Rosemount Manual: Rosemount 644 Head and Rail Mount Temperature Transmitters Manuals & Guides
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rosemount 644 Head and Rail Mount
Temperature Transmitters
www.rosemount.com
Reference Manual
NOTICE
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Rosemount 644
Temperature Transmitters
Rosemount 644 Hardware Revision
®
Device Revision
HART
Field Communicator Field Device Revision
OUNDATION
F
OUNDATION fieldbus Device Revision
F
Read this manual before working with the product. For personal and system safety, and for
optimum product performance, make sure to thoroughly understand the contents before
installing, using, or maintaining this product.
The United States has two toll-free assistance numbers and one international number.
Customer Central
1-800-999-9307 (7:00 a.m. to 7:00 P.M. CST)
National Response Center
1-800-654-7768 (24 hours a day)
Equipment service needs
International
1-(952) 906-8888
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 Process
Management Sales Representative.
™
fieldbus Hardware Revision
26
5.6
Dev v6, DD v1
5
1
www.rosemount.com
Reference Manual
00809-0100-4728, Rev KA
July 2010
Table of Contents
Rosemount 644
SECTION 1
Introduction
SECTION 2
Installation
SECTION 3
HART
Configuration
SECTION 4
Foundation
fieldbus
Configuration
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Return of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Multidrop Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Block Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Foundation fieldbus function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
APPENDIX A
Specifications and
Reference Data
APPENDIX B
Product
Certifications
APPENDIX C
Foundation
fieldbus Block
Information
HART and Foundation Fieldbus Specifications . . . . . . . . . . . . . . . . . A-1
Foundation Fieldbus Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
4–20 mA / HART Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Stainless Steel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Approved Manufacturing Locations . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
European Union Directive Information . . . . . . . . . . . . . . . . . . . . . . . . B-1
Hazardous Locations Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Installation Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Basic Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Resource Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Sensor Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Analog Input (AI) Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
LCD Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
PID Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
TOC-1
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rosemount 644
TOC-2
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Section 1 Introduction
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-2
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-3
Return of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4
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.
Warnings
Failure to follow these installation guidelines could result in death or
serious injury.
• Make sure only qualified personnel perform the installation.
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 HART or F
make sure the instruments in the loop are installed in accordance with intrinsically
safe or non-intrinsic 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.
OUNDATION fieldbus in an explosive atmosphere,
www.rosemount.com
Reference Manual
00809-0100-4728, Rev KA
Rosemount 644
OVERVIEW
Manual This manual is designed to assist in the installation, operation, and
maintenance of Rosemount 644 head mount and 644 rail mount.
Section 1: Introduction
• Transmitter and Manual Overview
• Considerations
• Return of Material
Section 2: Installation
• Mounting
• Installation
• Wiring
• Power Supply
• Commissioning
Section 3: HART Configuration
• Field Communicator
• Configuration
• Multidrop Communication
July 2010
Section 4: F
• Calibration
• Hardware Maintenance
• Diagnostic Messaging
Appendix A: Specifications and Reference Data
• Specifications
• Dimensional drawings
• Ordering Information
• Biotechnology, Pharmaceutical Industries, and Sanitary Applications
Appendix B: Approvals
• Product Certifications
• Installation Drawings
Appendix C: Foundation fieldbus Block Information
• Information regarding the Function Blocks
OUNDATION fieldbus Configuration
Transmitter Features of the Rosemount 644 include:
• Accepts inputs from a wide variety of sensors
• Configuration using HART protocol or F
• Electronics that are completely encapsulated in epoxy and enclosed in
a metal housing, making the transmitter extremely durable and
ensuring long-term reliability
• A compact size and two housing options allowing mounting flexibility for
the control room or the field
OUNDATION fieldbus
1-2
Reference Manual
00809-0100-4728, Rev KA
July 2010
Refer to the following literature for a full range of compatible connection
heads, sensors, and thermowells provided by Emerson Process
Management.
• Temperature Sensors and Assemblies Product Data Sheet, Volume 1
(document number 00813-0100-2654)
• Temperature Sensors and Assemblies Product Data Sheet, Volume 2
(document number 00813-0200-2654)
Rosemount 644
CONSIDERATIONS
General Electrical temperature sensors such as RTDs and thermocouples produce
low-level signals proportional to their sensed temperature. The 644 converts
the low-level sensor signal to a standard 4–20 mA dc, digital HART, or digital
OUNDATION fieldbus signal that is relatively insensitive to lead length and
F
electrical noise. This signal is then transmitted to the control room via two
wires.
