Emerson Rosemount 3410 Series Programming manual

Maintenance and Troubleshooting manual
00809-0200-3104, Rev AC
December2023
Rosemount™ 3410 Series Gas Ultrasonic
Flow Meters
3415, 3416 and 3417

Safety and approval information
This Rosemount product complies with all applicable European directives when properly installed in accordance with
the instructions in this manual. Refer to the EU Declaration of Conformity for directives that apply to this product. The
EU Declaration of Conformity, with all applicable European directives, and the complete ATEX installation drawings
and instructions are available on the Internet at Emerson.com or through your local Emerson support center.
Information affixed to equipment that complies with the Pressure Equipment Directive can be found on the Internet
at Emerson.com.
For hazardous installations in Europe, refer to standard EN 60079-14 if national standards do not apply.
Other information
Full product specifications can be found in the product data sheet. Troubleshooting information can be found in the
maintenance and troubleshooting manual.
Product data sheets and manuals are available on the Emerson website at Emerson.com.
Return policy
Follow Emerson procedures when returning equipment.
These procedures ensure legal compliance with government transportation agencies and help provide a safe working
environment for Emerson employees. Emerson will not accept your returned equipment if you fail to follow Emerson
procedures. Return procedures and forms are available on our website at Emerson.com or by phoning the Emerson
Customer Service department.
Emerson Flow customer service
•Worldwide: [email protected]
•Asia-Pacific: [email protected]
2

Contents
Chapter 1 Maintenance..............................................................................................................................5
1.1 Precautions for meter maintenance......................................................................................... 5
1.2 Field hydrostatic pressure testing procedures........................................................................6
1.3 Routine maintenance..................................................................................................................7
Chapter 2 Troubleshooting...................................................................................................................... 13
2.1 Meter status alarms.................................................................................................................. 13
2.2 Troubleshooting the meter......................................................................................................16
2.3 Troubleshooting maintenance log files and trend files....................................................... 32
2.4 Meter reset mode......................................................................................................................33
Chapter 3 Meter repairs........................................................................................................................... 35
3.1 Precautions prior to repairs.....................................................................................................35
3.2 T-Slot transducer removal and installation............................................................................38
3.3 T-Slot transducer holder removal and installation............................................................... 45
3.4 T-200 transducer assembly removal and installation...........................................................49
3.5 T-200 transducer capsule assembly removal and installation............................................ 53
3.6 T-200 transducer housing removal and installation.............................................................58
3.7 Transducer cable removal and installation............................................................................60
3.8 Replace the meter electronics................................................................................................. 66
3.9 Acquisition Module replacement............................................................................................ 76
Appendix A Conversion factors.................................................................................................................. 83
A.1 Conversion factors per units of measurement..................................................................... 83
A.2 K-Factor and inverse K-Factor conversions............................................................................84
Appendix B Engineering drawings.............................................................................................................85
B.1 Rosemount 3410 Series Ultrasonic Flow Meter Drawings...................................................85
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Contents Maintenance and Troubleshooting manual
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1 Maintenance
1.1 Precautions for meter maintenance
This section includes discussion of the maintenance of Rosemount 3410 Series Ultrasonic
Meters.
For reference, you may download the MeterLink™ Quick Start Guide.
WARNING
Crushing hazard
Do not remove flange stabilizers.
Attempting to do so could allow the meter to roll, resulting in serious injury or equipment
damage.
A. Flange stabilizers
WARNING
Hearing damage
Wear proper hearing protection before approaching a metering system that is generating
a large amount of audible noise. Obey all facility safety rules.
Failure to comply could result in temporary or permanent hearing loss.
CAUTION
Surface temperature hazard
The meter body and piping may be extremely hot or cold.
Wear appropriate personal protective equipment when coming in contact with the meter.
Failure to comply may result in injury.
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CAUTION
Transportation hazard
When moving the meter, do not insert the forks of a forklift into the bore.
Inserting the forks may cause the meter to become unstable, resulting in injury or damage
to the bore and sealing face.
CAUTION
Tripping hazard
Clear all obstacles or obstructions from the work area when transporting, installing, or
removing the meter.
