Safety Manual
00809-0600-4728, Rev AA
December 2021
Rosemount™ 644 Rail Mount Temperature
Transmitter
With RK Option and HART® 7
Protocol
Safety messages
NOTICE
Read this document before working with the product. For personal and system safety, and for optimum product performance,
make sure you 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 - 1-800-999-9307 (7:00 am to 7:00 pm Central Time)
Asia Pacific- 65 777 8211
Europe/Middle East/Africa - 49 (8153) 9390
North American Response Center
Equipment service needs.
1-800-654-7768 (24 hours—includes Canada)
Outside of these areas, contact your local Emerson representative.
WARNING
Follow instruction
Failure to follow these installation guidelines could result in death or serious injury.
Ensure only qualified personnel perform the installation.
Explosion
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 handheld communicator in an explosive atmosphere, ensure that 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
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.
Electric shock
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
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 your local Emerson Sales Representative.
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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Safety Manual Contents
00809-0600-4728 December 2021
Contents
Chapter 1 Introduction.............................................................................................................. 5
1.1 Using this manual........................................................................................................................ 5
1.2 Transmitter overview...................................................................................................................5
Chapter 2 Installation and commissioning..................................................................................7
2.1 IEC 61508 relevant requirements.................................................................................................7
2.2 Installation in SIS applications......................................................................................................7
2.3 Configuring in SIS applications...................................................................................................11
Chapter 3 Proof tests................................................................................................................39
3.1 Periodic proof test procedure.................................................................................................... 39
Chapter 4 Operating considerations.........................................................................................41
4.1 Reliability data........................................................................................................................... 41
4.2 Failure reporting........................................................................................................................ 41
4.3 Maintenance..............................................................................................................................41
Appendix A Terms and definitions...............................................................................................43
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Contents Safety Manual
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4 Rosemount 644
Safety Manual
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Introduction
1 Introduction
1.1 Using this manual
This document provides information about how to install, commission, and proof test a
Rosemount 644 Rail Mount Temperature Transmitter to comply with safety instrumented
systems (SIS) requirements.
NOTICE
This manual assumes that the following conditions apply:
• transmitter has been installed correctly and completely according to the instructions in
the transmitter Reference Manual and Quick Start Guide
• installation complies with all applicable safety requirements
• operator is trained in local and corporate safety standards
The following product variants are considered in this manual:
Description Suffix
DIN rail mounted 2w programmable temperature transmitters 644R*QT*
(1) The "*" represent various options and approvals which have no impact on the safety aspects of
the device.
Product purpose
This is a 2-wire HART® temperature transmitter for temperature measurement with TC
and RTD sensors. True dual input with high density 7 terminal design allows measurement
of two 4-wire RTDs. Sensor redundancy allows automatic switch to secondary sensor in
the event of primary sensor failure and sensor drift detection issues an alert when sensor
differential exceeds predefined limits. The device has been designed, developed and
produced for use in SIL 2/3 applications according to the requirements of IEC 61508 : 2010
Related documents
All product documentation is available at Emerson.com.
1.2 Transmitter overview
The transmitter supports the following features:
644T*QT*
(1)
(1)
• 4-20 mA/HART® protocol (Revision 7)
• Accepts either one or two inputs from a wide variety of sensor types (2-, 3-, and 4-wire
RTD, thermocouple, mV and ohm)
• Optional Safety Certification (IEC 61508 SIL 2)
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• Special dual-sensor features including Hot Backup™, Sensor Drift Alert, first good,
differential and average temperature measurements, and four simultaneous
measurement variable outputs in addition to the analog output signal
• Meets NAMUR NE21, NE43, NE44, NE89 and NE107 compliant diagnostics information.
Refer to the following literature for a full range of compatible connection heads, sensors,
and thermowells provided by Emerson:
• Rosemount 214C Temperature Sensors Product Data Sheet
• Rosemount Volume 1 Temperature Sensors and Accessories (English) Product Data
Sheet
• Rosemount DIN-Style Temperature Sensors and Thermowells (Metric) Product Data
Sheet
Table 1-1: Change Summary: Rosemount 644 Rail Mount HART Device Revision
Release date NAMUR
software
revision
May 2021 01.05.10 01.05.10 7 00809-0500-4728
(1) NAMUR software revision is located on the hardware tag of the device. HART software revision
can be read using a HART communication tool.