Commissioning The transmitter can be commissioned before or after installation. It may be
useful to commission it on the bench, before installation, to ensure proper
operation and to become familiar with its functionality. Make sure the
instruments in the loop are installed in accordance with intrinsically safe,
FISCO, or non-incendive field wiring practices.
Mechanical Location
When choosing an installation location and position, take into account the
need for access to the transmitter.
Special Mounting
Special mounting hardware is available for mounting a 644 head mount
transmitter to a DIN rail, or assembling a new 644 head mount to an existing
threaded sensor connection head (former option code L1).
Electrical Proper electrical installation is necessary to prevent errors due to sensor lead
resistance and electrical noise. For best results, shielded cable should be
used in electrically noisy environments.
Make wiring connections through the cable entry in the side of the connection
head. Be sure to provide adequate clearance for cover removal.
Environmental The transmitter electronics module is permanently sealed within the housing,
resisting moisture and corrosive damage. Verify that the operating
atmosphere of the transmitter is consistent with the appropriate hazardous
locations certifications.
Temperature Effects
The transmitter will operate within specifications for ambient temperatures
between –40 and 185 °F (–40 and 85 °C). Heat from the process is
transferred from the thermowell to the transmitter housing. If the expected
process temperature is near or beyond specification limits, consider the use of
additional thermowell lagging, and extension nipple, or a remote mounting
configuration to isolate the transmitter from the process.
Figure 1-1 provides an example of the relationship between transmitter
housing temperature rise and extension length.
1-3
Rosemount 644
Housing Temperature Rise, Above
Ambient °C (°F)
3 4 5 6 7 8 9
0
60 (108)
50 (90)
40 (72)
30 (54)
20 (36)
10 (18)
3.6
22
Extension Length (in.)
815 °C (1500 °F) Oven Temperature
540 °C (1000 °F)
Oven Temperature
250 °C (482 °F) Oven Temperature
Figure 1-1. 644 head mount
Transmitter Connection Head
Temperature Rise vs. Extension
Length
Reference Manual
00809-0100-4728, Rev KA
July 2010
Example
The transmitter specification limit is 85 °C. If the ambient temperature is 55 °C
and the process temperature to be measured is 800 °C, the maximum
permissible connection head temperature rise is the transmitter specification
limit minus the ambient temperature (moves 85 to 55 °C), or 30 °C.
In this case, an extension of 100 mm meets this requirement, but 125 mm
provides a margin of 8 °C, thereby reducing any temperature effects in the
transmitter.
RETURN OF MATERIALS To expedite the return process in North America, call the Emerson Process
Management National Response Center toll-free at 800-654-7768. This
center, available 24 hours a day, will assist you with any needed information
or materials.
The center will ask for the following information:
• Product model
• Serial numbers
• The last process material to which the product was exposed
The center will provide
• A Return Material Authorization (RMA) number
• Instructions and procedures that are necessary to return goods that
were exposed to hazardous substances
For other locations, please contact a Emerson Process Management sales
representative.
NOTE
If a hazardous substance is identified, a Material Safety Data Sheet (MSDS),
required by law to be available to people exposed to specific hazardous
substances, must be included with the returned materials.
1-4
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Section 2 Installation
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-9
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13
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.
Warnings
Failure to follow these installation guidelines could result in death or
serious injury.
• Make sure only qualified personnel perform the installation.
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 Field Communicator in an explosive atmosphere, make sure
the instruments in the loop are installed in accordance with instrinsically 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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Rosemount 644
START
HERE
Bench
Calibration?
BASIC SETUP
Set Sensor Type
Set Number of Wires
Set Units
Set Range Values
Set Damping
VERIFY
Simulate Sensor Input
Within
Specifications?
Refer to Section 4: Foundation
fieldbus Configuration
FIELD INSTALL
Set Failure Mode
Switch
Mount Transmitter
Wire Transmitter
Power Transmitter
FINISHED
Does not apply to the 644
with F
OUNDATION fieldbus
Figure 2-1. Installation Flowchart
Reference Manual
00809-0100-4728, Rev KA
July 2010
2-2
Reference Manual
Transmitter
Mounting
Hardware
Rail Clip
Transmitter
Mounting
Hardware
Rail Clip
Kit includes
replacement bracket
and screws.
Existing Threaded Sensor Connection Head
(Former option code L1)
00809-0100-4728, Rev KA
July 2010
Rosemount 644
MOUNTING Mount the transmitter at a high point in the conduit run to prevent moisture
from draining into the transmitter housing.
The 644 head mount installs
• In a connection head or universal head mounted directly on a sensor
assembly
• Apart from a sensor assembly using a universal head
• To a DIN rail using an optional mounting clip.
