Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644 Temperature Transmitter
with Profibus PA
www.rosemount.com
Reference Manual
NOTICE
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Rosemount 644 Temperature
Transmitter with Profibus PA
Rosemount 644 Hardware Revision 9
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 an Emerson Process
Management Sales Representative.
www.rosemount.com
Reference Manual
00809-0300-4728, Rev AA
January 2011
Table of Contents
Rosemount 644
SECTION 1
Introduction
SECTION 2
Configuration
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Transmitter Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Device Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Return of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Configuration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Profile 3.02 Identification Number Adaptation Mode . . . . . . . . . . . 2-3
Block Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Basic Setup Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Device Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assign Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Default Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Transmitter Setup Using Class 2 Master . . . . . . . . . . . . . . . . . . . . . . . 2-4
Basic Transmitter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Transmitter Online Setup with DD or DTM . . . . . . . . . . . . . . . . . . . . . 2-6
Basic Transmitter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION 3
Hardware Installation
SECTION 4
Electrical Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Typical European Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Typical North American Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-4
LCD Display Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Ground the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
TOC-1
Rosemount 644
Reference Manual
00809-0300-4728, Rev AA
January 2011
SECTION 5
Calibration
SECTION 6
Troubleshooting
APPENDIX A
Specifications and
Reference Data
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Sensor Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Diagnostics Identification and Recommendation. . . . . . . . . . . . . . . . . 6-2
Extended Diagnostics Identification with class one master . . . . . . 6-4
PlantWeb and NE107 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alert Messages and Fail Safe Type Selection . . . . . . . . . . . . . . . . . . . 6-6
Profibus PA Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Tagging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
APPENDIX B
Product Certifications
APPENDIX C
Profibus Block
Information
Approved Manufacturing Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
European Union Directive Information. . . . . . . . . . . . . . . . . . . . . . . . . B-1
Hazardous Locations Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Rosemount 644 with Profibus PA. . . . . . . . . . . . . . . . . . . . . . . . . . B-2
IECEx Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Russian GOST Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Kazakhstan GOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Ukraine GOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Condensed Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
TOC-2
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Section 1 Introduction
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
Transmitter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
Device Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3
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 Profibus devices in an explosive atmosphere, 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.
www.rosemount.com
Reference Manual
00809-0300-4728, Rev AA
Rosemount 644
January 2011
USING THIS MANUAL The sections in this manual provide information on installing, operating, and
maintaining the Rosemount 644 with Profibus PA protocol. The sections are
organized as follows:
Section 2: Configuration provides instruction on commissioning and operating
the Rosemount 644 PA transmitter. Information on software functions,
configuration parameters, and online variables is also included.
Section 3: Hardware Installation contains mechanical mounting and
installation instructions, and field upgrade options.
Section 4: Electrical Installation contains electrical installation instructions,
with wiring and power considerations.
Section 5: Calibration contains techniques for calibration and troubleshooting
Appendix A: Specifications and Reference Data supplies reference and
specification data, as well as ordering information.
Appendix B: Product Certifications contains intrinsic safety approval
information, European ATEX directive information, and approval drawings.
Appendix C: Profibus Block Information contains Profibus block and
parameter information.
TRANSMITTER OVERVIEW
Features of the Rosemount 644 with Profibus PA include:
• Accepts inputs from a wide variety of sensors (T/C, RTD, Ohm, mV)
• Configuration using Siemens SIMATIC PDM
• Electronics that are completely encapsulated in epoxy making the
transmitter extremely durable and ensuring long-term reliability
• A compact size and a variety of housing options allowing mounting
flexibility for the control room or the field
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 1067 compact sensor and 1097 Thermowell Product Data
Sheet (00813-0100-4951)
• Rosemount 65Q and 65B Resistance Temperature Sensors for
Hygienic and Sanitary Applications Product Data Sheet
(00813-0100-4827)
NOTE
For Rosemount 644 with HART
Product Manual 00809-0100-4728.
®
or FOUNDATION™ fieldbus, see Rosemount
1-2
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
DEVICE REVISION
Table 1-1. Device Revisions
(NE53)
Date
11/ 10 1.01.016 3.02 New
Software
Revision
Profibus
Profile
Changes to
Software
Product
Compatible Files
644 GSD: EPM1039.gsd
Profile:3.02 GSD: pa139700.gsd
DD: see Rosemount.com
DTM: see Rosemount.com
Manual
Revision
AA
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 digital Profibus PA signal that is relatively
insensitive to lead length and 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.
