Emerson Rosemount 644 User manual

Reference Manual
00809-0500-4728, Rev AC
December 2021
Rosemount™ 644 Rail Mount Temperature
Transmitter
with RK Option and HART® 7 Protocol

Safety messages
NOTICE
Read this document 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 Central Time)
Asia Pacific- 65 777 8211
Europe/Middle East/Africa - 49 (8153) 9390
North American Response Center
Equipment service needs.
1-800-654-7768 (24 hours—includes Canada)
Outside of these areas, contact your local Emerson representative.
WARNING
Follow instruction
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
Explosion
Explosions could result in death or serious injury.
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 that the instruments in the loop are
installed in accordance with intrinsically safe or non-incendive field wiring practices.
Verify that 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.
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.
Electric shock
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate
readings.
For information on Rosemount nuclear-qualified products, contact your local Emerson Sales Representative.
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.
2

Contents
Chapter 1 Introduction.............................................................................................................. 5
1.1 Using this manual........................................................................................................................ 5
1.2 Transmitter overview...................................................................................................................5
1.3 Mounting, installation, and programming................................................................................... 6
1.4 Product recycling/disposal...........................................................................................................6
Chapter 2 Installation.................................................................................................................7
2.1 Safety messages.......................................................................................................................... 7
2.2 Connections................................................................................................................................ 8
2.3 Multidrop mode...........................................................................................................................9
Chapter 3 Configuration...........................................................................................................11
3.1 Safety messages........................................................................................................................ 11
3.2 Configuration methods..............................................................................................................11
Chapter 4 Operation and Maintenance.....................................................................................13
4.1 Safety messages........................................................................................................................ 13
4.2 LED functionality........................................................................................................................13
4.3 Jumpers..................................................................................................................................... 14
4.4 Test pins.................................................................................................................................... 14
4.5 HART® commands..................................................................................................................... 14
Chapter 5 Troubleshooting...................................................................................................... 17
5.1 Primary value out of limits......................................................................................................... 17
5.2 Non-primary variable out of limits..............................................................................................17
5.3 Loop current saturated.............................................................................................................. 17
5.4 Primary sensor 1 error................................................................................................................17
5.5 Primary sensor 2 error (only if sensor 2 is enabled).....................................................................18
5.6 Dual input: Sensor Drift Alert..................................................................................................... 18
5.7 Hot Backup Active..................................................................................................................... 18
5.8 Hot Backup Active..................................................................................................................... 18
5.9 Configuration not supported by device......................................................................................18
5.10 Electronic temperature out of limits........................................................................................ 19
5.11 Power supply voltage issues.....................................................................................................19
5.12 Attempting or failed to enter SIL mode....................................................................................19
5.13 Electronics failure.................................................................................................................... 19
5.14 Electronics failure.................................................................................................................... 20
5.15 Power supply voltage issues.....................................................................................................20
5.16 Loop current read back error....................................................................................................20
5.17 Power supply voltage issues.....................................................................................................20
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5.18 Electronics failure.................................................................................................................... 20
5.19 Electronics failure.................................................................................................................... 21
5.20 Electronics failure.................................................................................................................... 21
5.21 Electronics failure.................................................................................................................... 21
5.22 Watchdog reset executed........................................................................................................21
5.23 Internal RTD sensor error......................................................................................................... 22
5.24 Sensor failure...........................................................................................................................22
5.25 Sensor measurement error...................................................................................................... 22
5.26 Sensor measurement error...................................................................................................... 22
5.27 Sensor measurement error...................................................................................................... 22
Appendix A Reference Data.........................................................................................................25
A.1 Product certifications................................................................................................................ 25
A.2 Ordering information, specifications, and drawings...................................................................25
A.3 Dimensional drawings............................................................................................................... 26
Contents Reference Manual
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1 Introduction
1.1 Using this manual
This manual is designed to assist in the installation, operation, and maintenance of
Rosemount 644R/T Rail Mount Temperature Transmitter.
•Installation
•Configuration
•Operation and maintenance
•Troubleshooting
•Reference data
1.2 Transmitter overview
The transmitter supports the following features:
•4-20 mA/HART® protocol (Revision 7)
•Accepts either one or two inputs from a wide variety of sensor types (2-, 3-, and 4-wire
RTD, thermocouple, mV and ohm)
•Optional Safety Certification (IEC 61508 SIL 2)
•Special dual-sensor features including Hot Backup™, Sensor Drift Alert, first good,
differential and average temperature measurements, and four simultaneous
measurement variable outputs in addition to the analog output signal
•Meets NAMUR NE21, NE43, NE44, NE89 and NE107 compliant diagnostics information.
