Emerson Rosemount 648 Reference Manual

Reference Manual

00809-0200-4648, Rev CA

Rosemount™ 648 Wireless Temperature
Transmitter

with Rosemount X-well™ Technology

May 2020

Safety messages

Rosemount 648 Wireless Hardware Revision
HART® Device Revision
Device Install Kit/DD Revision

1
4
Device Revision 4, DD Revision 1 or higher

NOTICE

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

For technical assistance. contacts are listed below:

Customer Central

Technical support, quoting, and order related questions.

United States:

Asia Pacific:

Europe/Middle East/Africa:

North American Response Center

Equipment service needs

1-800-654-7768 (24 hours - includes Canada)

Outside of these areas, contact your local Emerson representative.

The Rosemount 648 Wireless and all other wireless devices should be installed only after the Wireless Gateway has been installed
and is functioning properly. Wireless devices should also be powered up in order of proximity from the Wireless Gateway,
beginning with the closest. This will result in a simpler and faster network installation.

Shipping considerations for wireless products (lithium batteries: Black Power Module, model number 701PBKKF):

The unit was shipped to you without the power module installed. Remove the power module prior to shipping the unit. Each Black
Power Module contains two “C” size primary lithium-thionyl chloride battery. Primary lithium batteries are regulated in
transportation by the U. S. Department of Transportation, and are also covered by IATA (International Air Transport Association),
ICAO (International Civil Aviation Organization), and ARD (European Ground Transportation of Dangerous Goods). It is the
responsibility of the shipper to ensure compliance with these or any other local requirements. Consult current regulations and
requirements before shipping.

Power Module Considerations (Black Power Module, model number 701PBKKF):

The Black Power Module with the wireless unit contains two “C” size primary lithium-thionyl chloride battery (model number
701PGNKF). Each battery contains approximately 2.5 grams of lithium, for a total of 5 grams in each pack. Under normal
conditions, the battery materials are self-contained and are not reactive as long as the batteries and the pack integrity are
maintained. Care should be taken to prevent thermal, electrical or mechanical damage. Contacts should be protected to prevent
premature discharge. Battery hazards remain when cells are discharged. Power modules should be stored in a clean and dry area.
For maximum power module life, storage temperature should not exceed 30 °C.

1-800-999-9307 (7:00 a.m. to 7:00 p.m. CST)

65 777 8211

49 (8153) 9390

CAUTION

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 a Emerson Sales Representative.

WARNING

Follow instructions

Failure to follow these installation guidelines could result in death or serious injury.

Ensure only qualified personnel perform the installation.

2

WARNING

Explosions

Explosions could result in death or serious injury.

Installation of this transmitter in an explosive environment must be in accordance with the appropriate local, national, and
international standards, codes, and practices. Review the approvals section of this manual for any restrictions associated with a
safe installation.

Before connecting a communicator in an explosive atmosphere, ensure the instruments in the segment are installed in
accordance with intrinsically safe or non-incendive field wiring practices.

Process leaks

Process leaks could result in death or serious injury.

Install and tighten process connectors 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.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following conditions:

This device may not cause harmful interference.

This device must accept any interference received, including interference that may cause undesired operation.

This device must be installed to ensure a minimum antenna separation distance of 8-in. (20 cm) from all persons.

The power module may be replaced in a hazardous area. The power module has surface resistivity greater than one gigaohm and
must be properly installed in the wireless device enclosure. Care must be taken during transportation to and from the point of
installation to prevent electrostatic charge build-up.

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.

3

4

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Contents

Chapter 1 Introduction.............................................................................................................. 7

1.1 Using this manual........................................................................................................................ 7

1.2 Product recycling/disposal...........................................................................................................7

Chapter 2 Configuration............................................................................................................ 9

2.1 Overview..................................................................................................................................... 9

2.2 Safety messages.......................................................................................................................... 9

2.3 Sensor connections....................................................................................................................11

2.4 Bench top configuration............................................................................................................ 15

2.5 HART menu tree........................................................................................................................ 17

2.6 Fast Key sequence..................................................................................................................... 20

2.7 Basic setup.................................................................................................................................20