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
00809-0300-4728, Rev AA
January 2011
Figure 1-1 provides an example of the relationship between transmitter
housing temperature rise and extension length.
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 an Emerson Process Management sales
representative.
1-4
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.
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Section 2 Configuration
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Configuration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-3
Basic Setup Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-3
Transmitter Setup Using Class 2 Master . . . . . . . . . . . . .page 2-4
Transmitter Online Setup with DD or DTM . . . . . . . . . . . .page 2-6
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 Profibus devices in an explosive atmosphere, make sure the
instruments in the loop are installed in accordance with intrinsically safe or
non-incendive field wiring practices.
• Verify that the operating atmosphere of the transmitter is consistent with the
appropriate hazardous locations certifications.
• All connection head covers must be fully engaged to meet
explosion-proof requirements.
Process leaks 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.
www.rosemount.com
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 2: Configuration
FIELD INSTALL
Mount Transmitter
Wire Transmitter
Power Transmitter
FINISHED
Figure 2-1. Configuration
Flowchart
Reference Manual
00809-0300-4728, Rev AA
January 2011
2-2
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
CONFIGURATION GUIDELINES
Profile 3.02 Identification
Number Adaptation
Mode
To configure on the bench, required equipment includes a power supply, a
class 2 master with DP/PA coupler, proper cable, and terminators. Verify that
the Security hardware jumper is set to the OFF position in order to proceed
with configuration. See Figure 4-2 for jumper location.
Setup for the Rosemount 644 can be done via Siemens SIMATIC
software or any other DD or DTM based Class 2 master.
Rosemount 644 Profibus Profile 3.02 devices are set to Identification Number
Adaptation Mode when shipped from the factory. This mode allows the
transmitter to communicate with any Profibus class 1 master with either the
generic Profile GSD (9700) or Rosemount 644 specific GSD (1039).
®
PDM
Block Modes When configuring a device with a class 2 master, it is best practice to set
blocks to OOS when downloading parameters that affect the transmitter
output. However, the 644 will allow configuration changes made in AUTO to
be downloaded to the device. This prevents the class one master from seeing
a jump in output without a status change. Setting the blocks OOS and back
into Auto is done automatically when using the class two master configuration
wizards within the Rosemount 644 DD or DTM. This is done so no additional
action is required when configuring the device.
Configuration Tools The Rosemount 644 can be configured through the factory at order entry or
using a class 2 master. The C1 option code must be ordered to obtain
addressing and configuration of the device at the factory.
Class 2 masters require either DD or DTM files for configuration. These files
can be found at www.rosemount.com or by contacting your local Emerson
Process representative.
The remainder of this section will cover the configuration tasks using the
Class 2 master configuration tool.
NOTE
Instructions in this section use the terminology found in the class 2 master.
See Appendix C: Profibus Block Information to cross reference parameters
between the class2 master, and the Profibus specification.
BASIC SETUP TASKS
Device Description Before configuring the device, ensure the host has the appropriate Device
Description file revision for this device. The device descriptor can be found on
www.rosemount.com. The initial release of the Rosemount 644 with Profibus
PA protocol is device revision 1.
Assign Address The Rosemount 644 is shipped with a temporary address of 126. This must
be changed to a unique value between 1 and 125 in order to establish
communication with the class 1 master. Usually, addresses 1-2 are reserved
for masters, therefore transmitter addresses between 3 and 125 are
recommended for the device.
Address can be set using either:
• Factory Configuration (C1 option code)
• Class 2 master – see respective class 2 master manual for setting
instrument addresses
2-3
Reference Manual
00809-0300-4728, Rev AA
Rosemount 644
January 2011
Default Configuration Unless otherwise specified, the Rosemount 644 will be shipped with the
following settings:
Table 2-1. Temperature
configuration defaults
TRANSMITTER SETUP USING CLASS 2 MASTER
Basic Transmitter Setup
Table 2-2. Basic Transmitter
Configuration using Class 2
master
Device Address: 126
Sensor Type: RTD, Pt 100 (= 0.00385, 4 wire)
Damping: 5 sec.
Units of Measurement: °C
Alarm Limits:
• HI-HI: Infinity
• HI: Infinity
• LO: - Infinity
• LO-LO: Infinity
Local Display (when installed): Engineering Units of Temperature
Measurement Range: 0 °C to 100 °C
Desired Action Menu >> Parameter >> Value
Set Sensor Type Primary Value>>Sensor>>Sensor Type
Set Connection Type (Number of Wires) Primary Value>>Sensor>>Sensor Connection
Set Units
Set Upper Range Value Primary Value>>Process Value Scale>>Upper Value
Set Lower Range Value Primary Value>>Process Value Scale>>Lower Value
Set Damping Value Primary Value>>Sensor>>Damping Value
* Please see “Basic Transmitter Configuration using DD or DTM” on page 2-6 for considerations
when changing units.