Refer to the following literature for a full range of compatible connection heads, sensors,
and thermowells provided by Emerson:
•Rosemount 214C Temperature Sensors Product Data Sheet
•Rosemount Volume 1 Temperature Sensors and Accessories (English) Product Data
Sheet
•Rosemount DIN-Style Temperature Sensors and Thermowells (Metric) Product Data
Sheet
Table 1-1: Change Summary: Rosemount 644 Rail Mount HART Device Revision
Release date NAMUR
software
revision
NAMUR
hardware
revision
HART software
revision(1)
Manual document
number
May 2021 01.05.10 01.05.10 7 00809-0500-4728
(1) NAMUR software revision is located on the hardware tag of the device. HART software revision
can be read using a HART communication tool.
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1.3 Mounting, installation, and programming
•DIN rail mounting with up to 84 inputs per meter
•Communication via Asset Management tool (e.g. Pactware, AMS, HART®
communicator) for which all relevant DD, eDD and DTM files are available
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/regulations.
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2 Installation
2.1 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 ( ). Please refer to the following safety
messages before performing an operation preceded by this symbol.
WARNING
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
Explosions could result in death or serious injury.
Do not remove the housing covers 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 that 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.
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.
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
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2.2 Connections
Single input
2 w / 3 w / 4 w RTD or
lin. R
TC (internal CJC or
external 2 w / 3 w / 4 w
CJC)(1)
mV 3 w / 4 w
potentiometer
42 44
43
41
43 I1
41 42 44
43
+
-
CJC
3
41 42 44
43
+
41 42 44
43
4I1
(1) When using thermocouple input, the transmitter can be configured for either constant, internal
or external CJC via a Pt100 or Ni100 sensor. This must be selected during device configuration.
Dual inputs
Input 1
41 42 44
43 41 42 44 43 41 42 44 43
51 52 54
53 51 52 54 53 51 52 54 53 51 52 54 53
41 42 44
43
4I2
+
43 I1 +
-
+
43 I1 +
-
CJC
3
4I1
41 42 44
43
51 52 54
53
4 5
I1
4I2
A B D
F
C E
A B C D
Input 2
A. 2 w / 3 w / 4 w RTD or lin. R
B. TC (internal CJC or external 2 w / 3 w / 4 w CJC)(1)
C. mV
D. 3 w / 4 w potentiometer
E. 5 w potentiometer
F. 3 w potentiometer
Output
2-wire installation
11 12 14
13
mA
(1) When using thermocouple input, the transmitter can be configured for either constant, internal or external CJC via a Pt100
or Ni100 sensor. This must be selected during device configuration.
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2.3 Multidrop mode
The communication is either by means of a HART® communicator or a HART modem.
The HART communicator or a HART modem can be connected across BC or CD.
The outputs of maximum 63 transmitters can be connected in parallel for a digital HART 2-
wire communication.
Before it is connected, each transmitter must be configured with a unique number from 1
to 63. If two transmitters are configured with the same number, both will be excluded. The
transmitters must be programmed for multidrop mode (with a fixed output signal of 4
mA). Maximum current in the loop is therefore 252 mA.
B
C
D
+
-
+
-
A
E
F F F
A. Power supply
B. Connection
C. Connection
D. Connection
E. 250 Ω < Rload < 1100 Ω
F. Transmitter
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3 Configuration
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 ( ). Please refer to the following safety
messages before performing an operation preceded by this symbol.
WARNING
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
Explosions could result in death or serious injury.
Do not remove the housing covers 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 that 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.
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.
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
3.2 Configuration methods
The device can be configured in the following ways:
•With AMS Device Manager
•With a HART® communicator with Emerson's DDL driver
•Via programming framework (e.g. DCS, PACTware™)
HART communicator
To get access to product-specific commands, the HART communicator must be loaded
with Emerson's DDL driver. This can be ordered through either the FieldComm Group or
Emerson.
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44
43
42
41
51
11121314
12
11
A
BC
D
E
F
G
A. Rosemount transmitter
B. Ex area
C. Safe area
D. 250 Ω < Rload < 1100 Ω
E. Receiving equipment
F. +V supply
G. Input
Programming framework
Support for both EDD and FDT®/DTM™ technology, offering configuration and monitoring
via relevant DCS/Asset Management Systems and supported management packages (e.g.
PACTware).
12
11
+
-
44
43
42
41
51
11121314
A
B
D
C
A. Rosemount transmitter
B. 250 Ω < Rload < 1100 Ω
C. Process computer
D. DCS, etc.
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4 Operation and Maintenance
4.1 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 ( ). Please refer to the following safety
messages before performing an operation preceded by this symbol.
