Emerson Rosemount 3812 Programming manual

Maintenance and Troubleshooting Manual
00809-0100-3812, Rev AA
April 2022
Rosemount™ 3812 Liquid Ultrasonic Flow
Meters
for Direct or Remote Mount Meter Electronics

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 www.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 http://
www.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 user manual.
Product data sheets and manuals are available from the Emerson website at http://www.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 web support site
at Emerson.com, or by phoning the Emerson Customer Service department.
Emerson Flow customer service
Email:
•Worldwide: http://[email protected]
•Asia-Pacific: http://[email protected]
Telephone:
North and South America Europe and Middle East Asia Pacific
United States 800 522 6277 U.K. 0870 240 1978 Australia 800 158 727
Canada [phone] The Netherlands [phone] New Zealand 099 128 804
Mexico [phone] France 0800 917 901 India 800 440 1468
Argentina [phone] Germany 0800 182 5347 Pakistan 888 550 2682
Brazil [phone] Italy 8008 77334 China [phone]
Central & Eastern [phone] Japan [phone]
Russia/CIS [phone] South Korea [phone]
Egypt 0800 000 0015 Singapore [phone]
Oman 800 70101 Thailand 001 800 441 6426
Qatar 431 0044 Malaysia 800 814 008
Kuwait 663 299 01
South Africa 800 991 390
Saudi Arabia 800 844 9564
UAE 800 0444 0684
2

Contents
Chapter 1 Routine Maintenance.................................................................................................5
1.1 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 Troubleshoot Maintenance log files and trend files.................................................................... 31
Chapter 3 Meter maintenance..................................................................................................37
3.1 General maintenance tasks........................................................................................................37
3.2 Important safety information.....................................................................................................38
3.3 3812 meter options................................................................................................................... 40
3.4 Remove the shrouds.................................................................................................................. 43
3.5 Re-wet the transducers..............................................................................................................52
3.6 Transducer housings or housing seals replacement................................................................... 56
3.7 Transducers replacement.......................................................................................................... 62
3.8 Meter electronics replacement.................................................................................................. 90
3.9 Transmitter electronics maintenance........................................................................................ 91
3.10 Shrouds installation............................................................................................................... 106
3.11 Meter sealing.........................................................................................................................117
Appendix A Conversion factors................................................................................................. 127
A.1 Conversion factors per units of measurement......................................................................... 127
A.2 K-Factor and inverse K-Factor.................................................................................................. 128
Appendix B Engineering drawings............................................................................................ 129
B.1 Rosemount 3812 Liquid Ultrasonic Flow Meter drawings.........................................................129
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1 Routine Maintenance
1.1 Meter maintenance
This section includes discussion of the maintenance of Rosemount 3812 Series Ultrasonic
Meters.
For reference, you may download the MeterLink Quick Start Manual from:
http://www2.emersonprocess.com/en-US/brands/Flow/ultrasonics/Pages/Ultrasonic.aspx
MeterLink may be downloaded at no charge from:
https://www.emerson.com/en-us/catalog/rosemount-sku-meterlink-diagnostics-
software
CAUTION
SURFACE TEMPERATURE HAZARD
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.
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 to
personnel or damage to the bore and sealing face.
WARNING
CRUSHING HAZARD
During meter installation or removal, always place the unit on a stable platform or surface
that supports its assembled weight.
Failure to comply can cause the meter to roll, resulting in serious injury or equipment
damage.
CAUTION
TRIPPING HAZARD
Clear all obstacles or obstructions from the work area when transporting, installing or
removing the meter.
Failure to comply may cause injury to personnel.
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CAUTION
ESCAPING FLUIDS HAZARD
The purchaser of the meter is responsible for the selection of Emerson 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 to personnel or equipment damage.
Consult your Emerson Sales and Service representative to ensure you purchase the correct
components and seals for your application, below safety message.
1.2 Field hydrostatic pressure testing procedures
The Rosemount 3812 Liquid Ultrasonic Flow Meter can be field hydrostatic tested without
any special preparations or disassembly. The transducers are not exposed to the process
pressure and can remain installed in the meter.
The liquid ultrasonic meter pressure containing parts include, but are not limited to the
transducer housings. The Hydrostatic test is verification of the pressure containing
capability of the liquid ultrasonic meter pressure containing parts and seals. Each
Rosemount Liquid Ultrasonic Flow Meter is successfully hydrostatic pressure tested prior
to shipping from the factory.
The maximum field hydrostatic pressure test must be limited to 1.5 times the stamped
maximum working pressure. The maximum working pressure is stamped on the meter ID
tag.
CAUTION
LEAKAGE OR PRESSURE CONTAINING PARTS FAILURE
Use precautions to eliminate hazards to personnel in the event of leakage or failure of the
liquid 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.
NOTICE
A copy of this test is available by contacting Emerson Customer Support. Please provide
the body serial number when requesting a copy of the test report. The body serial number
is located on the downstream flange to the left of the hoist ring hole (when looking at the
flange face).
Emerson Customer Support contact information is located on the back page of the
manual.