The 644 rail mount attaches directly to a wall or to a DIN rail.
Mounting a 644H to a DIN Rail
To attach a head mount transmitter to a DIN rail, assemble the appropriate rail
mounting kit (part number 00644-5301-0010) to the transmitter as shown in
Figure 2-2. Follow the procedure under “Rail Mount Transmitter and Sensor
(HART only)”.
Figure 2-2. Assembling Rail Clip
Hardware to a 644H
G-Rail (asymmetric) Top Hat Rail (symmetric)
Figure 2-3. Assembling 644H for
Use in an Existing L1
Connection Head
Note: Kit includes Mounting Hardware and both types of Rail Kits.
Retrofitting a 644H for Use in an Existing Threaded Sensor Connection
Head
To mount a 644H in an existing threaded sensor connection head (former
option code L1), order the 644H retrofit kit (part number 00644-5321-0010).
The retrofit kit includes a new mounting bracket and all associated hardware
necessary to facilitate the installation of the 644H in the existing head. See
Figure 2-3.
2-3
Rosemount 644
A
D
B
C
E
F
INSTALLATION
Reference Manual
00809-0100-4728, Rev KA
July 2010
Typical European
Installation
Head Mount Transmitt er with DIN Plate Style Sensor
(HART and F
OUNDATION fieldbus)
1. Attach the thermowell to the pipe or process container wall. Install
and tighten the thermowell before applying process pressure.
2. Verify the transmitter failure mode switch (HART only).
3. Assemble the transmitter to the sensor. Push the transmitter
mounting screws through the sensor mounting plate and insert the
snap rings (optional) into the transmitter mounting screw groove.
4. Wire the sensor to the transmitter (see Figure 2-9 on page 2-11).
5. Insert the transmitter-sensor assembly into the connection head.
Thread the transmitter mounting screw into the connection head
mounting holes.Assemble the extension to the connection head.
Insert the assembly into the thermowell.
6. Attach a cable gland into the shielded cable.
7. Insert the shielded cable leads into the connection head through the
cable entry. Connect and tighten the cable gland.
8. Connect the shielded power cable leads to the transmitter power
terminals. Avoid contact with sensor leads and sensor connections.
9. Install and tighten the connection head cover. Enclosure covers must
be fully engaged to meet explosion-proof requirements.
A = 644H Transmitter D = Transmitter Mounting Screws
B = Connection Head E = Integral Mount Sensor with Flying Leads
C = Thermowell F = Extension
2-4
Reference Manual
A
B
C
D
E
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Typical North American
Installation
Head Mount Transmitter with Threaded Sensor
(HART and F
OUNDATION fieldbus)
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.
Seal the nipple and adapter threads with silicone tape.
3. Screw the sensor into the thermowell. Install drain seals if required for
severe environments or to satisfy code requirements.
4. Verify the transmitter failure mode switch (HART only).
5. Pull the sensor wiring leads through the universal head and
transmitter. Mount the transmitter in the universal head by threading
the transmitter mounting screws into the universal head mounting
holes.
6. Mount the transmitter-sensor assembly into the thermowell. Seal
adapter threads with silicone tape.
7. Install conduit for field wiring to the conduit entry of the universal
head. Seal conduit threads with silicone tape.
8. 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.
9. Install and tighten the universal head cover. Enclosure covers must
be fully engaged to meet explosion-proof requirements.
A = Threaded Thermowell D = Universal Head
B = Threaded Style Sensor E = Conduit Entry
C = Standard Extension
2-5
Rosemount 644
B
C
D
E
F
A
B
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rail Mount Transmitter and Sensor
(HART only)
1. Attach the transmitter to a suitable rail or panel.
2. Attach the thermowell to the pipe or process container wall. Install
and tighten the thermowell, according to plant standards, before
applying pressure.
3. Attach the sensor to the connection head and mount the entire
assembly to the thermowell.
4. Attach and connect sufficient lengths of sensor lead wire from the
connection head to the sensor terminal block.
5. Tighten the connection head cover. Enclosure covers must be fully
engaged to meet explosion-proof requirements.
6. Run sensor lead wires from the sensor assembly to the transmitter.
7. Verify the transmitter failure mode switch.
8. Attach the sensor wires to the transmitter (see Figure 2-9 on
page 2-11).
