pyromation 442 Series User manual

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Series 442 Installation and Operating Instructions
1 SAFETY NOTES
Safe and secure operation of the head transmitter can only be guaranteed if the operating instructions and all safety notes
contained are, understood, and followed.
1.1 Correct Use
The unit is a universal, presettable temperature transmitter for resistance thermometer (RTD), thermocouple (TC) as well as
resistance and voltage sensors. The unit is constructed for mounting in a connection head (form B) and field housing. The
manufacturer cannot be held responsible for damage caused by misuse of the unit.
Separate Ex (hazardous area) documentation is attached with this operating manual as drawing M006601, for measurement
systems in hazardous areas. The installation conditions and connection values indicated in these instructions must be followed!
1.2 Installation and operation
The unit is constructed using the most up-to-date production equipment and complies with the safety requirements of the EU
guidelines. If it is installed incorrectly or is misused then certain application dangers can occur. Trained personnel must do
installation, wiring and maintenance of the unit. These personnel must have read and understood these instructions and must
follow them to the letter.
1.3 Operational safety - Hazardous areas
When installing the unit in a hazardous area the national safety requirements must be met. Make sure that all personnel are
trained in these areas. The measurement and safety rules must be followed in all these installations.
2 FUNCTION AND SYSTEM CONSTRUCTION
2.1 Function
Electronic monitoring and transformation of various input signals into an analog output signal in industrial temperature
measurement. The head transmitter is mounted in a connection head (form B) or separated from the sensor in a field housing.
Setting up of the head transmitter is done using a “HARTCommunicator DXR 275” or PC and configuration software.
2.2 Measurement system
Transforming the following input signals:
•Resistance thermometers (RTD) and resistance sensors (in 2, 3 or 4 wire connection systems)
•Thermocouples (TC)
•Voltage sensors into a scalable analog output signal (4…20 or 20…4) mA
Fault monitoring of:
•Measurement range override or undercut
•Sensor breakage and short circuit - not for thermocouples (TC)
3 INSTALLATION
3.1 Installation conditions
Ambient temperature: (-40 to 85) °C [-40 to 185] °F (For hazardous areas, see drawing M006601)
Installation area: Field housing; connection head Form B according to DIN 43 729
Installation angle: No limit
Safety notes: The unit must only be powered by a power supply that operates using an IEC 61010-1 compliant energy limited
circuit.
3.2 Installation
•Feed the sensor leadwires through the central hole in the head transmitter
•Position the head transmitter in the connection head in such way so that the current output terminals (terminals 1 and 2) are
towards the cable entry gland.
•Feed the mounting screws (M4 x 20 mm long for form B heads) through the holes in the head transmitter.
•Screw the head transmitter into the field housing using a screwdriver while not over tightening.

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4 WIRING
4.1 Overview
Figure 4-1 Head transmitter wiring
4.2 Measurement unit connection
Attention: Switch off power supply before opening the housing cover. Do not install or connect the unit to power. If this is not
followed parts of the electronic circuit will be damaged.
•Sensors:
Connect the sensor leads to the respective head transmitter terminals (Terminals 3 to 6) by following the wiring diagram (see
figure 4-1).
•Output signal and power supply:
Connect dc power cables to terminals 1 and 2 according to the wiring diagram (see figure 4-1).
Hint: The screws on the terminals must be screwed tightly. Head transmitter configuration during measurement operation is
possible. There is no need to disconnect cables!
4.3 HART

connection
Connection is made directly using the (4 to 20) mA signal cables. Note: The measurement circuit must have a load of at least
250 Ω. See Figure 4-2 and 4-3.
Connection of a HART

hand operating module DXR 275
Figure 4-2 Electrical connection of the HARToperating module
A = HARTmodule
B = Loop power supply
C = HARTtransmitter
D = PLC with passive input
Pos. A
(11.5 to 30) V dc
(4 to 20) mA