2.8 Calibration.................................................................................................................................23

2.9 Advanced setup.........................................................................................................................27

2.10 Remove power module............................................................................................................31

Chapter 3 Installation...............................................................................................................33

3.1 Overview................................................................................................................................... 33

3.2 Safety messages........................................................................................................................ 33

3.3 Wireless considerations............................................................................................................. 34

3.4 Physical installation....................................................................................................................36

3.5 Ground the transmitter..............................................................................................................40

3.6 Fast Key sequence..................................................................................................................... 42

Chapter 4 Commissioning........................................................................................................ 43

4.1 Overview................................................................................................................................... 43

4.2 Safety messages........................................................................................................................ 43

4.3 Verify operation.........................................................................................................................45

Chapter 5 Operation and maintenance.....................................................................................49

5.1 LCD display screen messages.....................................................................................................49

5.2 Power module replacement.......................................................................................................57

Chapter 6 Troubleshooting...................................................................................................... 59

6.1 Overview................................................................................................................................... 59

Appendix A Reference data......................................................................................................... 67

A.1 Ordering information, specifications, and drawings...................................................................67

A.2 Product certifications................................................................................................................ 67

Appendix B Mapping for Non-DD Based Integration with Host Systems...................................... 69

B.1 Alert message mapping.............................................................................................................69

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B.2 Mapping of device variable index numbers................................................................................ 71

6 Rosemount 648 Wireless

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1 Introduction

1.1 Using this manual

The sections in this manual provide information on installing, operating, and maintaining
the Rosemount 648 Wireless Temperature Transmitter with WirelessHART™ protocol. The
sections are organized as follows:

Configuration provides instruction on commissioning and operating Rosemount 648

Wireless. Information on software functions, configuration parameters, and online
variables is also included.

Installation contains mechanical and electrical installation instructions.

Commissioning contains techniques for properly commissioning the device.

Operation and maintenance contains operation and maintenance techniques.

Reference data contains troubleshooting tips as well as information to contact technical

support over the phone or through email.

Reference data supplies procedure on how to get the specifications, ordering information,

and product certification.

Mapping for Non-DD Based Integration with Host Systems contains important alerts in the

HART® command 48 additional status field for the Rosemount 648 Wireless.

1.2 Product recycling/disposal

Consider recycling equipment and packaging. Dispose of the product and packaging in
accordance with local and national legislation.

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8 Rosemount 648 Wireless

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2 Configuration

2.1 Overview

This section contains information on configuration and verification that should be
performed prior to installation. Field Communicator and AMS Device Manager instructions
are given to perform configuration functions. For convenience, Field Communicator Fast
Key sequences are labeled “Fast Keys” for each software function below the appropriate
headings.

Sensor input trim example

Fast Keys sequence

2.2 Safety messages

Instructions and procedures in this section may require special precautions to ensure the
safety of the personnel performing the operations. Refer to the following safety messages
before performing an operation preceded by this symbol.

WARNING

Follow instructions

Failure to follow these installation guidelines could result in death or serious injury.

Ensure only qualified personnel perform the installation.

Explosions

Explosions could result in death or serious injury.

Installation of this transmitter in an explosive environment must be in accordance with the
appropriate local, national, and international standards, codes, and practices. Review the
approvals section of this manual for any restrictions associated with a safe installation.

Before connecting a communicator in an explosive atmosphere, ensure the instruments in
the segment are installed in accordance with intrinsically safe or non-incendive field wiring
practices.

1,2,3, etc.

Process leaks

Process leaks could result in death or serious injury.

Install and tighten process connectors before applying pressure.

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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.

This device complies with Part 15 of the FCC Rules. Operation is subject to the
following conditions:

This device may not cause harmful interference.

This device must accept any interference received, including interference that may cause
undesired operation.

This device must be installed to ensure a minimum antenna separation distance of 8-in.
(20 cm) from all persons.

The power module may be replaced in a hazardous area. The power module has surface
resistivity greater than one gigaohm and must be properly installed in the wireless device
enclosure. Care must be taken during transportation to and from the point of installation
to prevent electrostatic charge build-up.

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.