A = Rail Mount Transmitter
B = Sensor Leads with Cable Glands
C = Integral Mount Sensor with Terminal Block
D = Connection Head
E = Standard Extension
F = Threaded Thermowell
2-6
Reference Manual
A
D
E
C
B
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Rail Mount Transmitter with Threaded Sensor
(HART only)
1. Attach the transmitter to a suitable rail or panel.
2. Attach the thermowell to the pipe or process container wall. Install
and tighten the thermowell before applying pressure.
3. Attach necessary extension nipples and adapters. 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. Screw the connection head to the sensor.
6. Attach the sensor lead wires to the connection head terminals.
7. Attach additional sensor lead wires from the connection head to the
transmitter.
8. Attach and tighten the connection head cover. Enclosure covers must
be fully engaged to meet explosion-proof requirements.
9. Set the transmitter failure mode switch
10. Attach the sensor wires to the transmitter (see Figure 2-9 on
page 2-11).
A = Rail Mount Transmitter C = Standard Extension
B = Threaded Sensor Connection Head D = Threaded Style Sensor
E = Threaded Thermowell
2-7
Reference Manual
644H
Captive Mounting Screws and Springs
Meter Spacer
LCD Display
10 pin Connector
00809-0100-4728, Rev KA
Rosemount 644
July 2010
LCD Display Installation The LCD display provides local indication of the transmitter output and
abbreviated diagnostic messages governing transmitter operation.
Transmitters ordered with the LCD display are shipped with the meter
installed. After-market installation of the meter can be performed the
transmitter has a meter connector (transmitter revision 5.5.2 or later).
After-market installation requires the meter kit (part number
00644-4430-0001), which includes:
• LCD display assembly (includes LCD display, meter spacer,
and 2 screws)
• Meter cover with O-ring in place
Figure 2-4. Installing the LCD
Display
Use the following procedure to install the meter.
1. If the transmitter is installed in a loop, secure the loop and disconnect
the power. If the transmitter is installed in an enclosure, remove the
cover from the enclosure.
2. Decide meter orientation (the meter can be rotated in 90°
increments). To change meter orientation, remove the screws located
above and below the display screen. Lift the meter off the meter
spacer. Remove the 8-pin plug and re-insert it in the location that will
result in the desired viewing orientation.
3. Reattach the meter to the meter spacer using the screws. If the meter
was rotated 90° from its original position it will be necessary to
remove the screws from their original holes and re-insert them in the
adjacent screws holes.
4. Line up the 10-pin connector with the 10-pin socket and push the
meter into the transmitter until it snaps into place.
5. Attach the meter cover; tighten at least one-third turn after the O-ring
contacts the transmitter housing. The cover must be fully engaged to
meet explosion-proof requirements.
6. Use a Field Communicator, AMS software, or a F
OUNDATION fieldbus
Communication tool to configure the meter to the desired display.
Refer to “LCD Meter Options ( 644H Only)” for information on
configuring the LCD display.
2-8
NOTE
Observe the following LCD display temperature limits:
Operating: –4 to 185 °F (–20 to 85 °C)
Storage: –50 to 185 °F (–45 to 85 °C)
Reference Manual
Transmitter
No. 1
Transmitter
No. 2
R
Lead
R
Lead
R
Lead
Readout or
Controller No. 1
Readout or
Controller No. 2
To Additional
Transmitters
dc
Power
Supply
Backup
Battery
Between 250 and 1100 if no load resistor.
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Multichannel
Installations (HART)
In a HART installation, several transmitters can be connected to a single
master power supply, as shown in Figure 2-5. In this case, the system may be
grounded only at the negative power supply terminal. In multichannel
installations where several transmitters depend on one power supply and the
loss of all transmitters would cause operational problems, consider an
uninterrupted power supply or a back-up battery. The diodes shown in
Figure 2-5 prevent unwanted charging or discharging of the back-up battery.
Figure 2-5. Multichannel
Installations
WIRING All power to the transmitter is supplied over the signal wiring. Use ordinary
copper wire of sufficient size to ensure that the voltage across the transmitter
power terminals does not drop below 12.0 VDC for HART or 9 VDC for
OUNDATION fieldbus.
F
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.
NOTE
Do not apply high voltage (e.g., ac line voltage) to the transmitter terminals.
Abnormally high voltage can damage the unit. (Sensor and transmitter power
terminals are rated to 42.4 VDC. A constant 42.4 volts across the sensor
terminals may damage the unit.)
For multichannel HART installations, see above. The transmitters will accept
inputs from a variety of RTD and thermocouple types. Refer to Figure 2-6 on
page 2-10 when making sensor connections. Refer to Figure 2-8 on
page 2-10 for F
OUNDATION fieldbus installations.