NAMUR
hardware
revision
HART software
revision
(1)
Manual document
number
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2 Installation and commissioning
2.1 IEC 61508 relevant requirements
Table 2-1: Observed Standards
Standard Description
IEC 61508 Functional Safety of electrical / electronic / programmable
electronic safety-related systems
IEC 61508-2:2010 Part 2: Requirements for electrical / electronic / programmable
electronic safety-related systems
IEC 61508-3:2010 Part 3: Software requirements
IEC 61326-3-1:2008 Immunity requirements for safety-related systems
2.2 Installation in SIS applications
Installations are to be performed by qualified personnel. No special installation is required
in addition to the standard installation practices outlined in the applicable product
manual.
Environmental and operational limits are available in the product manual.
2.2.1
Basic safety specifications
Ambient operating temperature range
Storage temperature range
Supply voltage, non-Ex
Supply voltage, Ex ia
Additional minimum supply voltage when using
test terminals
Maximum internal power dissipation
Minimum load resistance at > 37 V supply
Mounting area
Mounting environment
-40...+80 °C
-50...+85 °C
7.5
7.5
0.8 V
≤ 850 mW
(Supply voltage – 37) / 23 mA
Zone 0, 1, 2 / Division 2 or safe area
Pollution degree 2 or better
(1)
(1)
(2)
...48
VDC (at terminals)
(2)
...30
VDC (at terminals)
Maximum wire size
Screw terminal torque
(1) The minimum supply voltage must be as measured at the terminals (i.e. all external drops must be considered).
(2) Ensure the device is protected from over-voltages by using a suitable power supply or by installing overvoltage protecting
devices.
Emerson.com/Rosemount 7
1 x 1.5 mm2 stranded wire
0.5 Nm
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December 2021 00809-0600-4728
2.2.2 Useful lifetime
The established failure rates of electrical components apply within the useful lifetime as
per IEC 61508-2:2010 section 7.4.9.5 (note 3), or as determined by user's own statistics.
The device contains no components that are especially sensitive to environmental
conditions, nor does it contain any unmanaged memory components with suspected
retention times.
2.2.3 Safety accuracy
The analog output corresponds to the applied input within the safety accuracy.
Safety accuracy
±2%
Minimum span
The selected range (PV Upper Range - PV Lower Range) shall be larger or equal to the
values below.
Configured input type Minimum span Unit
Pt100-Pt10000, Ni100-Ni1000, Cu100-Cu1000 25 °C
Pt50, Ni50, Cu50 50 °C
Pt20, Ni20, Cu20 125 °C
Pt10, Ni10, Cu10 250 °C
Cu5 500 °C
TC: E, J, K, L, N, T, U 100 °C
TC: Lr, R, S, W3, W5, B 400 °C
Voltage -20...100 mV 1.3 mV
Voltage -0.1...1.7 V 0.12 V
Voltage ±0,8 V 0.12 V
Linear Ohms 0...400 Ohm 10 Ohm
Linear Ohms 0...100 kOhm 1 kOhm
Potentiometer 10 %
Range limitations
For SIL applications, TC input type B shall not be used below +400 °C since the accuracy will
be lower than the specified safety accuracy.
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2.2.4 Associated equipment
RTD, or linear resistance sensor wiring
If Input 1 Number of Wires / Input 2 Number of Wires is configured to 2 or 3, and Input Type
1 / Input Type 2 is RTD, Ohm, or kOhm, the end user must ensure the applied sensor wiring
does not introduce failures exceeding the requirements for the safety application.
Potentiometer sensor wiring
If Input 1 Number of Wires is configured to 3 or 4, and Input Type is Potentiometer, the end
user must ensure the applied sensor wiring does not introduce failures exceeding the
requirements for the safety application.
Sensor short circuit errors
Detection of short-circuited sensors, or short-circuited sensor wires, is ignored for both
Input 1 and Input 2 if either of their Input Types is configured as listed below:
• Ohms or kOhms
• Pt50 or Ptx and RTD Factor < 100
• Nix and RTD Factor < 50
• Cu10, Cu50, or Cux and Sensor Custom RTD Resistance < 100
• Potentiometer and Input 1 Upper Limit (potentiometer size) < 18 Ohm
For Potentiometer there is no short circuit detection on potentiometer arm.