WARNING
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
Explosions could result in death or serious injury.
Do not remove the housing covers 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 that 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.
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.
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
4.2 LED functionality
Onboard LED indicates faults according to NAMUR NE44 and NE107.
Condition LED status
Device OK Constant green
No supply Off
Fault indication independent of the device (e.g. wire break,
sensor short circuit, violation of input or output limits)
Flashing red
Device error Constant red
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4.3 Jumpers
The Rosemount Single and Dual Input 644R/T Transmitters have two front jumpers: one to
enable Write Protection and one to select the output current at Safe State to go above 21
mA as specified in NAMUR NE43.
If the jumper is not inserted, the output current at Safe State will go lower than 3.6 mA as
specified in NAMUR NE43.
Write protect Safe state > 21 mA No function No function
4.4 Test pins
The test pins allow measurement of loop current directly while maintaining loop integrity.
Power must be connected to the transmitter (terminals 11 and 12) when using the test
pins (terminals 13 and 14).
CAUTION
For hazardous area installation, only certified test equipment may be used.
4.5 HART® commands
For definitions and further information on HART commands, consult the HART Field
Device Specification.
Table 4-1: Advanced functions
Function Description
Differential Analog output signal is proportional to the difference between Sensor 1 and
Sensor 2 measurements.
Analog output = Sensor 1 – Sensor 2 or Sensor 2 – Sensor 1 or |Sensor 2 – Sensor
1|
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Table 4-1: Advanced functions (continued)
Function Description
Average
measurement
Analog output signal is proportional to the average of Sensor 1 and Sensor 2
measurements.
Analog output = 0.5* (Sensor 1 + Sensor 2)
Maximum Analog output is proportional to the Sensor with the highest value.
IF (Sensor 1 > Sensor 2) THEN AnalogOutput = Sensor 1 ELSE AnalogOutput =
Sensor 2
Minimum Analog output is proportional to the Sensor with the lowest value.
IF (Sensor 1 < Sensor 2) THEN AnalogOutput = Sensor 1 ELSE AnalogOutput =
Sensor 2
Sensor drift If the differential between Sensor 1 and Sensor 2 measured values exceed a
predefined limit then a sensor drift error is indicated.
IF ABS (Sensor 1 – Sensor 2) > SensorDriftLimit THEN IndicateSensor-DriftError
Redundancy
(Hot Backup™)
Analog output is proportional to Sensor 1 as long as no error is detected and
Sensor is within user-defined limits. If sensor error on Sensor 1 is detected or if
sensor 1 value is outside userdefined limits, analog output then becomes
proportional to Sensor 2 and a warning indication is generated.
IF(NoSensorErrorOnSensor1 AND Sensor1InsideLimits) THEN AnalogOutput =
Sensor 1
ELSEIF(NoSensorErrorOnSensor2 AND Sensor2InsideLimits) THEN AnalogOutput
= Sensor 2
Customized
linearization -
polynomial
type
Supports polynomial linearization up to five segments, each with up to 4th order
polynomials.
Customized
linearization -
Callendar Van
Dusen
Supports direct entry of CVD constants.
Customized
linearization -
table
linearization
Supports table linearization with up to 60 in/out values.
Customized
linearization -
2nd order
spline
linearization
Supports 2nd order spline linearization with up to 40 output values.
Runtime
meter -
transmitter
electronics(1)
< -50 °C
-50...-30 °C
-30...-10 °C
-10...+10 °C
+10...+30 °C
+30...+50 °C
+50...+70 °C
+70...+85 °C
>85 °C
Runtime
meter -
Sensors
Recording of Sensor measurement values during operation, logging time spent in
each of nine fixed sub Sensor ranges.
Subranges are defined individually for each Sensor type.
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Table 4-1: Advanced functions (continued)
Function Description
Slave pointer -
transmitter
electronics
Recording of minimum/maximum internal transmitter temperature for device’s
complete lifetime.
Slave pointer -
Sensors
Recording of minimum/maximum values for Sensor/s measurements is saved.
Values are reset when measurement configuration is changed.
(1) Recording of internal transmitter temperatures during operation, logging time spent in each of
nine fixed sub temperature ranges.
Dynamic variable mapping
Four dynamic variables are supported, PV, SV, TV, and QV.
Using HART commands, these may be assigned to the Device Variables shown in the table
below.
The device variable mapped to PV controls the loop current.