Use the following steps to wire the power and sensor to the transmitter:
1. Remove the terminal block cover (if applicable).
2. Connect the positive power lead to the “+” terminal. Connect the
negative power lead to the “–” terminal (see Figure 2-7).
3. Tighten the terminal screws. When tightening the sensor and power
wires, the max torque is 6-in.-lbs (0.7 N-m).
4. Reattach and tighten the cover (if applicable).
5. Apply power (see “Power Supply”).
2-9
Rosemount 644
1 2 3 4
Sensor
Terminals
Communication
Terminals
Power Terminals
Sensor
Terminals
Power/
Configuration
Terminals
Max torque is 6
in.-lbs (0/7 N-m)
250 RL 1100
Power
Supply
Field
Communicator
250 RL 1100
Power
Supply
Field Communicator
Power
Supply
6234 ft (1900 m) max
(depending upon cable characteristics)
Integrated Power
Conditioner and Filter
Terminators
(Spur)
(Spur)
(Trunk)
(The power supply,
filter, first
terminator, and
configuration
tool are typically
located in the
control room.)
Devices 1
through 16
F
OUNDATION
fieldbus
Configuration
Tool
Power/
Signal
Wiring
Reference Manual
00809-0100-4728, Rev KA
July 2010
Figure 2-6. Transmitter Power,
Communication, and Sensor
Te rm i na l s
Figure 2-7. Connecting a HART
Communication Tool to a
Transmitter Loop
644H 644 Rail Mount
644H 644 Rail Mount
Figure 2-8. Connecting a
F
OUNDATION fieldbus Host
System to a Transmitter Loop
2-10
Note: Signal loop may be grounded at any point or left ungrounded.
Note: A Field Communicator may be connected at any termination point in the signal loop. The signal
Note: Max torque is 6 in.-lbs (0/7 N-m)
loop must have between 250 and 1100 ohms load for communications.
Reference Manual
2-wire
RTD and
3-wire RTD
and
4-wire RTD
and
T/C
and mV
*
1234
1234
1234
1234
00809-0100-4728, Rev KA
July 2010
Rosemount 644
Sensor Connections The 644 is compatible with a number of RTD and thermocouple sensor types.
Figure 2-9 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.
Figure 2-9. Sensor Wiring
Diagrams
* Emerson Process Management provides 4-wire sensors for all single element RTDs. Use these
RTDs in 3-wire configurations by leaving the unneeded leads disconnected and insulated withelectrical
tape.
Thermocouple or Millivolt Inputs
The thermocouple can be connected directly to the transmitter. Use
appropriate thermocouple extension wire if mounting the transmitter remotely
from the sensor. Make millivolt inputs connections with copper wire. Use
shielding for long runs of wire.
644 Sensor Connections Diagram
RTD or Ohm Inputs
The transmitters will accept a variety of RTD configurations, including 2-wire,
3-wire, 4-wire. If the transmitter is mounted remotely from a 3-wire or 4-wire
RTD, it will operate within specifications, without recalibration, for lead wire
resistances of up to 60 ohms per lead (equivalent to 6,000 feet of 20 AWG
wire). In this case, the leads between the RTD and transmitter should be
shielded. If using only two leads, both RTD leads are in series with the sensor
element, so significant errors can occur if the lead lengths exceed three feet
of 20 AWG wire (approximately 0.05 °C/ft). For longer runs, attach a third or
fourth lead as described above.
Sensor Lead Wire Resistance Effect– RTD Input
When using a 4-wire RTD, the effect of lead resistance is eliminated and
has no impact on accuracy. However, a 3-wire sensor will not fully cancel
lead resistance error because it cannot compensate for imbalances in
resistance between the lead wires. Using the same type of wire on all
three lead wires will make a 3-wire RTD installation as accurate as
possible. A 2-wire sensor will produce the largest error because it directly
adds the lead wire resistance to the sensor resistance. For 2- and 3-wire
RTDs, an additional lead wire resistance error is induced with ambient
temperature variations. The table and the examples shown below help
quantify these errors.