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Connection of HART

modem using TransComm Software
Figure 4-3 Electrical connection of the HARTmodem
A = HARTmodem
B = Loop power supply
C = HARTtransmitter
D = PLC with a passive input
4.4 Shield grounding
Please take note when installing the head transmitter remotely in a field housing. The shield on the (4 to 20) mA signal output must
have the same potential as the shield at the sensor connections! When using grounded thermocouples, shielding of the output (4
to 20) mA cable is recommended. In plants with strong electromagnetic fields, shielding of all cables with a low ohm connection to
the transmitter housing is recommended.
5 OPERATION
5.1 Communication
The temperature transmitter is setup using the HARTprotocol. The values measured can also be read using the HARTprotocol
using a universal hand operating module “HARTCommunicator DXR 275/375.
5.2 HART

Communicator DXR 275
Selection of the unit functions using the “HARTCommunicator” is done using various menu levels as well as with the help of a
special HARTfunction matrix (see figure 6-2).
Hint: When using the HARThand unit all parameters can be read out, however, the programming is blocked. It is possible to
release the HARTfunction matrix by entering 281 in the LOCK function. The condition remains even after a power failure. The
HARTfunction matrix can be locked again by releasing the personal code number. More detailed information to the HARThand
operation module can be found in its respective operating manual.
6 INSTALLING
6.1 Installation check
Monitor all connections making sure they are tight. In order to guarantee fault free operation the terminal screws must be tight onto
the connection leads. The unit is now ready for operation.
6.2 Function check
Measuring the analog (4 to 20) mA output signal or following failure signals:
Underranging
Linear drop from 4.0 to 3.8 mA
Overranging Linear increase from 20.0 to 20.5 mA
Failure, e.g. sensor breakage; sensor
short circuit
≤3.6 mA (“low”) or ≥21 mA (“high”), can be selected
The “high” alarm setting can be set between 21.6 mA and 23 mA, thus providing the
flexibility needed to meet the requirements of various control systems.
6.3 Installation
Once the power supply has been connected the head transmitter is operational.

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6.4 Quick Setup
The head transmitter left the factory with a default parameter configuration. If no customer specific configuration was mentioned on
the order then the default parameter configuration is constructed as follows:
Sensor
Pt100 (RTD)
Connection mode 3-wire
Measurement range and units (0 to 100) °C
Using the Quick Setup the operator is led through all the most important unit functions that must be setup for standard
measurement operation of the unit. Using the HARThand module a quick set-up of the black highlighted fields of the HART
function matrix (see figure 6-2) is possible.
• Type of sensor (V2H0)
• Unit meas. Value (V2H2)
• Value of 4 mA (V2H4)
• Value of 20 mA (V2H5)
• Connection (V2H6)
6.5 Configuration with HART

protocol
Selection of all head transmitter functions using the HARThand module is done with various menu levels with the help of the
Pyromation function matrix (see figure 6-2). All head transmitter functions are described in 6.6, Description of unit functions.
What needs to be done:
1. Switch on the hand module:
- Measurement unit is not yet connected. The HARTmain menu appears. This menu level appears for all HART
programming independent of the type of instrumentation. Information to offline programming can be found in the
“Communicator DXR 275/375 operating manual.
- Measuring unit is connected. The menu level “Online” appears. In this “Online” menu level the actual measured data such
as measured value (PV) and output current (AO) are continuously displayed. Entry into the Series 442 operating matrix is
done using the line “Matrix parameters”. This matrix systematically contains all HARTaccessible functions.
2. Using “Matrix parameters” the function group can be selected (e.g. basic calibration) and then followed by the required
function, e.g. “Sensor input”.
3. Enter numeric values or change settings. Then acknowledge using the F4 “Entry” function key.
4. “SEND” appears when operating the F2 function key. Once the F2 key has been operated all values entered in the hand
module are transmitted to the Series 442 measurement system.
5. A return to the “Online” menu level is made using the F3 “HOME” function key. Here, the actual transmitter values measured
with the new settings can be read.
Figure 6-1 Configuration at the hand module example “Sensor input”