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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, routine diagnostics should be performed. 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. Use the Logs/Reports menu
and click Maintenance Logs and Reports. MeterLink displays the Maintenance Logs and
Reports dialog. Choose the time duration, log format and collection rate for the output file
and click the Start button. 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 are 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 over time. 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 3812 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 (i.e. U.S. Customary or Metric), must have
the same pressure type (i.e. 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 that 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
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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 include the Meter Configuration file.
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1.3.2 Pipeline cleaning maintenance
WARNING
BURST HAZARD
Before pipeline cleaning and maintenance (“pigging operations”), remove straightening
vanes or flow conditioners.
Failure to comply can cause excessive pressure in the meter system, resulting in death,
serious injury or equipment damage.
Straightening vanes or flow conditioners 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.
Important
The excessive pressure may damage the meter or the transducer ports may collect debris
which may impede data acquisition and flow measurement.
Plugging hazard
Pipeline cleaning and maintenance (“pigging operations”) through the ultrasonic meter is
not recommended. The transducer ports may become plugged with debris and adversely
affect the transducer’s signal strength.
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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 (Summary) view
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 the Check Status button 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 the Check Status button if any of the LEDs are yellow or red to see more specific
information causing the status alarm. Some alarms do not require an acknowledgement
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 the ACK
button 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 the Check Status button and MeterLink opens the Status Summary dialog box that
gives a short description of all alarms present.
Figure 2-3: Meter Monitor Status Summary
A. Active alarm conditions from Meter Monitor page
B. Status Summary page with alarm examples
Following is a list and a brief description of the types of alarms:
•System
•Field I/O
•Validity
•Comms
•Check Status
2.1.2 System alarm
The System alarm indicates a failure in the hardware that should 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.
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2.1.3 Chord A and Chord B alarm
Chord A and Chord B - These alarms indicate how a chord is functioning.
LED Color Problem
Green No alarms are present. Chord is operating properly.
Yellow 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 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 should
be inspected by a service technician.
Gray The chord has manually been set to inactive, or option is not
available.
2.1.4 Field I/O alarm
Reports various field I/O devices that are in alarm. Click the Check Status button for more
details on specific alarms. The field does not appear if the 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 TCP/IP commands between MeterLink and the connected meter. For
troubleshooting communications with the 475 Field Communicator for the HART®
Protocol, refer to Section 5 of the Emerson 475 Field Communicator User’s Manual, Rev D.
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This manual may be downloaded from the following location: http://
www2.emersonprocess.com/en-US/brands/Field-Communicator/Pages/
Documentation.aspx
For troubleshooting communications with AMS™ Device Manager, refer to the help
documentation and support at the following web site: http://
www2.emersonprocess.com/en-US/brands/amssuite/amsdevicemanager/Pages/
AMSDeviceManager.aspx
2.2 Troubleshooting the meter
Table 2-1 and the following sections show errors that may occur with the meter hardware,
firmware or connections and recommended actions to resolve the problem(s).
Table 2-1: Troubleshooting
Error Recommended action(s)
Acquisition Module Error •Check interconnect cable between Acquisition Module and
the CPU Module.
•Attempt the Program Download procedure to install the
firmware.(1)
—Cycle power to the meter.
—Replace the Acquisition Module (see Replace the
Acquisition Module for direct or remote mount
electronics).
—If the Acquisition Module cannot be reprogrammed,
collect a complete Archive log and contact your local
area Emerson Flow service representative.
Acquisition Module is not
compatible with firmware
•Upgrade the firmware in the meter to the latest version
using MeterLink. Contact your Emerson Flow service
representative to obtain the latest firmware.
•Replace the Acquisition Module.
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Table 2-1: Troubleshooting (continued)
Error Recommended action(s)
Chord failure Chord is hard failed (Chord A or Chord B) and meter is unable to
obtain measurement data from this pair of transducers.
•If Chord A (or Chord B) is failed and no other transducers are
failed or are 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 make sure
connections are secure and wired correctly.
•Verify that the meter run is not partially full where the top
transducer pair (Chord A) is not submerged in the process
fluid.
•Verify the average gain of this transducer pair is not above
90dB. The gain value can be read in MeterLink on the
Monitor page.
•Check the Acquisition Module transducer wiring for this pair
of transducers to make sure connections are secure and
wired correctly.
•If transducer cabling allows, swap cabling of failed
transducer pair with a pair with equal path lengths (Chord
A1 and B1, Chord A2 and B2) or access the acquisition
module and swap the cabling of the failed transducer pair
with a pair with 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.
•Collect a Maintenance Log, Configuration file and
Waveform stream file with MeterLink and contact your
Emerson Flow service representative.
