thermowell to the pipe or process container wall.
2. Install and tighten thermowells before applying process pressure.
3. Attach necessary extension nipples and adapters to the thermowell.
4. Seal the nipple and adapter threads with silicone tape.
5. Screw the sensor into the thermowell. Install drain seals if required
for severe environments or to satisfy code requirements.
6. Verify the transmitter failure mode switch is in the desired position.
7. Verify the correct installation of Integral Transient Protection (option
code T1).
a) Ensure the transient protector unit is firmly connected to the
transmitter puck assembly.
b) Ensure the transient protector power leads are adequately
secured under the transmitter power terminal screws.
c) Verify the transient protector’s ground wire is secured to the
internal ground screw found within the universal head.
Note
The transient protector requires the use of an enclosure of at least
3.5-in. (89 mm) in diameter.
8. Pull the sensor wiring leads through the universal head and
transmitter center hole.
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9. Mount the transmitter in the universal head by threading the
transmitter mounting screws into the universal head mounting
holes.
10. Mount the transmitter-sensor assembly into the thermowell, or
remote mount if desired.
11. Seal adapter threads with silicone tape.
12. Pull the field wiring leads through the conduit into the universal
head. Attach the sensor and power leads to the transmitter.
Avoid contact with other terminals.
13. Install and tighten the universal head cover.
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
Example
A. Threaded thermowell
B. Threaded style sensor
C. Standard extension
D. Universal head (transmitter inside)
E. Conduit entry
2.3.3 Field mount transmitter with threaded sensor installation
Procedure
1. Attach the thermowell to the pipe or process container wall. Install
and tighten thermowells before applying process pressure.
2. Attach necessary extension nipples and adapters to the thermowell.
3. Seal the nipple and adapter threads with silicone tape.
4. Screw the sensor into the thermowell. Install drain seals if required
for severe environments or to satisfy code requirements.
5. Verify the transmitter failure mode switch is in the desired position.
6. Mount the transmitter-sensor assembly into the thermowell or
remote mount if desired.
7. Seal adapter threads with silicone tape.
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8. Pull the field wiring leads through the conduit into the field mount
housing. Wire the sensor and power leads to the transmitter.
Avoid contact with other terminals.
9. Install and tighten the covers of two compartments.
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
Example
A
C
B
D
E
A. Threaded thermowell
B. Threaded style sensor
C. Standard extension
D. Field mount housing (transmitter inside)
E. Conduit entry
2.4 Wire and apply power
2.4.1 Wire the sensor to the transmitter
The wiring diagram is located on the device’s top label below the terminal
screws.
Figure 2-5: Rosemount™ 644 Head Mount Transmitter
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Figure 2-6: Rosemount 644 Head Mount - Single and Dual Input Wiring
Diagrams
•The transmitter must be configured for at least a three-wire RTD in order
to recognize an RTD with a compensation loop.
•Emerson provides a four-wire sensors for all single element RTDs. Use
these RTDs in three-wire configurations by leaving the unneeded leads
disconnected and insulated with electrical tape.
Figure 2-7: Rosemount 644 Field Mount Transmitter
Figure 2-8: Rosemount 644 Field Mount - Single and Dual Input Wiring
Diagrams
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2.4.2 Power the transmitter
An external power supply is required to operate the transmitter.
Procedure
1. Remove the housing cover (if applicable).
2. Connect the positive power lead to the “+” terminal. Connect the
negative power lead to the “–” terminal.
If a transient protector is being used, the power leads will now be
connected to the top of the transient protector unit. See the
transient label for indication of “+” and “–“terminal connections.
3. Tighten the terminal screws. When tightening the sensor and power
wires, the max torque is 6 in-lb (0.7 N-m).
4. Reattach and tighten the cover (if applicable).
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
5. Apply power (12–42 Vdc).
2.4.3 Load limitation
The power required across the transmitter power terminals is 12 to 42.4
Vdc; the power terminals are rated to 42.4 Vdc. To prevent damaging the
transmitter, do not allow terminal voltage to drop below 12.0 Vdc when
changing the configuration parameters.
2.4.4 Ground the transmitter
To ensure proper grounding, it is important the instrument cable shield be:
•Trimmed close and insulated from touching the transmitter housing.
•Connected to the next shield if cable is routed through a junction box.
•Connected to a good earth ground at the power supply end.
Note
Shielded twisted pair cable should be used for best results. Use 24 AWG or
larger wire and do not exceed 5,000 ft. (1500 m).
2.4.5 Ungrounded thermocouple, mV, and RTD/Ohm inputs
Each process installation has different requirements for grounding. Use the
grounding options recommended by the facility for the specific sensor type
or begin with grounding option 1 (the most common).
Ground the transmitter: option 1
Procedure
1. Connect sensor wiring shield to the transmitter housing.
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2. Ensure the sensor shield is electrically isolated from surrounding
fixtures that may be grounded.
3. Ground signal wiring shield at the power supply end.
Example
A
B
C
DCS
D
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4–20 mA loop
Ground the transmitter: option 2
Procedure
1. Connect signal wiring shield to the sensor wiring shield.
2. Ensure the two shields are tied together and electrically isolated from
the transmitter housing.
3. Ground shield at the power supply end only.
4. Ensure the sensor shield is electrically isolated from the surrounding
grounded fixtures.
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A
B
C
D
DCS
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4–20 mA loop
5. Connect shields together, electrically isolated from the transmitter.
Ground the transmitter: option 3
Procedure
1. Ground sensor wiring shield at the sensor, if possible.
2. Ensure the sensor wiring and signal wiring shields are electrically
isolated from the transmitter housing.
3. Do not connect the signal wiring shield to the sensor wiring shield.
4. Ground signal wiring shield at the power supply end.
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