Emerson Rosemount 644 User manual

Quick Start Guide
00825-0200-4728, Rev LC
April2023
Rosemount™ 644 Temperature
Transmitter
with 4–20 mA HART® Protocol (Revision
5 and 7)

Contents
About this guide...........................................................................................................................3
System readiness......................................................................................................................... 5
Transmitter installation...............................................................................................................6
Safety instrumented systems...................................................................................................24
Product certifications................................................................................................................ 25
Declaration of Conformity........................................................................................................ 44
China RoHS................................................................................................................................. 48
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2 Rosemount 644

1 About this guide
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.
Safety messages
WARNING
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 Emerson nuclear-qualified products, contact your
local Emerson Sales Representative.
Follow instructions
Failure to follow these installation guidelines could result in death or
serious injury.
Ensure only qualified personnel perform the installation.
Physical access
Unauthorized personnel may potentially cause significant damage to
and/or misconfiguration of end users’ equipment. This could be
intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and
fundamental in protecting your system. Restrict physical access by
unauthorized personnel to protect end users’ assets. This is true for
all systems used within the facility.
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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. Kindly 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 that 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.
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.
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.
CAUTION
Conduit/cable entries
Unless otherwise marked, the conduit/cable entries in the
housing enclosure use a ½–14 NPT form. Only use plugs,
adapters, glands, or conduit with a compatible thread form when
closing these entries.
Entries marked "M20" are M20 x 1.5 thread form.
When installing in a hazardous location, use only appropriately
listed or Ex certified plugs, glands, or adapters in cable/conduit
entries.
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2 System readiness
2.1 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 the transmitter for either HART Revision
5 or 7.
2.2 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 2-1 provides the information necessary to ensure the
correct Device Driver files and documentation are being used.
Table 2-1: 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 00809-010
0-4728
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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3 Transmitter installation
3.1 Mount the transmitter
Mount the transmitter at a high point in the conduit run to prevent
moisture from draining into the transmitter housing.
3.1.1 Head mount transmitter with DIN plate style sensor
installation
WARNING
Enclosure
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
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.
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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
3.1.2 Head mount transmitter with threaded sensor installation
(two or three conduit entries)
WARNING
Enclosure
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
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.
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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.
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.
A. Threaded thermowell
B. Threaded style sensor
C. Universal head (transmitter inside)
D. Standard extension
E. Conduit entry
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3.1.3 Field mount transmitter with threaded sensor installation
WARNING
Enclosure
Enclosure covers must be fully engaged to meet explosion-proof
requirements.
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.
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.
A
C
B
D
E
A. Threaded thermowell
B. Threaded style sensor
C. Standard extension
D. Field mount housing (transmitter inside)
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E. Conduit entry
3.2 Wire and apply power
3.2.1 Wire the sensor to the transmitter
Figure 3-1: 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 3-2: Rosemount 644 Field Mount — Single and Dual Input
Wiring Diagrams
3.2.2 Power the transmitter
An external power supply is required to operate the transmitter.
Procedure
1. Remove the housing cover (if applicable).
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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).
WARNING
Enclosue
Enclosure covers must be fully engaged to meet explosion-
proof requirements.
5. Apply power (12–42 Vdc).
3.2.3 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.
3.2.4 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).
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).
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Ground the transmitter: option 1
Procedure
1. Connect sensor wiring shield to the transmitter housing.
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.
A
B
C
DCS
D
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4-20 mA loop
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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.
A
B
C
D
DCS
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4-20 mA loop
Note
Connect shields together, electrically isolated from the
transmitter.
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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 the signal wiring shield at the power supply end.
DCS
A
B
C
D
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4-20 mA loop
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Grounded thermocouple inputs
Ground the transmitter: option 4
Procedure
1. Ground sensor wiring shield at the sensor.
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.
DCS
A
B
C
D
A. Sensor wires
B. Transmitter
C. Shield ground point
D. 4–20 mA loop
3.3 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.
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6. Apply power and set the loop to automatic control (if
applicable).
Figure 3-3: Alarm Switch Placement
A
Rosemount 644 Transmitter Rosemount 644 Field Mount
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.
WARNING
Enclosure
Enclosure covers must be fully engaged to meet explosion-
proof requirements.
3.4 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 Guide for more
information.
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3.4.1 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 3-1. 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.
Note
Emerson recommends installing the latest DD to access the complete
functionality. Visit Emerson.com/Field-Communicator for information
on updating the DD Library.
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3.4.2 Field Communicator user interface
Two user interfaces are available to configure this device.
Figure 3-4 may be used for transmitter configuration and startup.
Figure 3-4: Device Dashboard Field Communicator Interface
Table 3-1: 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
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
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Table 3-1: Device Revision 8 and 9 (HART® 5 and 7), DD Revision 1
Fast Key Sequence (continued)
Function HART 5 HART 7
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
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
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Table 3-1: Device Revision 8 and 9 (HART® 5 and 7), DD Revision 1
Fast Key Sequence (continued)
Function HART 5 HART 7
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
3.4.3 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, select 2 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.
3.4.4 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 3-2 and Figure 3-6 for button operation and menu
information.
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20 Rosemount 644