*
Primary Value>>Sensor>>Primary Value Unit
Process Alarms Process alarms activate an output alarm status when the configured alarm
point is exceeded. A process alarm will be transmitted continuously if the
output set points are exceeded. The alarms will reset once the value returns
within range.
Process Alarm parameters are defined as follows
• HI-HI Alarm: Changes Output Status to Good – Critical Alarm – Hi Limit
• HI Warning: Changes Output Status to Good – Advisory Alarm – Hi
Limit
• LO Warning: Changes Output Status to Good – Advisory Alarm – Lo
Limit
• LO-LO Alarm: Changes Output Status to Good – Critical Alarm – Lo
Limit
• Alarm Hysteresis: Amount the output value must pass back into range
before alarm is cleared.
Example: Upper Alarm = 100 °C. Alarm Hysteresis = 0.5 °C. After
activation at 100 °C, the alarm will clear once the output goes below
99.5 °C = 100 - 0.5 °C.
Process Alerts can be set using,
2-4
• Class 2 master – see Table 2-3 for configuration
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Table 2-3. Process Alarm
Configuration using Class 2
master
Desired Action Menu Path
Enter Process Alarm Levels Output>>Output Limits>>LO-LO Alarm
Output>>Output Limits>>LO Warning
Output>>Output Limits>>HI Warning
Output>>Output Limits>>HI- HI Alarm
Simulation Simulation is in the AI block and used to verify the output from the transducer
block. The Rosemount 644 has a simulation jumper located on the transmitter
puck top cover that must be set to the ON position in order to simulate.
NOTE
This jumper position is ignored when the transmitter is initially powered. The
jumper position must be changed while the transmitter is powered to activate
simulation. If power is removed and restored, the simulation mode will be OFF
regardless of jumper position.
With simulation enabled, the actual measurement value has no impact on the
OUT value or the status. The OUT value will equal the simulated value from
the transducer block plus any scaling or linearization effects performed in the
AI block.
Table 2-4. Simulation
configuration using Class 2
master
Once the simulation jumper is set to on, simulation mode can be activated
Using a Class 2 master see Table 2-4.
Desired Action Menu >> Parameter >> Value
Enable Simulate Main Setup>>Human Interface>>
Simulation Status>>State>>
Select Enabled
Enter Simulation Value
Select Simulation Status>>Press “Download
to device” icon
Disable Simulate Main Setup>>Human Interface>>
Simulation Status>>State>>
Select Disabled
Press “Download to device” icon
2-5
Rosemount 644
TRANSMITTER ONLINE SETUP WITH DD OR DTM
Basic Transmitter Setup
Reference Manual
00809-0300-4728, Rev AA
January 2011
Table 2-5. Basic Transmitter
Configuration using DD or DTM
Using Guided Setup
Desired Action Menu >> Category >> Method
Set Sensor Type Configure>>Guided Setup>>Configure Sensor Method
Set Connection Type Configure>>Guided Setup>>Configure Sensor Method
Set Units Configure>>Guided Setup>>Configure Sensor Method
Set Damping Configure>>Guided Setup>>Configure Sensor Method
Using Manual Setup
Desired Action Menu >> Category >> Tab >> Value
Set Sensor Type Configure>>Manual Setup>>Sensor>>Sensor Type
Set Connection Type
(Number of Wires)
Set Units Configure>>Manual Setup>>Classic
Set Damping Configure>>Manual Setup>>Sensor>>Damping Value
Set Upper Range Value Configure>>Manual Setup>>Classic View>>Analog
Set Lower Range Value Configure>>Manual Setup>>Classic View>>Analog
Configure>>Manual Setup>>Sensor>>Sensor
Connection
View>>Transducer Block>>Primary Value Unit
Input Block>>Analog Input Block_1>>Lower Range
Input Block>>Analog Input Block_1>>Upper Range
NOTE
Changes made to the PRIMARY_VALUE_UNIT parameter through Manual
Setup>>Classic View are only reflected in the Transducer Block parameters.
To change the AI OUT units the PV Scale and OUT Scale need to be updated
to mirror the upper and lower sensor limits in the desired units.
