Rosemount Ultrasonic 3810 Series User manual

Upgrade kit instructions
00825-0200-3810, Rev AB
January 2023
Rosemount™ Ultrasonic 3810 Series
Electronics

Signal words and symbols
Pay special attention to the following signal words, safety alert symbols, and statements:
Safety alert symbol
This is a safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
DANGER
Danger indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING
Warning indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Caution indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
Notice is used to address safety messages or practices not related to personal injury.
Important
Important is a statement the user needs to know and consider.
Tip
Tip provides information or suggestions for improved efficiency or best results.
Note
Note is “general by-the-way” content not essential to the main flow of information.
Contents
Plan................................................................................................................................................ 5
Install........................................................................................................................................... 16
Operate....................................................................................................................................... 31
Mark III Wiring I/O and switch settings.................................................................................. 45
Summary table of communications/output settings............................................................ 53
3810 Communication and Output settings............................................................................ 57
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3810 Series engineering drawings.......................................................................................... 71
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1 Plan
1.1 Introduction
1.1.1 General
Welcome to the Rosemount 3810 Series Ultrasonic Instruction
Manual.
This manual has been designed to provide you with a step-by-step
set of instructions for a Rosemount Liquid Ultrasonic meter with 3800
Series electronics to the new 3810 Series electronics.
NOTICE
Please read the “Before You Begin” section to make sure you have all
the components necessary to perform the before taking the meter
out of service.
1.2 Before you begin
This section shows all of the parts and tools required to perform the
upgrade. Ensure that all of these items are available before taking
the 3800 Series meter out of service.
1.2.1 Required parts
Ensure that you have received the to upgrade your meter.
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1.2.2 Tools required
Figure 1-1: Required Tools
A. ⅛-in. flat-blade screw driver
B. ¼-in. flat-blade screw driver
C. 3/8-in. drive ratchet wrench
D. 3/8-in. drive - extension - at least 3.5-in. long
E. 3/8-in. drive - 7/16-in. socket
F. Allen wrench - size 6 mm
G. Crescent wrench for cable glands and electrical conduit
MeterLink™ is required to communicate with the meter electronics,
access information and collect the configuration in the meter and
then convert and download the configuration into the new 3810
Series electronics. Always use the latest version of MeterLink™.
Upgrades to the latest version are available at: www.emerson.com.
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1.3 Before removing the 3800 Series Electronics
1.3.1 Procedure before removing the 3800 Series Electronics
Procedure
1. Before removing power from the meter being software to
connect to the meter.
2. Use the Edit/Compare Configuration screen in
MeterLink™ to read the configuration from the meter and save
it to a file on your computer. An example for a file name might
be “Meter Name, 3800 Series Final Config, 3-4-2013 10-15-02
AM.cfg”. MeterLink will be used later in this procedure (see
Configure the 3810 Series Electronics) to convert the
configuration and download it to the 3810 Series electronics.
CAUTION
Loss of set-up data
The current meter configuration file must be saved before
beginning the 3810 Series electronics .
Failure to save the current configuration file can result in the
loss of important set-up data.
Steps 3 through 8 provide more detailed instructions on
obtaining the required information with respect to the
communications set-up of the 3800 Series electronics,
however, if these settings are already known, these steps can
be skipped. Step 8 is for Frequency and Diagnostic outputs.
For reference, the known values should be entered in the
Summary table of communications/output settings. This
information will be required in the setup of the 3810 Series
electronics. For any setting which is not known, the applicable
step(s) for obtaining that information can be used.
3. Use the File|Meter Directory menu path, then select the
<meter name> you want to .
a) Click the Direct button on the lower left corner of the
Meter Directory dialog box.
b) The Direct Connection Properties For dialog appears.
c) Obtain the Modbus ID (same as Comms Address).
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Figure 1-2: Accessing Modbus ID for Ports A and B
4. Based on the information contained in the connection
properties window, enter the values for the following
parameters in the Summary table of communications/output
settings:
Port A and B: Modbus ID = _____(enter Comms Address).