Failure to clear the work area may cause injury to personnel.
CAUTION
Escaping fluids hazard
The purchaser of the meter is responsible for the selection of Rosemount components/
seals and materials compatible with the chemical properties of the measurement fluid.
Failure to select suitable meter components/seals may cause escaping fluids, resulting in
injury or equipment damage.
1.2 Field hydrostatic pressure testing procedures
CAUTION
Leakage or pressure containing parts failure
Use precautions to eliminate hazards to personnel in the event of leakage or failure of the
gas ultrasonic meter pressure containing parts or failure of the test equipment and to
prevent over-pressurization during the test procedure.
Failure to comply may result in injury to personnel or cause damage to the equipment.
1.2.1 T-Slot transducer assembly and mount
Procedure
1. Slowly vent all line pressure on the Rosemount 3410 Series Gas Ultrasonic Meter to
atmosphere.
2. Disconnect transducer cable from the transducer holder.
3. Loosen the T-Slot transducer assembly with a 1¼-in. (32 mm) wrench or socket.
Carefully remove the T-Slot transducer assembly.
4. Place a label on the transducer assembly to marks its location.
Port locations are marked on the transducer cable as well as on cast meter
housings.
5. Apply a small amount of nickel antiseize compound (PN 3-9960-134) to the threads
of the Hydrotest plug from Hydrotest kit and install it into the mount. Required kit
part numbers are listed below.
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3415 Quantity 1 x 1-360-01-220
Quantity 1 x 1-360-01-221
3416 Quantity 1 x 1-360-01-220
Quantity 1 x 1-360-01-222
3417 Quantity 2 x 1-360-01-220
6. Repeat Step3 through Step5 for the other transducer(s) being careful to note the
location of each transducer in the meter assembly.
7. Run the field hydrostatic test.
8. Reverse the steps above to reinstall the transducers into their appropriate ports.
Before reinstalling the transducer assemblies, ensure the transducer ports, mounts,
and transducer holders are clean and free of debris. Apply a small amount of nickel
antiseize compound to the outer threads of the transducer holders before installing
them into the mounts.
1.2.2 T-200 transducer assembly
The T-200 transducer assembly has full-metal structure and can remain in place during
field hydrostatic pressure test.
Procedure
1. Leave T-200 transducers installed on the Rosemount 3410 Series Gas Ultrasonic
Meter while the line is pressurized.
2. Run the field hydrostatic test.
1.3 Routine maintenance
Routine maintenance operations requires adherence to all applicable regulations and laws
and safety training for personnel to perform the maintenance operations. Review your
organization's best practices procedures before performing routine maintenance.
1.3.1 Maintenance logs and reports
To monitor the performance health of the meter, and ensure it is operating within
acceptable specifications, it is recommended to perform routine diagnostics.
Collecting a maintenance log gives you a snapshot of the current health of the meter, and
you can compare the inspection reports from previously saved logs. Go to Logs/Reports
→ Maintenance Logs and Reports. MeterLink™ displays the Maintenance Logs and Reports
dialog box. Choose the time duration, log format, and collection rate for the output file and
click Start. You can open the file immediately after it is generated or view it at a later time.
It is recommended that a maintenance log be collected after an upset in the system.
In establishing a baseline to be used for the trending of the meter diagnostics, it is very
helpful if a set of log files is collected immediately after the meter has been installed in
the field. Preferably, collect the log files at several velocities within the operating range of
the meter. This helps establish that the flow profile is relatively constant throughout the
meters operating range (except velocities below 3 ft./sec where the profile may vary).
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Maintenance log collection
Figure 1-1: Maintenance log collection parameters
Trend maintenance log collection
Merging the results of two or more maintenance logs into a single file allows you to build a
historical database of the meter's performance.
Trending the logs indicates changes from the original installation of the meter or over
time. Looking at a single inspection report, that is either collected monthly or quarterly,
can give you an indication of the meter's health.