Detection of short-circuited sensor or short-circuited sensor wires is ignored for Input 1 or
Input 2 if its Input Type is configured as listed below:
• Micro-volts, Milli-volts or Volts (bipolar or unipolar)
• Any TC type (detection of shorted External CJC sensor is NOT ignored)
If any of these input types shall be used in a Safety Application, the user must ensure the
applied sensors, including wiring, have failure rates that qualify them, without detection of
short-circuited sensors or wires.
Extension port
Only equipment designed specifically for connection to the extension port of the
transmitter may be connected. This equipment will specify the applied maximum
operating voltage drop; V
. The user must make sure the supply voltage, minus any
EXT
drops for external measurement or communication resistances, and minus the applied
maximum drop for the equipment attached to the extension port, will be higher than the
minimum specified supply voltage:
V
SUPPLY
> 7.5 + V
EXT
+ V
DROP
Process calibration (input trimming)
If a process calibration on Input 1 or Input 2 has been carried out before entering SIL-mode
operation, it is mandatory that the accuracy of the device (and sensor, if applicable) is
tested by the end user after SIL-mode is entered, in addition to the normal functional test
(see Process calibration (input trimming).
Emerson.com/Rosemount 9
42 44
43
41
43
I1
41 42 44
43
+
-
CJC
3
41 42 44
43
+
41 42 44
43
4
I1
41 42 44
43
41 42 44
43
41 42 44
43
51 52 54
53
51 52 54
53
51 52 54
53
51 52 54
53
41 42 44
43
4
I2
+
43
I1
+
-
+
43
I1
+
-
CJC
3
4
I1
41 42 44
43
51 52 54
53
4 5
I1
4
I2
A B D
F
C E
A B C D
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Analog output
The connected safety PLC shall be able to detect and handle the fault indications on the
analog output of the transmitter by having a NAMUR NE43-compliant current input. The
safety PLC must be able to detect and react to error signals according to NE43 within one
second. If Output Limit Check is disabled (see Output) in SIL mode, the connected safety
PLC shall also be able to detect and react to a current in the extended range according to
NAMUR NE43, within one second. The limits for the detection shall be <20.5 mA and >3.8
mA.
Failure rates
The basic failure rates from the Siemens standard SN 29500 are used as the failure rate
database. Failure rates are constant; wear-out mechanisms are not included. External
power supply failure rates are not included.
2.2.5
Installation considerations
The device must be installed as required for the SIL application according to Connections.
All assumption and restrictions as described in Installation considerations must be
observed.
Connections
Single input
2 w / 3 w / 4 w RTD or
lin. R
TC (internal CJC or
external 2 w / 3 w / 4 w
CJC)
(1)
(1) When using thermocouple input, the transmitter can be configured for either constant, internal
or external CJC via a Pt100 or Ni100 sensor. This must be selected during device configuration.
Dual inputs
Input 1
mV 3 w / 4 w
potentiometer
Input 2
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Safety Manual Installation and commissioning
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A. 2 w / 3 w / 4 w RTD or lin. R
B. TC (internal CJC or external 2 w / 3 w / 4 w CJC)
(3)
C. mV
D. 3 w / 4 w potentiometer
E. 5 w potentiometer
F. 3 w potentiometer
Output
2-wire installation
2.3 Configuring in SIS applications
2.3.1
Use any HART® capable configuration tool to communicate with and verify configuration
of the transmitter.
Note
Transmitter output is not safety-rated during the following: configuration changes,
multidrop, and loop test. Alternative means should be used to ensure process safety
during transmitter configuration and maintenance activities.
Safe parameterization
The user is responsible for verifying the correctness of the configuration parameters. After
parametrization it is not possible to simulate any measurements or the analog output. The
following restrictions applies to the configuration parameters.
Function/parameter
Sensor 1/2 Input Type Cannot be set to Callendar Van Dusen or Custom
Output Range 0% Must be 4.0 mA
Output Range 100% Must be 20.0 mA
Limit Check
Configuration
Output Limit – Error
Value
SIL requirements
Must be set to Limit Check Enabled on Input Range or Limit Check Enabled on
Input and Output Range
Must be ≤ 3.6 mA or ≥ 21.0 mA (if enabled on output)
Output Lower Limit Must be 3.8 mA
Output Upper Limit Must be 20.5 mA
Sensor Error Action Must be set to Broken and Shorted
(3) When using thermocouple input, the transmitter can be configured for either constant, internal or external CJC via a Pt100
or Ni100 sensor. This must be selected during device configuration.