2-6
Example: (All values are arbitrary)
The default configuration of the device is:
4-wire PT100_A_385 AI.OUT = 23 °C
PRIMARY_VALUE_UNIT = °C PV_SCALE = 100, 0
PV.VALUE = 23 °C OUT_SCALE = 100,0, °C
SV.VALUE = 23 °C
USL = 850 °C
LSL = -200 °C
If the user desires to change the units to °F, only the parameters in Bold will
change with the PRIMARY_VALUE_UNIT. The AI.OUT will stay in °C until the
PV_SCALE and OUT_SCALE are configured to match each other. (This can
be with the measurement range or the sensor limits.
4-wire PT100_A_385 AI.OUT = 23 °C
PRIMARY_VALUE_UNIT = °C PV_SCALE = 212, 32
PV.VALUE = 73 °C OUT_SCALE = 100,0, °C
SV.VALUE = 73 ° C
USL = 1562 °C
LSL = -328 °C
So the following change is needed:
PV_SCALE = 1562,-328 (make the same as USL and LSL)
OUT_SCALE = 1562,-328, °F (make the same as PV_SCALE)
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Process Alarms Process Alarms can be set using a DD or DTM – see Table 2-6 for
configuration.
Table 2-6. Process Alarm
Configuration using DD or DTM
Desired Action Menu Path
Enter Process Alert Levels Configure>>Alarm Setup>>LO-LO>>[Value]
Configure>>Alarm Setup>>LO>>[Value]
Configure>>Alarm Setup>>HI >>[Value]
Configure>>Alarm Setup>>HI-HI >>[Value]
LCD Display The LCD display connects directly to the top of the transmitter puck and uses
a 10-pin connector to directly connect to the electronics board. A display
cover is provided to accommodate the display.
The display always indicates the transmitter output temperature as well as
abbreviated diagnostic status when applicable. When turned on, the display
will alternate between the selected variables.
For LCD display configuration using a DD or DTM see Table 2-7.
Table 2-7. LCD Display
Configuration using DD or DTM
Desired Action Menu >> Parameter >> Value
Select Display Parameters Configure>>Manual Setup>>Display Tab>>Select
Parameters to display
Simulation Once the simulation jumper is set to on, simulation mode can be activated
Using DD or DTM see Table 2-8.
Table 2-8. Simulation
Configuration using DD or DTM
Desired Action Menu >> Parameter >> Value
Enable Simulate Service Tools>>Simulate>>Select Enabled State
Enter Simulation Value
Select Simulation Status>>Press Transfer button
Disable Simulate Service Tools>>Simulate>>Select Disabled State
>>Press Transfer button
2-7
Rosemount 644
Reference Manual
00809-0300-4728, Rev AA
January 2011
2-8
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Section 3 Hardware Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
OVERVIEW The information in this section covers installation considerations for the
Rosemount 644. A Quick Installation Guide is shipped with every transmitter
to describe pipe-fitting, wiring procedures, and basic configuration for initial
installation.
SAFETY MESSAGES Procedures and instructions in this section may require special precautions to
ensure the safety of the personnel performing the operations. Information that
raises potential safety issues is indicated by a warning symbol ( ). Refer to
the following safety messages before performing an operation preceded by
this symbol.
Warnings
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. Please review
the approvals section of this reference manual for any restrictions associated with a safe
installation.
• In an Explosion-Proof/Flameproof installation, do not remove the transmitter
covers when power is applied to the unit.
Process leaks may cause harm or result in death.
• Install and tighten process connectors before applying pressure.
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.
Individual transmitters are clearly marked with a tag indicating the approvals
they carry. Transmitters must be installed in accordance with all applicable
codes and standards to maintain these certified ratings. Refer to ““Hazardous
Locations Certificates” on page B-2 for information on these approvals.
www.rosemount.com
Reference Manual
Transmitter
Mounting
Hardware
Rail Clip
Transmitter
Mounting
Hardware
Rail Clip
00809-0300-4728, Rev AA
Rosemount 644
January 2011
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 3-1.
Figure 3-1. Assembling Rail Clip
Hardware to a 644
G-Rail (asymmetric) Top Hat Rail (symmetric)
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 644 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 3-2.
3-2
Reference Manual
Kit includes
replacement bracket
and screws.
Existing Threaded Sensor Connection Head
(Former option code L1)
A
D
B
C
E
F
00809-0300-4728, Rev AA
January 2011
Figure 3-2. Assembling 644H for
Use in an Existing L1
Connection Head
INSTALLATION
Rosemount 644
Typical European
Installation
Head Mount Transmitter with DIN Plate Style Sensor
1. Attach the thermowell to the pipe or process container wall. Install
and tighten the thermowell before applying process pressure.