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Figure 6-2 HARTfunction matrix
6.6 Description of unit functions
The following table contains a listing and description of all functions of the HARTprotocol that can be used for setting up the
temperature transmitter. Note: Factory default values are shown in bold text. The HARToperating module (DXR275) display is
indicated by the following symbol.
Function group: WORKING PARAMETERS
Primary value
•V0H0
•(PV)
Display of actual measured temperature
Display: 7-digit number with floating decimal point and engineering unit.
(e.g. 199.98 Ohm; -62.36 deg. C)
Int. temperature
•V0H1
Display of the actual measured temperature of the internal comparison measurement point.
Filter time
•V0H2
Digital filter selection 1st grade.
Input: (0 to 100) seconds
0 s
RJ Mode
•V0H3
Selection of internal (Pt100) or external (0 to 80) °C cold junction compensation.
Entry: Internal; External
Internal
RJ External Value
•V0H4
Entry of external cold junction value.
Entry: (-40.00 to 85.00) °C (°C, °F, K)
0.00
°
C
Hint! Entry only possible on selection of an external cold junction compensation in unit function
RJ MODE.
Bias Input (Offset)
•V0H5
Entry of zero point correction (Offset).
Entry: (-10.00 to 10.00) °C (°C, °F, K)
0.00
°
C
Hint! Entry returns to factory default values when changing sensor type!

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Function group: BASIC CALIBRATION
Type of sensor
•V2H0
Entry of sensor used:
Sensor type Range start Range end value
(-10 to 75) mV -10 mV 75 mV
(10 to 400) Ω10 Ω400 Ω
(10 to 2000) Ω10 Ω2000 Ω
Pt100 DIN -200 °C [-328 °F] 850 °C [1562 °F]
Pt100 JIS -200 °C [-328 °F] 649 °C [482 °F]
Pt500 -200 °C [-328 °F] 250 °C [482 °F]
Pt1000 -200 °C [-328 °F] 250 °C [482 °F]
Ni100 -60 °C [-76 °F] 180 °C [356 °F]
Ni500 -60 °C [-76 °F] 150 °C [302 °F]
Ni1000 -60 °C [-76 °F] 150 °C [302 °F]
Polynom RTD -270 °C [-454 °F] 2500 °C [4532 °F]
Type B 0 °C [32 °F] 1820 °C [3308 °F]
Type C 0 °C [32 °F] 2320 °C [4208 °F]
Type D 0 °C [32 °F] 2495 °C [4523 °F]
Type E -270 °C [-454 °F] 1000 °C [1832 °F]
Type J -210 °C [-346 °F] 1200 °C [2192 °F]
Type K -270 °C [-454 °F] 1372 °C [2501 °F]
Type L -200 °C [-328 °F] 900 °C [1652 °F]
Type N -270 °C [-454 °F] 1300 °C [2372 °F]
Type R -50 °C [-58 °F] 1768 °C [3214 °F]
Type S -50 °C [-58 °F] 1768 °C [3214 °F]
Type T -270 °C [-454 °F] 400 °C [752 °F]
Type U -200 °C [-328 °F] 600 °C [1112 °F]
Polynom TC -270 °C [-454 °F] 2500 °C [4532 °F]
Pt100 DIN
Temp. Compensation
•V2H1
Selection of temperature compensation of the cold junction when using customer specific
linearization of the TC polynomial
Input:
None, Type B, Type C, Type D, Type E, Type J, Type K, Type L, Type N, Type R, Type S, Type T,
Type U
None
Measuring Unit
•V2H2
Enter engineering units.
Entry: °C, °F, K
°
C
Current output
•V2H3
Enter standard (4 to 20) mA or inverse (20 to 4) mA current output signal.
Entry: 4-20 mA
20-4 mA
4-20 mA
Value of 4 mA
•V2H4
Entry: For limits see unit function SENSOR TYPE
0.00
°
C
Value of 20 mA
•V2H5
Entry: For limits see unit function SENSOR TYPE.
100.00
°
C
Connection
•V2H6
•RTD connection
Entry of RTD Connection mode
Entry: 2 wire
3 wire
4 wire
3 wire