2-11
Rosemount 644
Basic Error
Imbalance of Lead Wires
PtRo
------------------------------------------------------------------=
Error due to amb. temp. variation
Cu
T
amb
Imbalance of Lead Wires
Pt
Ro
-------------------------------------------------------------------------------------------------------------------------=
Basic error
0.5
0.00385 / C100
--------------------------------------------------------------------------------- - 1.3 C==
Error due to amb. temp. var. of 25 °C
0.0039 / C25 C 0.5
0.00385 / C100
-------------------------------------------------------------------------------------------------------
0.1266 C==
Basic Error
Lead Wire Resistance
PtRo
----------------------------------------------------------=
Error due to amb. temp. variation
Cu
T
amb
Lead Wire Resistance
Pt
Ro
-----------------------------------------------------------------------------------------------------------------=
Basic error
7.5
0.00385 / C100
--------------------------------------------------------------------------------- - 19.5 C==
Error due to amb. temp. var. of 25 °C
0.0039 / C25 C 7.5
0.00385 / C100
-------------------------------------------------------------------------------------------------------
1.9 C==
Table 2-1. Examples of
Approximate Basic Error
Reference Manual
00809-0100-4728, Rev KA
July 2010
Sensor Input Approximate Basic Error
4-wire RTD None (independent of lead wire resistance)
3-wire RTD ± 1.0 in reading per ohm of unbalanced lead wire resistance
(Unbalanced lead wire resistance = maximum imbalance between
any two leads.)
2-wire RTD 1.0 in reading per ohm of lead wire resistance
Examples of Approximate Lead Wire Resistance Effect Calculations
Given:
Total cable length: 150 m
Imbalance of the lead wires at 20 °C: 1.5
Resistance/length (18 AWG Cu): 0.025 /m °C
Temperature coefficient of Cu (Cu): 0.039 / °C
Temperature coefficient of Pt(Pt): 0.00385 / °C
Change in Ambient Temperature (T
RTD Resistance at 0 °C (Ro): 100 (for Pt 100 RTD)
• Pt100 4-wire RTD: No lead wire resistance effect.
• Pt100 3-wire RTD:
): 25 °C
amb
Lead wire imbalance seen by the transmitter = 0.5
• Pt100 2-wire RTD:
Lead wire resistance seen by the transmitter = 150 m × 2 wires ×
0.025
/m = 7.5
2-12
Reference Manual
4–20 mA dc
1322
1100
1000
750
500
250
0
1012.0 20 30 40 42.4
Load (Ohms)
Supply Voltage (VDC)
Operating
Region
00809-0100-4728, Rev KA
July 2010
POWER SUPPLY HART Installation
To communicate with a transmitter, a 18.1 VDC minimum power supply is
required. The power supplied to the transmitter should not drop below the
transmitter lift-off voltage (see Figure 2-10). If the power drops below the
lift-off voltage while the transmitter is being configured, the transmitter may
interpret the configuration information incorrectly.
The dc power supply should provide power with less than 2 percent ripple.
The total resistance load is the sum of the resistance of the signal leads and
the load resistance of any controller, indicator, or related pieces of equipment
in the loop. Note that the resistance of intrinsic safety barriers, if used, must
be included.
Figure 2-10. Load Limits
Rosemount 644
Maximum Load = 40.8 x (Supply Voltage – 12.0)
OUNDATION fieldbus Installation
F
Powered over F
OUNDATION fieldbus with standard fieldbus power supplies.
The transmitter operates between 9.0 and 32.0 VDC, 11 mA maximum.
Transmitter power terminals are rated to 42.4 VDC.
The power terminals on the 644 with F
OUNDATION fieldbus are polarity
insensitive.
2-13
Reference Manual
Sensor Wires
F
OUNDATION fieldbus segment
or 4–20 mA loop
Shield ground point
Connect shields together, electrically isolated from the transmitter.
Transmitter
00809-0100-4728, Rev KA
Rosemount 644
July 2010
Ground the Transmitter The transmitter will operate with the current signal loop either floating or
grounded. However, the extra noise in floating systems affects many types of
readout devices. If the signal appears noisy or erratic, grounding the current
signal loop at a single point may solve the problem. The best place to ground
the loop is at the negative terminal of the power supply. Do not ground the
current signal loop at more than one point.
The transmitter is electrically isolated to 500 V DC/AC rms (707 VDC), so the
input circuit may also be grounded at any single point. When using a
grounded thermocouple, the grounded junction serves as this point.
Neither side of the loop should be grounded on F
OUNDATION fieldbus devices.
Only the shield wire should be grounded.
NOTE
Do not ground the signal wire at both ends.
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).
Option 1:
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 that the sensor shield is electrically isolated from the
surrounding grounded fixtures.
2-14
Option 2:
1. Connect sensor wiring shield to the transmitter housing (only if the
housing is grounded).
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.