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Figure 1-2: Trend log collection
This is important, since many diagnostics change slowly overtime. Trending the
maintenance logs helps identify these changes and makes problems much more obvious
than merely viewing a single inspection report. The Trending feature is integral to
MeterLink™, which allows all important parameters to be trended. MeterLink supports
trending files in a Microsoft® Excel ® workbook from multiple Rosemount 3410 Series meter
maintenance logs. Some parameters, like gain, signal level, and noise level, may show a
shift over time which can be useful in detecting changes in the meter and the installation.
Maintenance logs or Trend files to be trended must all have matching column headings.
This means the logs must be in the same units (US customary or metric), must have the
same pressure type (gauge or absolute), and must have the same time base (1/second,
1/minute, 1/hour, 1/day). If not, an error message will be displayed stating the column
headings do not match, and the file will not be added to the workbook to trend list.
Archive log collection
Archive logs may be collected, and the options include:
Daily log Generated every 24 hours on the contract hour
Hourly log Generated every hour at the top of the hour
Event log Collects the alarm and event log records
Figure 1-3: Archive log collection parameters
The logs may be collected in a single file, or you can choose to collect one type of log. Each
of the meter archive logs includes the Meter Configuration file.
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1.3.2 Pipe cleaning maintenance
WARNING
BURST HAZARD
Before pipeline cleaning and maintenance ("pigging operations"), remove straightening
vanes or flow conditioners.
Failure to comply may cause excessive pressure in the meter system, resulting in death,
serious injury or equipment damage.
Figure 1-4: 3410 Series Gas Ultrasonic Flow Meter with flow conditioner for uni-
directional flow
A. Flow Conditoner: Rosemount Profiler, CPA 50E or CPA 55E
Figure 1-5: 3410 Series Gas Ultrasonic Flow Meter with flow conditioner for bi-
directional flow
A. Flow Conditioner: Rosemount Profiler, CPA 50E or CPA 55E
B. Flow Conditioner: Rosemount Profiler, CPA 50E or CPA 55E
Straightening vanes or flow profilers must be removed during pipeline cleaning
maintenance operations (“pigging operation”). If the meter run is pigged with a flow
conditioner in line, pressure may build up and cause the pipes and flanges to burst
and severely injure personnel. The excessive pressure may damage the meter or
the transducer ports may collect debris which may impede data acquisition and flow
measurement.
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1.3.3 Visual inspection
Periodically inspect the meter and meter run for signs of components loosening or seals
leaking.
Inspect for:
•Leaking from seals. For liquids, you can see leaks. For gases, leaks may be audible. Ice
may also form at a point of a gas leak.
•Movement of components that must be rigid.
•Excessive noise due to vibration could be a sign of a loose component. Inspection must
be more frequent in systems with a large amount of vibration.
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2 Troubleshooting
2.1 Meter status alarms
Run MeterLink™ and open the Meter Monitor (Summary) view to perform a diagnostics
health check.
Figure 2-1: Meter Monitor status alarms
If the meter is measuring flow and operating within the calibration parameters, the Meter
Status LED is green. If the Meter Status LED is red, an active alarm exists that requires
you to take corrective action. Click Check Status to display the Status Summary screen. The
alarms are shown with the primary causes listed first. Click the question mark, , next to
the alarm to display a help topic related to the alarm and recommended actions to resolve
the issue.
Figure 2-2: Status summary
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2.1.1 Check status
Click Check Status if any of the LEDs are yellow or red to see more specific information
causing the status alarm.
Some alarms do not require an acknowledge and will clear automatically when the alarm
condition goes away. Alarms that require a user to acknowledge them will have a button to
the right titled ACK. Clicking ACK changes the button text to Wait and sends a request to
the meter to clear the alarm. The alarm will disappear from the Check Status dialog once
the alarm actually clears.
Click Check Status, and MeterLink™ opens the Status Summary dialog box that gives a
short description of all alarms present.
Figure 2-3: Status Summary
A. Active alarm conditions from Meter Monitor page
B. Status summary page with alarm examples
Types of alarms:
•System
•Power Loss
•Field I/O
•Validity
•Comms
•Check Status
2.1.2 System alarm
The System alarm indicates a failure in the hardware that must be addressed by a service
technician.