Input Type PV SV, TV, QV
Single Sensor Sensor 1 Electronics Temperature
Dual Sensor Sensor 1 Sensor 2
S1, with S2 Hot Backup Average S1 and S2
Difference S1-S2
Difference S2-S1
Absolute Difference S1-S2
S2, with S1 with Hot Backup
Electronics Temperature
Write protection by software
The default active password when the device leaves the factory is ‘********’; this value
can be changed by the user.
The universal active password “00002008” will always be accepted and this value cannot
be changed. The universal active password shall only be used if the active password has
been lost and needs to be reset to a known value.
When changing the password, use only Latin-1 characters that can be entered and
displayed on any terminal.
When write protection is enabled, no “write” commands are accepted regardless of the
“Write Protect” hardware jumper position.
Write protection by jumper
If a hardware jumper is set in “Write Protect” position, no “write” commands are accepted
even if disabled by software.
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5 Troubleshooting
5.1 Primary value out of limits
LED status: flashing red
The device variable mapped to PV (and Analog Output Current) is beyond its operating
limits.
Recommended action
Reconnect or repair sensor.
5.2 Non-primary variable out of limits
LED status: flashing red
Any other device variable is beyond its operating limits.
Recommended action
Reconnect or repair sensor.
5.3 Loop current saturated
LED status: flashing red
The loop current has reached the Current Output Upper Limit (UL) or Output Lower Limit
(LL) as configured, and is no longer corresponding to the PV value.
Recommended action
Reconnect or repair sensor.
5.4 Primary sensor 1 error
LED status: flashing red
A sensor error (broken/shorted sensor) is detected on Sensor 1.
Recommended action
Reconnect or repair sensor.
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5.5 Primary sensor 2 error (only if sensor 2 is
enabled)
LED status: flashing red
A sensor error (broken/shorted sensor) is detected on Sensor 2. This is only possible if
Sensor type 2 is <> ʺNoneʺ.
Recommended action
Reconnect or repair sensor.
5.6 Dual input: Sensor Drift Alert
LED status: flashing red
The difference between measurements on Sensor 1 and Sensor 2 is outside the configured
sensor drift limit.
Recommended actions
Reconnect or repair sensor.
5.7 Hot Backup Active
LED status: no impact
A sensor error (broken/shorted) is detected, backup sensor is in use.
Recommended actions
Reconnect or repair sensor.
5.8 Hot Backup Active
LED status: no impact
A sensor error (broken/shorted) is detected on the backup sensor, no backup available.
Recommended actions
Reconnect or repair sensor.
5.9 Configuration not supported by device
LED status: solid red
Configuration is temporary invalid < 3 seconds, e.g. while downloading parameters.
Recommended action
Correct and re-send the configuration.
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5.10 Electronic temperature out of limits
LED status: flashing red
The device is operated outside its specified temperature range.
Recommended action
Check operating temperature.
LED status: solid red
The device is operated outside its specified temperature range in SIL mode.
Recommended action
Check operating temperature.
5.11 Power supply voltage issues
LED status: off
Power is applied but still too low.
Recommended action
1. Check power supply (at output terminals).
2. If the error is persistent send the device for evaluation or replace the device.
5.12 Attempting or failed to enter SIL mode
LED status: solid red
The device is transitioning to SIL mode, or has failed to do so.
Recommended actions
The SIL configuration must be validated or normal operation must be re-selected.
5.13 Electronics failure
LED status: solid red
An unrecoverable error occurred in the internal communication to the input CPU.
Recommended action
1. Reset or re-power the device.
2. If the error is persistent send the device for evaluation or replace the device.
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5.14 Electronics failure
LED status: solid red
An unrecoverable error occurred in the input CPU.
Recommended action
1. Reset or re-power the device.
2. If the error is persistent send the device for evaluation or replace the device.
5.15 Power supply voltage issues
LED status: solid red
The device is operated below its specified voltage supply range.
Recommended action
1. Check power supply (at output terminals). Reset or re-power the device.
2. If the error is persistent send the device for evaluation or replace the device.
5.16 Loop current read back error
LED status: solid red
The read back loop current differs from the calculated output current.
Recommended actions
1. Check power supply (at output terminals). Reset or re-power the device.
2. If the error is persistent send the device for evaluation or replace the device.
5.17 Power supply voltage issues
LED status: solid red
The device is operated above its specified voltage supply range.
Recommended actions
1. Check power supply (at output terminals). Reset or re-power the device.
2. If the error is persistent send the device for evaluation or replace the device.
5.18 Electronics failure
LED status: solid red
The configuration in the NVM has become inconsistent.
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