Rosemount 644
Sensor Wires
Shield ground point
Transmitter
F
OUNDATION fieldbus segment
or 4–20 mA loop
Sensor Wires
Shield ground point
Transmitter
F
OUNDATION fieldbus segment
or 4–20 mA loop
Sensor Wires
Shield ground point
Transmitter
F
OUNDATION fieldbus segment
or 4–20 mA loop
Reference Manual
00809-0100-4728, Rev KA
July 2010
Option 3:
1. Ground sensor wiring shield at the sensor, if possible.
2. Ensure that 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.
Grounded Thermocouple Inputs
1. Ground sensor wiring shield at the sensor.
2. Ensure that 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.
2-15
Rosemount 644
Reference Manual
00809-0100-4728, Rev KA
July 2010
2-16
Reference Manual
00809-0100-4728, Rev KA
July 2010
Section 3 HART Configuration
Rosemount 644
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Field Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Multidrop Communication . . . . . . . . . . . . . . . . . . . . . . . . . page 3-18
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . page 3-19
OVERVIEW This section provides information on configuring, troubleshooting, operating,
and maintaining the Rosemount 644 with HART protocol.
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.
Warnings
Failure to follow these installation guidelines could result in death or
serious injury.
• Make sure only qualified personnel perform the installation.
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 Field Communicator in an explosive atmosphere, make sure
the instruments in the loop are installed in accordance with instrinsically 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.
HART
www.rosemount.com
HART
Reference Manual
00809-0100-4728, Rev KA
Rosemount 644
July 2010
Surges/Transients The transmitter will withstand electrical transients of the energy level
encountered in static discharges or induced switching transients. However,
high-energy transients, such as those induced in wiring from nearby lightning
strikes, welding, heavy electrical equipment, or switching gears, can damage
both the transmitter and the sensor. To protect against high-energy transients,
install the transmitter into a suitable connection head with the Rosemount 470
Transient Protector. Refer to the 470 Transient Protector Product Data Sheet
(document number 00813-0100-4191) for more information.
COMMISSIONING The 644 must be configured for certain basic variables to operate. In many
cases, all of these variables are pre-configured at the factory. Configuration
may be required if the transmitter is not configured or if the configuration
variables need revision.
Commissioning consists of testing the transmitter and verifying transmitter
configuration data. 644 transmitters can be commissioned either before or
after installation. Commissioning the transmitter on the bench before
installation using a Field Communicator or AMS ensures that all transmitter
components are in working order.
To commission on the bench, connect the transmitter and the Field
Communicator or AMS as shown in Figure 2-7 on page 2-10. Make sure the
instruments in the loop are installed according to intrinsically-safe or
non-incendive field wiring practices before connecting a communication in an
explosive atmosphere. Connect HART Communication leads at any
termination point in the signal loop. For convenience, connect them to the
terminals labeled “COMM” on the terminal block. Connecting across the
“TEST” terminals will prevent successful communication. Avoid exposing the
transmitter electronics to the plant environment after installation by setting all
transmitter jumpers during the commissioning stage on the bench.
When using a Field Communicator, any configuration changes made must be
sent to the transmitter by using the “Send” key (F2). AMS configuration
changes are implemented when the “Apply” button is clicked.
For more information on using the Field Communicator with the 644
transmitter, see Section 3: HART Configuration.
Setting the Loop to
Manual
When sending or requesting data that would disrupt the loop or change the
output of the transmitter, set the process application loop to manual. The Field
Communicator or AMS will prompt you to set the loop to manual when
necessary. Acknowledging this prompt does not set the loop to manual. The
prompt is only a reminder; set the loop to manual as a separate operation.
Failure Mode As part of normal operation, each transmitter continuously monitors its own
performance. This automatic diagnostics routine is a timed series of checks
repeated continuously. If diagnostics detect an input sensor failure or a failure
in the transmitter electronics, the transmitter drives its output to low or high
depending on the position of the failure mode switch. Saturation levels are
3.90 mA for standard configuration (3.8 mA if configured for NAMURcompliant operation) on the low end and 20.5 mA for standard or NAMURcompliant configuration on the high end, if the sensor temperature is outside
of range limits. These values are also custom configurable by the factory or
using the Field Communicator.
3-2
Reference Manual
00809-0100-4728, Rev KA
July 2010
Rosemount 644
The values to which the transmitter drives its output in failure mode depend
on whether it is configured to standard, NAMUR-compliant, or custom
operation. See “Hardware and Software Failure Mode” on page A-7 for
standard and NAMUR-compliant operation parameters.
Changing Switch
Positions
To change the failure mode on the 644 transmitter, follow the steps below.
1. If applicable, remove the enclosure cover.
2. Locate the orange failure mode switch. On the 644H the switch is
located near the power terminals and located in the center of the front
panel on the 644 rail mount (see Figure 2-6).