5. Exit MeterLink and disconnect your PC from the meter
electronics. The remaining information required before doing
the , is based on the wiring terminations and the settings of
various switches on the boards that comprise the electronics.
6. Power down the electronics.
CAUTION
Equipment damage
Remove power from the meter electronics.
Failure to remove power from the meter electronics may result
in damage to the equipment.
7. Remove the end caps from the upper electronics housing of
the meter to access the electronic circuit boards. See Figure
1-4 for board layout of the 3800 Series stacks. See Figure 2-14
for the 3810 Series electronics for board layout.
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Figure 1-3: Remove End Caps from the Upper Electronics
Enclosure
A. End cap
B. Upper enclosure
C. Enclosure bolts
D. Base enclosure
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Figure 1-4: 3800 Series Electronics Assembly board layout
A. Upper explosion- proof Mark III housing assembly
B. I.S. interface board
C. Option boards
D. CPU board assembly
E. Field termination board
F. Base unit Mark III Electronics
G. Acquisition board
8. Remove the 3800 Series electronics CPU board, the HART
Option Board, and the Field Termination Board from the
enclosure. Fill out the Summary table of communications/
output settings based on the Field Connection Board wire
terminations and/or switch settings of the CPU board and
Option Board, if installed. This information will be used to
configure the new 3810 Series electronics later in this
procedure.
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Figure 1-5: 3800 Series CPU Board Showing Switch Settings
Figure 1-6: 3800 Series CPU Board with I.S. Barrier Board
Piggy-Backed on CPU Board
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1.4 Removing 3800 Series Electronics
1.4.1 Procedure to remove the 3800 Series Electronics
Procedure
1. Having obtained all the information related to the set-up of
the 3800 Series electronics configuration and communications,
all the components related to the electronics can now be
physically removed from the meter. Unscrew all wiring from
the Field Termination Board. It may be helpful to label the
wires to make it easier to connect the 3810 Series electronics.
2. Remove any conduit and wiring attached to all six conduit
ports.
3. Remove any ground wire attached to the ground lug on the
outside of the upper electronics housing. At this point there
should be no wires connected to the upper electronics
housing.
Figure 1-7: Ground Wire Removed
4. Use the 6 mm Allen wrench (supplied with kit) to remove the
two bolts holding the base enclosure.
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Figure 1-8: Remove Bolts from Base Enclosure Cover
5. Remove the upper electronics housing from the base
enclosure.
a) Remove the Acquisition cable, which comes down from
the upper electronics to the Acquisition module in the
base enclosure.
NOTICE
Figure 1-9 shows the Acquisition module for the 3400
Series electronics.
b) Loosen the two screws on the ends of the Acquisition
cable connector, and disconnect it from the Acquisition
module.
c) Set the upper electronics housing aside once the
housing is removed.
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Figure 1-9: Remove the Acquisition Cable
6. Remove all the screws that hold the transducer wires in the
terminal blocks that attach the transducers to the Acquisition
module.
a) Remove the screws from the ends of the two
connectors.
b) Disconnect the connectors and remove each of the
transducer wires from the connector.
7. Loosen the cable glands on the base enclosure and pull all of
the transducer cables out of the base enclosure.
8. Unscrew the three screws holding the Acquisition module in
the base enclosure and remove the Acquisition module.
The four mounting bolts holding the enclosure cover to the
meter body are sealed with an RTV silicone adhesive/sealant.
9. Remove the RTV with a flat blade screwdriver or utility knife
around the perimeter of the recessed opening and the RTV
eases the removal of the sealant.
a) Use the 7/16-in. socket wrench to remove the four
mounting bolts.
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Figure 1-10: Remove Old RTV
10. Remove the base enclosure from the meter body.
11. If RTV silicone adhesive/sealant was used to seal the base
enclosure to the meter body, remove the adhesive/sealant so
the 3810 base enclosure will have a clean mounting surface.