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2.3 Sensor connections

The Rosemount 648 Wireless is compatible with a number of RTD and thermocouple
sensor types. Figure 2-1 shows the correct input connections to the sensor terminals on
the transmitter. To ensure a proper sensor connection, anchor the sensor lead wires into
the appropriate compression terminals and tighten the screws.

Make sensor connections through the cable entry in the side of the connection head. Be
sure to provide adequate clearance for cover removal.

When using Rosemount X-well Technology, the Rosemount 648 Wireless is required to be
assembled to a Rosemount 0085 Pipe Clamp RTD Sensor in a direct mount 3-wire
configuration.

Thermocouple or millivolts inputs

The thermocouple can be connected directly to the transmitter. Use appropriate
thermocouple extension wire if mounting the transmitter remotely from the sensor.

RTD or ohm inputs

The wireless transmitter will accept a variety of RTD or ohmic configurations, including 2-,
3-, or 4-wire connections. If the device is mounted remotely using a 3- or 4-wire
connection, it will operate withing specifications without recalibration for lead wire
resistances of up to 5 ohms per lead (equivalent to 500 ft. of 20 AWG wire). In this case,
the leads between the RTD and transmitter is recommended to be shielded.

2.3.1

Sensor lead wire resistance effect—RTD input

Since the lead wires are part of the RTD circuit, the lead wire resistance needs to be
compensated for to achieve the best accuracy. This becomes especially critical in
applications where long sensor and/or lead wires are used. There are three lead wire
configurations commonly available.

A 4-wire design is ideal because the lead wire resistance is inconsequential to the
measurement. It uses a measurement technique where a very small constant current of
about 150 micro amps is applied to the sensor through two leads and the voltage
developed across the sensor is measured over the other two wires with a high-impedance
and high resolution measuring circuit. In accordance with Ohm's Law, the high impedance
virtually eliminates any current flow in the voltage measurement leads and therefore the
resistance of the leads is not a factor.

In a 3-wire configuration, compensation is accomplished using the third wire with the
assumption that it will be the same resistance as the other two wires and the same
compensation is applied to all three wires.

In a 2-wire configuration there can be no compensation for lead wire resistance since the
lead wires are in series with the element and appear to the transmitter as part of the
sensor's resistance causing inherent accuracy degradation.

Table 2-1: Examples of Approximate Basic Error

Sensor input Approximate basic error

4-wire RTD Negligible

(1)

Rosemount 648 Wireless 11

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

2-wire

RTD and Ω

3-wire

RTD and Ω

4-wire

RTD and Ω

T/C and mV

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Table 2-1: Examples of Approximate Basic Error (continued)

Sensor input Approximate basic error

3-wire RTD Error in reading is equivalent to unbalanced lead wire resistance

2-wire RTD Error in reading equivalent total lead wire resistance

(1) Independent of lead wire resistance up to 5Ω per lead.
(2) Unbalanced lead wire resistance is the maximum resistance differences between any of two

leads.

Figure 2-1: Sensor Wiring

Thermocouple/mV 4-Wire RTD and Ω

(2)

3-Wire RTD and Ω 2-Wire RTD and Ω

Figure 2-2: Sensor Connections

Note

Emerson provides 4-wire sensors for all single element RTDs. Use these RTDs in 3-wire
configurations by leaving the unneeded leads disconnected and insulated with electrical
tape.

12 Rosemount 648 Wireless

White (1)

White (2)

Red (3)

Red (4)

White (1)

White (2)

Red (3)

Red (4)

+ White (2)

- Red (3)

+ Purple (2)

- Red (3)

+ Yellow (2)

- Red (3)

+ Blue (2)

- Red (3)

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2.3.2 Lead wire configuration

Figure 2-3: Rosemount 68Q, 78 Standard Temperature Range, and 58 RTD Sensor
Single Element

Figure 2-4: Rosemount 65, 78 High Temp, 68 RTD Single Element

Figure 2-5: Rosemount 183 Thermocouple

Type J Type E

Type K Type T

Rosemount 648 Wireless 13

+ Black (2)

- White (3)

+ Pink (2)

- White (3)

+ Green (2)

- White (3)

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Figure 2-6: Rosemount 185 Thermocouple

Type J Type N

Type K

2.3.3

Note

Wire color examples apply to Rosemount sensors, but will vary by manufacturer.