3. Move the switch to the desired alarm setting. To set the failure mode
to high alarm, position the switch toward the “HI” mark on the terminal
block. To set the failure mode to low alarm, position the switch in the
opposite direction.
4. Replace the enclosure cover (if applicable). Enclosure covers must
be fully engaged to meet explosion-proof requirements.
FIELD COMMUNICATOR The Field Communicator exchanges information with the transmitter from the
control room, the instrument site, or any wiring termination point in the loop.
To facilitate communication, connect the Field Communicator in parallel with
the transmitter (see Figure 2-11). Use the loop connection ports on the rear
panel of the Field Communicator. The connections are non-polarized. Do not
make connections to the serial port or the NiCad recharger jack in explosive
atmospheres. Before connecting the Field Communicator in an explosive
atmosphere, make sure the instruments in the loop are installed in
accordance with intrinsically safe or non-incendive field wiring practices.
For more information regarding the Field Communicator, please see the Field
Communicator Reference Manual.
HART
CONFIGURATION The 644 transmitter can be configured either on-line or off-line using a Field
Communicator or AMS. During on-line configuration, the transmitter is
connected to a Field communicator. Data is entered in the working register of
the communicator and sent directly to the transmitter. Off-line configuration
consists of storing configuration data in a Field Communicator while it is not
connected to a transmitter. Data is stored in nonvolatile memory and can be
downloaded to the transmitter at a later time.
3-3
HART
The review menu lists all of the
information stored in the 644. This
includes device information, measuring
element, output configuration, and
software revision
1. TEST DEVICE
2. CALIBRATION
3. Write Protect
On-line Menu
1. Snsr 1 Digital Reading
2. Terminal Digital Reading
1. Snsr 1 Input Trim
2. Snsr 1 Trim-Fact
3. Active Calibrator
1. Loop Test
2. Self test
3. Master Reset
4. Status
1. SNSR 1 TRIM
2. D/A trim
3. Scaled D/A trim
1. Revision #s
2. Sensor Review
3. Dev Outputs Review
4. Device Information
5. Measurement
Filtering
1. PROCESS
VARIABLES
2. DIAGNOSTICS
AND SERVICE
3. CONFIGURA TION
4. REVIEW
1. VARIABLE
MAPPING
2. SENSOR
CONFIGURATION
3. DEVICE OUTPUT
CONFIGURATION
4. DEVICE
INFORMATION
5. MEASUREMENT
FILTERING
1. TRANSMITTER VARS
2. PV is
3. PV Digital Reading
4. PV AO
5. PV% rnge
6. PV LRV
7. PV URV
8. PV Lower Sensor Limits
9. PV Upper Sensor Limits
10.PV Damping
1. DEVICE SETUP
2. PV is
3. PV
4. PV AO
5. % RNGE
6. PV LRV
7. PV URV
1. PV is
2. SV is
3. TV is
4. QV is
5. Variable re-map
1. SENSOR 1
2. TERMINAL TEMP
1. Connections
2. SNSR 1 SETUP
3. CAL VANDUSEN
4. Sensor S/N
1. Terminal Units
2. Terminal Damp
3. Terminal LSL
4. Terminal USL
1. PV RANGE
VALUES
2. ALARM
SATURATION
3. HART OUTPUT
4. LCD METER
OPTIONS
1. AO Alarm Type
2. Low Alarm
3. High Alarm
4. Low Sat.
5. High Sat.
1. Poll Addr
2. Num Req Preams
3. Burst Mode
4. Burst Option
1. Meter Configuration
2. Meter Decimal Pt
1. Tag
2. Date
3. Descriptor
4. Message
5. Final Assembly number
1. 50/60 Hz Filter
2. Active Calibrator
3. Open Sensor Holdoff
4. Intermit Detect
5. Intermit Thresh
1. 2-wire Offset
2. Snsr 1 Units
3. Snsr 1 Damp
4. Snsr LSL
5. Snsr USL
1. R0
2. Alpha
3. Delta
4. Beta
1. PV LRV
2. PV URV
3. PV Damping
4. PV Units
5. Apply Values
6. PV LSL
7. PV USL
8. PV Min. Span
These numbers are to
be entered by the user.
When the hardware alarm
switches are changed, the
communicator should be
power cycled to see new
readings.
Reference Manual
00809-0100-4728, Rev KA
Rosemount 644
July 2010
HART Menu Tree Options listed in bold type indicate that a selection provides other options. For
ease of operation, changing calibration and setup, such as sensor type,
number of wires, and range values, can be completed in several locations.
Figure 3-1. Field Communicator Menu Tree
3-4
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