The 3800 Series electronics should be completely removed
from the meter body at this time.
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2 Install
2.1 Installing the 3810 Series Electronics
2.1.1 Procedure to install the 3810 Series Electronics
Procedure
1. Remove the 3810 Upgrade components from the packaging.
a) Use the 6 mm Allen wrench to remove the two screws
from the base enclosure cover.
2. Lift the upper electronics housing from the base enclosure.
The acquisition cable connector from the upper electronics is
attached to the acquisition module with two screws. The cable
is also secured by a cable clamp to a mounting bolt.
a) Remove the screw securing the cable clamp and then
loosen the two screws on the acquisition cable
connector and disconnect the acquisition cable
connector from the acquisition module.
Figure 2-1: Remove Acquisition Cable and Module
A. Acquisition cable
B. Acquisition cable connector
3. Unscrew the remaining two mounting screws from the
acquisition module in the base enclosure and remove the
acquisition board.
4. Place an insulating gasket on the meter body where the
electronics will be mounted (see gasket in Figure 2-14).
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5. Place the base enclosure on top of the meter body on top of
the insulating gasket. Note that the transducer port openings
on the base enclosure are labeled with transducer locations
(i.e., A1, A2, B1, B2, C1, C2, D1, D2).
a) Orient the base so that the A1 transducer port is closest
to the A1 transducer location on the meter body. The
meter body has the transducer location labels
embossed in the body next to each transducer boss.
The ports on the base enclosure must be oriented
outward (towards the sides of the meter body,
perpendicular to meter axis).
Figure 2-2: Base Enclosure Orientation
6. Use the four ¼-in. bolts with stainless steel washers and nylon
shoulder washers to secure the base enclosure to the meter
body.
a) Use a nut driver to tighten the bolts to a torque of 55 to
65 inch-lbs.
Figure 2-3: Insert ¼-in. Bolts
7. Fill up the base enclosure wells with RTV adhesive/sealant
around and over the four ¼-in. bolts.
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This will ensure a water-tight seal. Any excess sealant can be
removed by using a scraper to leave the sealant flush with the
top of the well. Excess sealant will adhere to the acquisition
board when it is installed, and make future removal of the
board difficult.
Figure 2-4: Apply RTV Sealant Around Bolts
8. Insert the Acquisition board in the base enclosure and secure
it with the two screws as shown for now.
Figure 2-5: Acquisition Module Attachment Screws
A. Acquisition Module screw
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Figure 2-6: Acquisition Module Wiring
A. Acquisition Module A1 transducer wiring
B. Base enclosure A1 transducer port
9. Route the transducer cables through the cable glands with the
correct label number (i.e. A1) which matches the label on the
transducer cable.
Figure 2-7: Base Enclosure Cable Glands Installation
10. Judge the proper length and cut off the excess.
11. Strip the outer insulation, outer shield, and inner insulation
using a utility knife. Verify that insulation of individual wires
was not cut while removing outer layers. Strip each wire 0.28-
in.
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Figure 2-8: Transducer Cable Cut Instructions
12. Insert tubing over wires, inner insulation and under shield
approximately 1.5-in. of shield should overlap.
13. Insert and secure transducer cables through cable glands
verify Line Mark is as referenced in Figure 2-7.
Figure 2-9: Line Mark
14. Using a torque screwdriver set to 78±7 oz.-in. secure the wires
to the terminal plugs of the Acquisition Module.
15. Verify the cable lengths are still an appropriate length and if
necessary, cut the transducer cables to the correct length with
allowance for the wiring terminations and connector
placement.
16. Ensure that the contacts clamp on the bare wires and not on
the wire insulation when the wires are being terminated on
the connector.
a) Leave the connector plugged into the Acquisition board
while terminating the individual wires.
b) Tighten the connector screws on the either end of the
connector after terminating all the wires on the
applicable connector.
c) Repeat this procedure for the transducer cables on the
other side of the meter.
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