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Function/parameter SIL requirements
2.3.2
Broken Sensor – Error
Value
Shorted Sensor – Error
Value
Sensor Drift – Error
Value
Input Limits – Error
Value
Analog Output
Calibration Gain
Analog Output
Calibration Offset
Loop Current Mode Must be set to Enabled
Write Protection Must be set to The configuration is protected by Password
Must be ≤ 3.6 mA or ≥ 21.0 mA
Must be ≤ 3.6 mA or ≥ 21.0 mA
Must be ≤ 3.6 mA or ≥ 21.0 mA (if enabled)
Must be ≤ 3.6 mA or ≥ 21.0 mA
Must be 1.0 (calibration of output current is not allowed)
Must be 0.0 (calibration of output current is not allowed)
For detailed description of the configuration parameters, see Safe parameterization - user
responsibility.
HW jumper
For SIL applications, any detected device error must force the analog output to a value
below 3.6 mA (i.e. in SIL mode, the HW jumper from P7-P8 may NOT be inserted). The HW
write protection by inserting a jumper from P1-P2 can be applied as an extra write
protection, after configuration and after SIL mode is entered.
Note
For SIL applications, the password write protection must be applied. (See Safe
parameterization for more information).
Write protect
Safe state > 21 mA No function No function
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2.3.3 Installation in hazardous areas
The IECEx Installation drawing, ATEX Installation drawing and FM Installation drawing shall
be followed if the products are installed in hazardous areas.
2.3.4 FMEDA reports
The FMEDA reports are issued by exida. The reports can be downloaded from
Emerson.com.
2.3.5 Device states
The states of the device are defined as shown, specific failure rates for each mode are
included.
Device state Description
Normal operation
(4-20 mA)
Detected failure (safe
state)
Dangerous state Dangerous state applies when current output is within the range 4...20
2.3.6 Device modes
The device can operate in various modes.
Normal mode
SIL mode
Mode Description SIL status Current
Reset/
startup
Non-safety operation for use in non-safety related applications
Safety operation and safety error for use in safety related applications
The device has just been started
up or reset, and is determining
the next mode.
The device will leave this mode
after maximum two seconds.
The safe current output is within the defined safety accuracy range.
The safe current output is ≤ 3.6 mA (defined as a failure signal) or ≥ 21
mA.
mA and deviates from the correct process value by more than the defined
safety accuracy range for longer than 60 seconds.
Safe current
output value
INT Failure signal ≤
3.5 mA
output
Yes
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Mode Description SIL status Current
output value
Nonsafety
operation
(normal
mode)
Safety
validation
mode
(transfer
from
normal
mode to
SIL mode)
Safety
operation
(SIL
mode)
The device is operating without
user-validated safe
parameterization.
The device may operate with
factory default configuration, or
with a specific ordered
configuration. This mode is valid
for use in non-safety related
applications only.
The user shall assign safety
related parameters to the device
in this mode.
The device is in the process of
validating the entered safety
parameters and the safety
function (see Safe
parameterization - user
responsibility for more
information). The device will
leave this mode when the user
either accepts or rejects the
safety parameterization.
The device operates in safe mode
and delivers safe measurement
output on the current output.
When operating in this mode, the
device is valid for safety related
applications.
OPEN Operation
signal (4 to 20
mA)
INT Failure signal ≤
3.5 mA
LOCK Operation
signal (4 to 20
mA)
Safe current
output
No
Yes
Yes
Safe
parametri
zation
failed
Safety
error (SIL
mode)
The device has failed the
validation of the current
configuration for safety
operation.
The device enters this mode if the
system detects a safety related
error in Safety Operation mode.
The possible errors are listed in
the error list of the device.
FAIL Failure signal ≤
3.5 mA
LOCK Failure signal ≤
3.6 mA or ≥ 21
mA
Yes
Yes
2.3.7 Functional specification of the safety function
All safety functions relate exclusively to the analog 4...20 mA current output signal.
Conversion of voltage signals, potentiometer, linear resistance, RTD sensor signals, or
thermocouple sensor signals in hazardous areas to the output signal within specified
accuracy. For RTD, potentiometer, and linear resistance inputs, cable resistances of up to
50 Ohm per wire can be compensated if 3- or 4-wire connection is configured (4- or 5-wire
for potentiometer). For thermocouple sensors, cold junction temperature errors can be
compensated, either by an internally mounted temperature sensor, by an external
temperature sensor, or by a fixed temperature value. The selection of CJC measurement
must be done and verified by the end user.
14 Rosemount 644
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