2. 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.
3. Wire the sensor to the transmitter (see Figure 4-3 on page 4-3).
4. 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.
5. Attach conduit or a cable gland to the open connection head entry.
6. Insert the shielded cable leads into the connection head through the
conduit or cable entry. Seal the entry properly.
7. Connect the shielded power cable leads to the transmitter power
terminals. Avoid contact with sensor leads and sensor connections.
8. 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
3-3
Rosemount 644
A
B
C
D
E
Reference Manual
00809-0300-4728, Rev AA
January 2011
Typical North American
Installation
Head Mount Transmitter with Threaded Sensor
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. 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.
5. Mount the transmitter-sensor assembly into the thermowell. Seal
adapter threads with silicone tape.
6. Install a cable gland or conduit for field wiring to the conduit entry of
the universal head. Seal threads with silicone tape.
7. 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.
8. Install and tighten the universal head cover. Enclosure covers must
be fully engaged to meet explosion-proof requirements.
3-4
A = Threaded Thermowell D = Universal Head
B = Threaded Style Sensor E = Conduit Entry
C = Standard Extension
Reference Manual
644H
Captive Mounting Screws and Springs
Meter Spacer
LCD Display
10 pin Connector
00809-0300-4728, Rev AA
January 2011
Rosemount 644
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 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 3-3. 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 10-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 and tighten the universal head cover. Enclosure covers must
be fully engaged to meet explosion-proof requirements.
6. Use a Profibus Class 2 master to configure the meter to the desired
display parameters.
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)
3-5
Rosemount 644
Reference Manual
00809-0300-4728, Rev AA
January 2011
3-6
Reference Manual
00809-0300-4728, Rev AA
January 2011
Rosemount 644
Section 4 Electrical Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2
OVERVIEW The information in this section covers installation considerations for the
Rosemount 644. A Quick Installation Guide is shipped with every transmitter
to describe pipe-fitting, wiring procedures, and basic configuration for initial
installation.
SAFETY MESSAGES Procedures and instructions 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 powering Profibus devices segment in an explosive atmosphere, make sure
the instruments in the loop are installed in accordance with intrinsically safe or
non-incendive field wiring practices.
• Verify that the operating atmosphere of the transmitter is consistent with the
appropriate hazardous locations certifications.
• All connection head covers must be fully engaged to meet
explosion-proof requirements.
Process leaks 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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Reference Manual
1 2 3 4
Sensor
Terminals
Communication
Terminals
Power Terminals
00809-0300-4728, Rev AA
Rosemount 644
January 2011
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 9 Vdc for Profibus PA. 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.)
The transmitters will accept inputs from a variety of RTD and thermocouple
types. Refer to Figure 4-1 when making sensor connections. Refer to
Figure 4-2 for Profibus installations.
Use the following steps to wire the power and sensor to the transmitter:
1. Connect the positive power lead to the .+. terminal. Connect the
negative power lead to the .-. terminal.
2. Tighten the terminal screws. When tightening the sensor and power
wires, the max torque is 6-in.-lbs (0.7 N-m).
3. Apply power.
Figure 4-1. Transmitter Power,
Communication and Sensor
Te rm i na l
644H
4-2
Reference Manual
Profibus DP
Profibus PA
MBP-IS at 31.25KBd
Terminator
6234 ft (1900m) max
(Depending on cable characteristics)
DP/PA
Coupler
PROFIBUS
Class 2
Master
(Configurati
on Tool)
RS-485 up to 12 MBD
Profibus Transmitter
Power/
Signal
Wiring
2-wire
RTD and
3-wire RTD
and
4-wire RTD
and
T/C
and mV
*
1234
1234
1234
1234
00809-0300-4728, Rev AA
January 2011
Figure 4-2. Typical connection of
a Profibus configuration host to
a transmitter loop
Rosemount 644
NOTE
1. Each Segment in a Profibus trunk must be terminated at both ends.
2. Some DP/PA couplers contain the power supply, one terminator, and
the power conditioner within the coupling device.
3. The configuration tool is typically located in the control room.
Sensor Connections The 644 is compatible with a number of RTD and thermocouple sensor types.
Figure 4-3 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 4-3. 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 with electrical
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 input connections with copper wire. Use
shielding for long runs of wire.
644 Sensor Connections Diagram
4-3
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