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2 wire comp.
•V2H7
Entry of leadwire compensation on RTD 2 wire connection
Entry: (0.00 to 30.00) Ohm
0.00 Ohm
Failsafe mode
•V2H8
Entry of failure signal on sensor fracture or short circuit.
Entry: Max (≥21.0 mA)
Min (≤3.6 mA)
Min
Function group: USER LINERIZATION
The following function fields are only active in the unit function SENSORTYPE (V2H0) on selection of customer-specific linearization (Polynomial TC or RTD)
Coefficient X0
•V3H0
Input of first coefficient for customer-specific linearization (4th order polynomial with five
coefficients), see 6.8, Interactive setting up of the temperature transmitter
Coefficient X1
•V3H1
Input COEFFICIENT X1, see 6.8, Interactive setting up of the temperature transmitter
Coefficient X2
•V3H2
Input COEFFICIENT X2, see 6.8, Interactive setting up of the temperature transmitter
Coefficient X3
•V3H3
Input COEFFICIENT X3, see 6.8, Interactive setting up of the temperature transmitter
Coefficient X4
•V3H4
Input COEFFICIENT X4, see 6.8, Interactive setting up of the temperature transmitter
Function group: SERVICE
Error code
•V9H0
Display of actual error code.
Display: See “8.1, Application fault messages”
0
Last diagnostic
•V9H1
Display of previous error code.
Display: See “8.1, Application fault messages”
0
Config. changed
•V9H2
Parameter changes are done.
Display: Yes/no
No
Min Indication
•V9H3
Display the minimum process value. The process value is accepted at the beginning of the
measurement.
Hint! Min. process value will be changed to the actual process value on write. On reset to factory
default, the default value is entered.
+10 000
Max Indication
•V9H4
Display the maximum process value. The process value is accepted at the beginning of the
measurement.
Hint! Max. process value will be changed to the actual process value on write. On reset to factory
default, the default value is entered.
-10 000

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Default values
•V9H5
Entry: 182 (Reset to factory default settings)
0
Output current
•V9H6
Display of the actual output current signal.
Simulation mode
•V9H7
Entry of simulation mode.
Entry: Off
On
Off
Simulation value
•V9H8
Entry of simulation value (current).
Entry: (3.58 to 21.7) mA
0.00 mA
Security locking
•V9H9
Release code for setting up.
Entry: Lock= 0
Release= 281
281
Function group: USER INFORMATION
Tag number
•VAH0
Entry and display of measure point description (TAG).
Entry: 8 characters
Descriptor
•VAH1
Entry and display of plant description.
Entry: 16 characters
Hardware version
•VAH2
Display of unit version.
e.g.: 1.0000 indicates version 1.00.00
Software version
•VAH3
•Software Rev.
Display of software version.
e.g.: 8010 indicates version 1.0
Serial Number
•VAH4
8-digit display of Pyromation device serial numbers