CPU Module LINK LED •When connecting directly:
—Use a cross-over cable connection (P/N 2-3-3400-079)
•When Using a Hub:
—Use straight-through patch cable between the meter
and the hub and a straight-through patch cable
between the hub and the PC
—Do not connect either the meter or PC to the hub
UPLINK port
—Check the CPU Module LED1 is on (either solid red or
flashing green). If the LED is not on, check power to the
meter
—If the LED is on, check the Ethernet cable connections
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Table 2-1: Troubleshooting (continued)
Error Recommended action(s)
CPU Module LINK LED is on but I
can't communicate with the
meter using Ethernet
•If you are connecting for the first time
•Enable the DHCP switch on the CPU Module
•Verify that the PC has received an IP address from the meter
as follows:
—Bring up DOS prompt window (Start → Run-(type) cmd)
—In the DOS prompt window, type ipconfig
•If you get the following: IP 192.168.135.35 (note the
last .35 can be up to .44) 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 DHCP
server wait (up to 30 seconds) to receive an IP address
before attempting to connect to the meter
—after 30 seconds the PC has not received an IP address
from the DHCP server or the IP address shown above
(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)
Communication line connected
to the flow computer but no
signal is received
•Check for loose connections at the flow meter and the flow
computer.
•Check the CPU Module settings.
Communicating with meter but
all chords display failures
•Verify that the resistance of transducers is within
specification (2 MΩ).
•Check the Acquisition Module.
•Check the interconnect cables between the Base Enclosure
and the Transmitter Electronics Enclosure.
Cannot communicate with
MeterLink program
•Ensure that the meter is properly powered.
•Ensure that the computer cable is properly connected and
check your interface pins (RS-485 or RS-232).
•Verify that the communication parameters of the MeterLink
program are correctly set.
•Check RS-485 or RS-232 communication.
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Table 2-1: Troubleshooting (continued)
Error Recommended action(s)
Cannot communicate with Field
Communicator
Refer to the Emerson 475 Field Communication User’s Manual,
Rev D. This manual may be downloaded from the following
location: http://www2.emersonprocess.com/en-US/brands/
Field-Communicator/Pages/Documentation.aspx
Note
The 375 Field Communicator is no longer available for purchase
since the release of the 475 Field Communicator. Customer
support for the 375 Field Communicator remains available.
Cannot communicate with AMS
Device Manager
Refer to the AMS help documentation and support at the
following web site: http://www.emersonprocess.com/ams/
suppinde.htm
Connect to multiple meters via
Ethernet when they are on the
same LAN
•Configure each meter with a unique user-specified IP
address.
•Contact your IT department for valid IP addresses for your
LAN and Gateway addresses.
•Disable the DHCP server.
Connect to multiple meters via
Ethernet when they are on the
same hub but not connected to
an intranet LAN
•Configure each meter with a unique user-specified IP
address.
•Assign each meter on the hub a unique IP address within
the range 192.168.135.150 through 192.168.135.254
(Gateway address for each meter may be left unconfigured
as 0.0.0.0).
•A PC may receive its IP address from an external DHCP
server; in this case, one and only one meter must have its
DHCP server enabled (the DHCP server will serve up to 10 IP
addresses to PCs attempting to talk to all meters on the
hub).
•Once a meter's IP address is configured, the meter may be
connected to the hub and accessed using that IP address.
Configuration changed One or more parameters have been modified in the meter's
configuration
•Collect an Audit log using MeterLink in order to see what
configuration parameters changed and when they changed.
•Run the Tools → Edit/Compare Configuration utility and
click the Write All button or select the checkbox in the
value column and click Write Checked button to write the
changes to the meter.
•Save the configuration file.
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Table 2-1: Troubleshooting (continued)
Error Recommended action(s)
Configuration lost The meter configuration has reset to default values and the
meter is not configured correctly to measure flow and the
meter has performed a Cold Start.
•Unless the Cold Start occurred after upgrading firmware,
replace the CPU Module (see Replace the CPU Module).
•If the cold start occurred after a firmware upgrade, fully re-
configure the meter from a previously saved configuration
using the Tools → Edit/Compare Configuration in
MeterLink.
Electronics Temperature is Out
Of Nominal Range
Temperature of the electronics is out of nominal operating
range (below -40 °C or above 100 °C) which could lead to a
system failure.
•Attempt to warm or cool the meter electronics housing.
•If the electronics is mounted to the meter and the process
fluid in the meter is over 65 °C, you must remote mount the
electronics off of the meter body.
•Collect a Maintenance log using MeterLink while the meter
is experiencing the issue and contact your Emerson Flow
service representative.
Flow pressure is outside the
alarm limits
•Startup Issues:
—Verify that there is voltage to the pressure sensor from
either the meter's power supply board or from an
external power supply.
—If using an analog pressure device, verify that the
pressure sensor is properly wired to the connector.
—Verify the input is properly configured for your pressure
input.
—If using a flow computer to write pressure to the meter,
verify that it is properly writing to fixed flow pressure in
the proper units.
•Run Time Issues:
—If using an analog pressure device and input reading is 0,
check if IsAI2Avail is equal to 1 in the Meter Information
dialog in MeterLink. If it is not 1, either the I/O Board has
been removed or is damaged. Reinstall or replace the
CPU Module if this value is 0.
—If using an analog pressure device, verify that the
pressure sensor is working properly.
—If using an analog pressure device, recheck wiring and
switch settings.
—If a flow computer is writing values to the fixed flow
pressure, verify that the flow computer is still writing
valid values without Modbus write errors.
—Re-verify the pressure input settings are correct.
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