Sensor leads

If the sensor is installed in a high-voltage environment and a fault condition or installation
error occurs, the sensor leads and transmitter terminals could carry lethal voltages. Use
extreme caution when making contact with the leads and terminals.

Use the following steps to wire the sensor and supply power to the transmitter:

1. Remove the transmitter enclosure cover (if applicable).

2. Attach the sensor leads according to the wiring diagrams.

3. Connect the power module.

4. Verify the connection by observing the LCD display (if applicable).

5. Reattach and tighten the cover (if applicable).

14 Rosemount 648 Wireless

COMM

P/N 00753-9200-0020

1

2

3

4

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2.4 Bench top configuration

Bench top configuration consists of testing the transmitter and verifying transmitter
configuration data. The transmitter must be configured before installation, which may be
performed either directly or remotely. Direct configuration can be performed using a Field
Communicator, AMS Device Manager, AMS Wireless Configurator, or any WirelessHART
Communicator. Remote configuration can be performed using AMS Device Manager, AMS
Wireless Configurator, or the Wireless Gateway.

The power module must be installed to provide power to the transmitter for
configuration. To communicate to the transmitter, begin by removing the power module­side housing cover, indicated as “Field terminals” by text located on the side of the device.
This will expose the terminal block and HART Communication terminals, which are labeled
“COMM”. Connect the power module to supply power for configuration. See Figure 2-7.

Figure 2-7: Connection Diagram for Rosemount 648 Wireless and Field
Communicator

™

2.4.1

Field Communicator

When performing device configuration directly, connect the bench equipment as shown
in Figure 2-7 above, and turn on the field communicator by pressing the ON/OFF key.
When using a Field Communicator, any configuration changes must be sent to the
transmitter by using the Send key (F2).

The Field Communicator will search for a HART®-compatible device and indicate when the
connection is made. If the Field Communicator fails to connect, it will indicate that no
device was found. If this occurs, refer to Troubleshooting.

Note

For HART Wireless transmitter communication via a Field Communicator, a Rosemount
648 Wireless Device Dashboard (DD) is required. Rosemount 648 Wireless Transmitters
equipped with Rosemount X-well Technology requires DD revision 648 Dev. 4 Rev. 1 or
higher to view Rosemount X-well functionality. To obtain the latest DD, visit

Emerson.com/Field-Communicator.

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2.4.2 AMS Device Manager and AMS Wireless Configurator

When configuring the Rosemount 648 Wireless using AMS Device Manager or AMS
Wireless Configurator, double click the Rosemount 648 Wireless device icon (or right click
and select Configure/Setup), then select the Configure/Setup tab. AMS Device Manager
configuration changes are implemented when the Apply button is selected.

Note

For HART Wireless transmitter communication via AMS Device Manager, a Rosemount
648 Wireless Device Dashboard (DD) is required. Rosemount 648 Wireless Transmitters
equipped with Rosemount X-well Technology requires DD revision 648 Dev. 4 Rev. 1 or
higher to view Rosemount X-well functionality. To obtain the latest DD, visit the Emerson

Easy Upgrade site.

2.4.3

2.4.4

Wireless Gateway

The Rosemount 648 Wireless supports limited remote configuration through the Wireless
Gateway. The Gateway allows configuration of the following device parameters: HART
Tag, Short Tag, Descriptor, Engineering Units, Update Rate and Range Values.

Default settings

The Rosemount 648 Wireless default configuration is shown below:

Sensor type

Engineering units °C

Number of lead wires 4

Network ID Factory-generated network parameters

Join Key Factory-generated network parameters

Update rate 1 minute

Note

The C1 option code can be used to enable factory configuration of the Update Rate, Date,
Descriptor and Message fields. This code is not required to have the factory configure the
Sensor Type, Connection or the Self Organizing Network parameters.