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6.7 Configuration using HARTprotocol and TransComm
The configuration of the head transmitter can be done using both the HARTprotocol and the TransComm software. The following
table shows the structure of the interactive menu led operation of TransComm.
Configurable parameters
Standard settings
• Sensor type
• Connection mode (2, 3 or 4 wire connection)
• Units (°C or °F)
• Measurement range start (depends on sensor)
• Measurement range end (depends on sensor)
• Coefficient X0 to X4 (on sensor type Polynom RTD/TC)
• Temperature-compensation (on sensor type Polynom TC)
Expanded settings
• Cold junction compensation (internal/external on TC connection)
• Temperature external (on TC with cold junction compensation external)
• Compensation resistance (0 to 20) Ωon 2 wire connection
• Fault condition reaction (≤3.6 mA or ≥21.0 mA)
• Output (analog standard/inverse)
• Damping (0 to 8) s
• Offset (-9.9 to +9.9) °C [-17.8 to +17.8] °F
• TAG (Measurement point identification)
• Identifier (Descriptor)
Service functions • Simulation (on/off)
For detailed TransComm operating instructions please read the online documentation contained in the software.
6.8 Interactive setting up of the temperature transmitter
Customer specific linearization and sensor matching is done using the TransComm configuration software. The program
calculates the linearization coefficients X0 to X4 that need to be entered into the PC configuration software.
7 MAINTENANCE
The head transmitter is maintenance free.
8 TROUBLESHOOTING
Always start troubleshooting with the checklists below if faults occur after start up or during operation. This takes you directly (via
various queries) to the cause of the problem and the appropriate remedial measures. Note: Due to its design, the device cannot
be repaired. However, it is possible to send the device in for examination.
8.1 Application fault message
Application fault messages are shown in the display of the HARThand operating module “DXR275/375” once the menu point
“ERROR CODE” has been selected.
Fault code
Cause
Action/cure
0 No fault, Warning None
10 Hardware fault (unit defective) Replace head transmitter
11 Sensor short circuit Check sensor
12 Sensor cable open circuit Check sensor
13 Reference measurement point defective None
14 Unit not calibrated Return head transmitter to manufacturer
106
Up/Download active None (will be automatically acknowledged)
201
Warning: Measured value too small Enter other values for measured value range start
202 Warning: Measured value too large Enter other values for measured range end
203 Unit is reset (to factory default settings) None

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8.2 Application faults without messages
General errors
Problem
Possible cause
Remedy
Device not reacting
Supply voltage does not match that
specified on the nameplate. Apply the correct voltage.
No contact between connecting cables and
terminals.
Check the contacting of the cables and
correct if necessary.
Output current < 3.6 mA Signal cable is wired incorrectly. Check wiring.
Electronics are defective. Replace the device.
HART communication not
working.
Missing or incorrectly installed
communication resistor. Install the communication resistor (250 Ω) correctly.
HART-Modem is connected incorrectly.
Connect HART-Modem correctly.
Application errors for RTD sensor connection
Problem
Possible cause
Remedy
Measured value is
incorrect/inaccurate.
Incorrect sensor orientation. Install the sensor correctly.
Heat conducted by sensor.
Observe the face-to-face length of the
sensor.
Device programming is incorrect (number of
wires).
Change the Connection type device
function.
Device programming is incorrect (scaling).
Change scaling.
Incorrect RTD configured.
Change the Sensor type device function.
Sensor connection.
Check that the sensor is connected
correctly.
The cable resistance of the sensor (2-wire)
was not compensated.
Compensate the cable resistance.
Offset incorrectly set.
Check offset.
Failure current (≤ 3.6 mA or
≥ 21 mA)
Faulty sensor. Check the sensor.
RTD connected incorrectly.
Connect the connecting cables correctly
(terminal diagram).
Incorrect device programming (e.g. number
of wires).
Change the Connection type device
function.
Incorrect programming.
Incorrect sensor type set in the Sensor type
device function. Set the correct sensor type.

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Application errors for TC sensor connection
Problem
Possible Cause
Remedy
Measured value is
incorrect/inaccurate
Incorrect sensor orientation.
Install the sensor correctly.
Heat conducted by sensor.
Observe face-to-face length of the sensor.
Device programming is incorrect (scaling).
Change scaling.
Incorrect thermocouple type (TC)
configured.
Change the Sensor type device function.
Incorrect comparison measuring point set. Set the correct reference junction.
Interference via the thermocouple wire
welded in the thermowell (interference
voltage coupling).
Use a sensor where the thermocouple wire
is not welded.
Offset incorrectly set. Check offset.
Failure current (≤ 3.6 mA or
≥ 21 mA)
Faulty sensor. Check the sensor.
Sensor is connected incorrectly.
Connect the connecting cables correctly
(terminal diagram).
Incorrect programming
Incorrect sensor type set in the Sensor type
device function. Set the correct sensor type.