This includes memory checksum errors and communication errors within the hardware. A
red LED indicates a System alarm condition. Collect a maintenance log and an audit/alarm
log and then contact your Emerson Flow service representative. This could be an alarm
condition that occurred and remains latched until the condition is resolved and the alarm
is cleared by clicking the ACK button on the Monitor → Check Status → Status Summary
page.
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2.1.3 Chord A, Chord B, Chord C and Chord D alarms
These alarms indicate how a chord is functioning.
Table 2-1: LED colors
LED color Problem
Green No alarms are present. Chord is operating properly.
Yellow The chord has failed or is in acquisition. This chord is not used for this batch. Chords
that have failed or are shown to be in acquisition for repeated batches indicates that
the meter must be inspected by a service technician.
The chord has manually been set to inactive. At least one sample in the batch caused
an alarm but it did not cause the chord to fail. The sample will not be used in the
batch. Discarding occasional samples can occur during normal operation such as
during flow velocity changes.
Red The in-use length is not equal to the calculated length for chord. If this is a new meter
or an upgraded meter, check that the chord length and correct if needed. If incorrect,
check all meter parameters against the meter Zero Flow Calibration report. This
report can be requested from your local area Emerson Flow service representative.
Gray The chord has manually been set to inactive.
2.1.4 Field I/O (input/output) alarm
Reports various field I/O devices that are in alarm.
Click Check Status for more details on specific alarms. The field is grayed out if the
Rosemount 3410 Series Ultrasonic Gas Flow Meter does not support this alarm.
2.1.5 Validity alarm
This alarm indicates that the meter may not be measuring accurately. Click Check Status to
see a description of which validity alarms are active. The validity alarms QMeter and QFlow
indicate an issue with the meter collecting enough information from the chords to make an
accurate measurement. The validity alarms for pressure and temperature indicate that the
value is above or below the alarm limits for these values. Red and green are the only colors
used for this alarm.
2.1.6 Comms alarm
The Comms alarm indicates that communications between MeterLink™ and the meter
failed. This could be due to a poor communication link. MeterLink continues to retry
communications. Red and green are the only colors used for this alarm.
2.1.7 Communications
The Communications Analyzer (via MeterLink™ Tools → Menu → Communications Analyzer
menu path) displays communications between MeterLink and the ultrasonic meter.
This utility is useful for troubleshooting communications to the meter. It displays many of
the transmission control protocol/Internet protocol (TCP/IP) commands between MeterLink
and the connected meter.
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2.2 Troubleshooting the meter
The following sections show errors that may occur with the meter hardware, firmware, or
connections and recommend actions to resolve the problems.
2.2.1 Acquisition Module Error
Recommended actions
1. Check/replace intrinsically safe (IS) barrier.
2. Check/replace acquisition module.
3. Attempt the program download procedure to reinstall the firmware.
a) Cycle power to the meter.
b) Replace the acquisition module.
c) If the acquisition module cannot be reprogrammed, collect a complete
archive log and contact your local Emerson Flow service representative.
2.2.2 Acquisition module is not compatible with firmware
Recommended actions
1. Check that acquisition module is compatible with model number configured in
meter (3414 four-path or 3418 eight-path).
2. Replace the acquisition module.
2.2.3 Chord failure
Potential cause
Chord is hard failed, and meter is unable to obtain measurement data from a pair of
transducers.
Recommended actions
1. If a chord is failed and no other transducers are failed or reporting status alerts,
the issue is most likely isolated to this pair of transducers or its cabling. Check
the transducer wiring for this pair of transducers to ensure connections are
secure and wired correctly.
2. Remove the transducer cable from the transducer and measure the resistance
with an ohm meter.
•For T-21, T-22, T-32, and T-41 transducers:
a. Remove the transducer cable and transformer retainer assembly from
the transducer holder and measure the resistance with an ohm meter
across the two pins, making sure not to touch the ohm meter probe
tips with your fingers.
If the value is not 1 Mohm ± 0.2 Mohm, try cleaning the pins with
alcohol and a small object, like a toothpick, to see if that lowers the
resistance.