Pt 100 (α = 0.00386)

2.4.5

16 Rosemount 648 Wireless

Device sensor configuration

Every temperature sensor has unique characteristics. In order to ensure the most accurate
measurement, the device should be configured to match the specific sensor that it will be
connected to. Prior to installation, verify the configuration and connection settings of the
temperature sensor through a Field Communicator or AMS Device Manager.

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2.5 HART menu tree

This section displays the navigation paths to the primary commands and options via a Field
Communicator. For HART Wireless transmitter communication via a Field Communicator,
a Rosemount 648 Wireless Device Dashboard (DD) is required. Rosemount 648 Wireless
Transmitters with Rosemount X-well Technology requires DD revision 648 Dev. 4 Rev.1 or
higher to view Rosemount X-well functionality. To obtain the latest DD, visit the

Emerson.com/Field-Communicator.

Figure 2-8: Overview

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Figure 2-9: Configure

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Figure 2-10: Service Tools

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2.6 Fast Key sequence

Table 2-2 lists the Fast Key sequences for common transmitter functions.

Note

The Fast Key sequences assumes that the latest Device Dashboard (DD) is being used. The
latest DD revision can be found on the title page of this document.

Table 2-2: Rosemount 648 Wireless Fast Key Sequence

Function Fast Key sequence Menu items

Device
Information

Guided Setup 2, 1 Configure Sensor, Join to Network, Config Advance

Manual Setup 2, 2 Wireless, Sensor, Display, HART, Device Temperature,

Wireless
Configuration

Sensor
Configuration

Sensor
Calibration

2, 2, 7 Tag, Long Tag, Descriptor, Message, Date

2, 2, 1 Network ID, Join to Network, Broadcast Info

2, 2, 2, 5 Type, Connection, Units, Serial Number, Transmitter-

3, 5, 2 Sensor Value, Sensor Status, Current Lower Trim,

2.7 Basic setup

2.7.1 Configure sensor type

Fast Keys 2, 1, 1

Broadcasting, Calibrate Sensor

Terminal Temperature, Device Information, Power,
Security

Sensor Matching, RMT X-well Setup

Current Upper Trim, RTD 2 Wire Offset, Lower Sensor
Trim, Upper Sensor Trim, Device variable trim reset

Every temperature sensor has unique characteristics to achieve the most accurate
measurement. Configure the wireless transmitter to match the specific sensor type.

Procedure

1. From the Home screen, select 2: Configure.

2. Select 1: Guided Setup

3. Select 1: Configure Sensor, then follow on the on-screen instructions to complete
the configuration.

This method allows selection of the number of lead wires and temperature
engineering units for the sensor.

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2.7.2 Join device to network

Fast key 2, 1, 2

To communicate with the Wireless Gateway, and ultimately the host system, the
transmitter must be configured to communicate over the wireless network. This step is
the wireless equivalent of connecting wires from a transmitter to the host system.

Procedure

1. From the Home screen, select 2: Configure.

2. Select 1: Guided Setup.

3. Select 2: Join to Network.

4. Using a Field Communicator or AMS Device Manager to communicate with the
transmitter, enter the Network ID and Join Key so they match the Network ID and
Join Key of the Wireless Gateway and the other devices in the network.

Note

If the Network ID and Join Key are not identical to those set in the Gateway, the
transmitter will not communicate with the network. The Network ID and Join Key may be
obtained from the Wireless Gateway on the System Settings → Network → etwork
Settings page of the Wireless Gateway web based user interface.

Figure 2-11: Wireless Gateway Network Settings Page

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2.7.3 Configure update rate

Fast Keys 2, 1, 3

The Update Rate is the frequency at which a new measurement is taken and transmitted
over the wireless network. This by default is one minute. This may be changed at
commissioning, or at any time via AMS Device Manager. The update rate is user selectable
from one second to 60 minutes.

Procedure

1. From the Home screen, select 2: Configure.

2. Select 1: Guided Setup.

3. Select 3: Configure Update Rate.

4. When the device configuration is completed, remove the power module and
replace the module cover.

Postrequisites

NOTICE

The power module should be inserted only when the device is ready to be commissioned.
Use caution when handling the power module.

Figure 2-12: Terminal Block

Connect the HART® Communication leads to the COMM terminals on the terminal block.

22 Rosemount 648 Wireless