If not, depressurize the meter, remove the transducer holders, and
remove the transducer capsules from the holder.
b. Ensure the transducer capsules are clean and dry.
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c. With the ohm meter, try measuring the resistance across the two pins
on the back of the transducer capsule.
If the value is not 1 Mohm ± 0.2 Mohm, then replace the transducers.
d. Measure the resistance across the two pins on the transformer
module that connect to the electronics through the transducer cables.
If the value is over 2 ohms, replace the transformer module.
e. Measure the resistance across the two pins on the transformer
module that lead to the electronics.
If the value is over 2 ohms, replace the transformer module.
f. Measure the resistance across the two pins on the transformer
module that connect to the transducer holder.
If the value is not between 30 and 40 ohms for the T-21 and T-41
transformer module, replace the transformer module.
If the value is not between 50 and 75 ohms for the T-22 transformer
module, replace the transformer module.
If the value is not between 7 and 12 ohms for the T-32 transformer
module, replace the transformer module.
g. If possible, measure the capacitance of the transducer capsule with
an LCR meter by measuring across the two pins on the back of the
capsule.
If the value is not between 450 and 600 pF for the T-21 and T-41
transducer, replace the transducer.
If the value is not between 215 and 350 pF for the T-22 transducer,
replace the transducer.
If the value is not between 400 and 550 pF for the T-32 transducer,
replace the transducer.
•For T-200 transducers:
a. Remove the transducer cables from the transducers.
b. Measure the resistance with an ohm meter across the two pins on the
back of the transducer capsules.
If the values are over 2 ohms, replace the transducer capsules.
If the values are under 2 ohms, remove the transducer capsules, clean
and reapply the coupling fluid to the front face of the transducer
capsules, and reinstall the transducer capsules.
If this does not correct the issue, remove the transducer assembly
from the meter and verify there is no debris or liquid build-up on the
transducer housing face causing the chord failure.
Consult Emerson Flow support if this does not address the issue.
3. If transducer cabling allows, swap cabling of failed transducer pair with a pair of
equal path lengths.
If the alarm remains active for this chord, then the transducers are working
properly. If this alarm clears, but the chord that was swapped now fails, the
issue is with the transducer.
4. Collect a Maintenance log, Configuration file, and Waveform stream file with
MeterLink™ and contact your Emerson Flow service representative.
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2.2.4 CPU (Central Processing Unit) Module Link LED
Recommended actions
Check the following:
•When connecting directly, check the crossover cable connection (PN 1-360-01-596).
•When using a hub:
a. Use straight-through patch cable between the meter and the hub and a
straight-through patch cable between the hub and the PC.
b. Do not connect either the meter or PC to the hub UPLINK port.
c. Check that the CPU Module LED 1 is on (either solid red or flashing green). If
the LED is not on, check power to the meter.
d. If the LED is on, check the Ethernet cable connections.
2.2.5 CPU (Central Processing Unit) Module Link LED is on, but I
can't communicate with the meter using Ethernet
Recommended actions
1. If you are connecting for the first time, refer to the Rosemount 3410 Series Gas
Ultrasonic Flow Meters Installation Manual (00825-0700-3104) Wiring and inputs/
outputs section for instructions on initial communication (via Ethernet) setup.
2. Enable the Dynamic Host Configuration Protocol (DHCP) switch on the CPU
module.
3. Verify that the PC has received an Internet Protocol (IP) address from the meter
as follows:
a) Open the Command Prompt window (Start → Run → (type) cmd.
b) In the Command Prompt window, type ipconfig.
If you get the following: IP 192.185.135.35(1) with a Subnet Mask of
255.255.255.0 and Default Gateway, you should be able to connect to
the meter.
If you get the following: Ethernet Adapter Local Area
Connection 1 IP Address: 0.0.0.0, the PC has not yet received
an IP address from the Ethernet server. Wait up to 30 seconds. If after
30 seconds, the PC has not received an IP address from the DHCP
server or the IP address from ipconfig is different from the range of
192.168.135.35 through 192.168.135.44, verify that the PC is configured
to receive its IP address automatically (via DHCP).
2.2.6 Communication line connected to the flow computer, but
no signal is received
Recommended actions
1. Check for loose connections at the flow meter and the flow computer.
2. Check the central processing unit (CPU) module settings.
(1) The last .35 can be up to .44.
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2.2.7 Communication issues due to blocked network ports
Blocked network ports on the computer running MeterLink™ or on a company local area
network (LAN) can prevent connections to the meter or prevent certain features from
working. These issues may occur over Ethernet, modem, and direct serial connections.
Reference the list of network ports used by MeterLink in the Help file and the symptoms of
having blocked ports. Contact your information technology (IT) department for assistance
in resolving these issues.
Error condition of a blocked network
•Cannot connect to a meter
•Cannot collect Archive log files
•Cannot view or stream waveforms in Waveform Viewer or Signal Analyzer
•Cannot upgrade firmware
•Communications lost over serial or modem connections while MeterLink is idle on a
screen
Symptoms of a blocked network
1. If a PING is blocked on this network port, serial or modem connections could be
lost after approximately 15 seconds of inactivity. This issue can be confirmed by
checking the log_meter_log file in the Temp data folder. The path of the Temp
data folder is shown in the MeterLink About dialog.
2. A blocked file transfer protocol (FTP) port will generally not prevent a connection
to the meter, but will prevent log collections and program downloads. A
blocked FTP port could prevent a connection in the event the meter is running
a newer version of firmware for which MeterLink does not currently have
a database configuration file. If this is the case, a message stating Error
reading database config file dbconfig <databaseversion>.xml
from the meter. will be displayed.
3. A blocked DB application programming interface (API) port will report Error
10001 opening database connection to <IP address>.
4. A blocked Streaming port will report an error message Unable to open a
control socket. This will occur when opening the Signal Analyzer window
or clicking Read or Stream to File in the Waveform Viewer.
2.2.8 Communicating with meter, but all chords display failures
Recommended actions
1. Verify that the resistance of transducers is within specification (2 Ω).
2. Check the acquisition module.
3. Check the interconnect cables between the base assembly and the transmitter
electronics enclosure.
2.2.9 Cannot communicate with MeterLink™ program
Recommended actions
1. Ensure that the meter is properly powered.
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2. Ensure that the computer cable is properly connected and check your interface
pins (RS-485 or RS-232).
3. Verify that the communication parameters of the MeterLink program are
correctly set.
4. Check RS-485 or RS-232 communication LEDs.
2.2.10 Cannot communicate with Field communicator
Refer to the AMS Trex Field Communication User’s Manual, Rev D. Download this manual
here: Emerson.com/FieldCommunicators.
Note
The 375 or 475 field communicators are obsolete and have been replaced with AMS Trex
field communicator.
2.2.11 Connect to multiple meters via Ethernet when they are on
the same Local Area Network (LAN)
Recommended actions
1. Configure each meter with a unique user-specified Internet protocol (IP)
address (following the initial communication quick start instructions in the
Rosemount 3410 Series Gas Ultrasonic Flow Meters Installation Manual
(00825-0700-3104) in Serial Connections).
2. Contact your information technology (IT) department for valid Internet protocol
(IP) addresses for your LAN and Gateway addresses.
3. Disable the dynamic host configuration protocol (DHCP) server.
2.2.12 Configuration changed
One or more parameters have been modified in the meter's configuration.
Recommended actions
1. Collect an Audit log using MeterLink™ in order to see what configuration
parameters changed and when they changed.
2. Run the Tools → Edit/Compare Configuration utility and select Write All or Write
Checked values to write the changes to the meter.
3. Save the configuration file.
2.2.13 Configuration lost
The meter configuration has reset to default values, the meter is not configured correctly
to measure flow, and the meter has performed a cold start.
Recommended actions
1. Unless the cold start occurred after upgrading firmware, replace the central
processing unit (CPU) board.
2. If the cold start occurred after a firmware upgrade, fully reconfigure the
meter from a previously saved configuration using the Tools → Edit/Compare
Configuration in MeterLink™. For Rosemount Series 3410 Firmware v1.60 and
later, the user database must either be imported from a saved user database
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