Emerson Rosemount 3812 Maintenance And Troubleshooting Manual Download Page 94

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11. If replacing other electronics or the fuse, continue with

Replace the fuse

Replace

the Backplane

Replace the I.S. Barrier board

Replace the Power Supply Board

Replace the Acquisition Module for direct or remote mount electronics

before

replacing the end caps and sealing the enclosure.

12. If you encounter problems replacing the electronics, see the Emerson Customer

Support contact information on the back cover of this manual.

3.9.2

Replace the fuse

Procedure

1. Disable electrical power to the meter.
2. Refer to

Meter electronics replacement

for the tools required to complete this

procedure.

3. Disconnect the Transmitter Electronics Enclosure security seals, loosen the end cap

security latch (requires a 3 mm Allen wrench) on the terminal end of the enclosure
(see

Figure 3-56

) and remove the end cap.

4. Use a 1/4 inch (7mm) standard flat head screw driver and remove the Fuse holder

cap (see

Replace the CPU Module

Figure 3-58: Fuse holder cap

A. Fuse holder cap

5. Remove the fuse from the holder.
6. Insert the replacement fuse (Littlefuse #218002.HXP) into the Fuse holder.

Meter maintenance

Maintenance and Troubleshooting Manual

April 2022

00809-0100-3812

Emerson.com/Rosemount

Summary of Contents for Rosemount 3812

Page 1: ...Maintenance and Troubleshooting Manual 00809 0100 3812 Rev AA April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meters for Direct or Remote Mount Meter Electronics ...

Page 2: ...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 custom...

Page 3: ...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 ...

Page 4: ...Contents Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 4 Emerson com Rosemount ...

Page 5: ...ay 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 we...

Page 6: ... 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 elimina...

Page 7: ...s 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 ver...

Page 8: ...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 Routine Maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 8 Emerson com Rosemount ...

Page 9: ...on 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 th...

Page 10: ...ay 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 Routine Maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 10 Emerson com Rosemount ...

Page 11: ...ed 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...

Page 12: ...Routine Maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 12 Emerson com Rosemount ...

Page 13: ...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 Maintenance and Troubleshooting ...

Page 14: ...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 t...

Page 15: ...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 Com...

Page 16: ...ecommended 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 conta...

Page 17: ... 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 Maint...

Page 18: ...m 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...

Page 19: ...ub 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 ena...

Page 20: ...ive 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...

Page 21: ... Time Issues If using an analog temperature 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 temperature device verify that the pressure sensor is working properly If using an analog temperature devi...

Page 22: ... Error 10001 opening database connection to Click OK and you will be prompted to Attempt FTP only connection Click Yes and if successful the MeterLink caption displays Connected to meter name Go to the Tools pull down menu and select Program Download to attempt the firmware upgrade again If the firmware upgrade is successful the meter should start working as normally as the meter s configuration i...

Page 23: ...ble connectors Check the resistance of the transducers should be approximately 2 MΩ Problem also may be caused by a bad Acquisition Board or interconnect cable Check system status in the MeterLink program for any flagged errors Check the CPU Module If Chord A is not indicating change the transducer cables from Chord B to chord A If Chord B then fails the transducers are bad on Chord A Power Failur...

Page 24: ...ains an excessive amount of noise Use the MeterLink Meter Signal Analyzer to increase the StackSize until noise level decreases settings can be 1 none 2 4 8 or 16 If increasing the StackSize is not successful try turning on the filter or consult with Emerson Customer Support if you are unsure of how stacking a signal can affect the meter s operation 1 Note The latest version of the Rosemount Liqui...

Page 25: ...ctive alarms This indicates the meter is measuring flow and operating within the calibrated parameters Meter Status LED is red This indicates an active alarm Resolve and acknowledge active alarms as displayed on the Status Summary page Click the Help button beside the alarm description to display information about the alarm and recommended actions to resolve the issue Maintenance and Troubleshooti...

Page 26: ...eline values in the Maintenance log Inspection report Meter Monitor Summary view Meter Flow Properties Table Flow velocity Check the flow direction If reverse flow is detected check for valve leaks If the meter run typically has reverse flow when flow is stopped use the Field Setup Wizard General Page and reconfigure the ReverseFlowVolLmt to allow a higher volume Meter Monitor Detailed view Monito...

Page 27: ...st Electronics voltage out of range CPU board system voltages are valid if 1 0V 1 2V 2 5V 3 3V or the Acquisition Module valid voltages are 1 2V 2 5V or 3 3V Replace the CPU Module if one or more of the System Voltages is out of range Replace the Acquisition Module if one or more of the voltages is out of range MeterLink Tools Menu Frequency output Run the Frequency Outputs test If the output read...

Page 28: ...rection configuration and polarity Meter Electronics Acquisition Module communications error If the CPU Module LED 5 is not flashing green check interconnect cable between Acquisition Module and the CPU Module Check firmware revision and upgrade if necessary using MeterLink Tools Program Download If the CPU Board LED 5 is not flashing green replace Acquisition Module see Replace the Acquisition Mo...

Page 29: ...s the cold start occurred after upgrading firmware you may need to replace the CPU Module If the Cold Start occurred after a firmware upgrade you must reconfigure the meter from a previously saved configuration file using the Edit Compare Configuration screen Then clear the latched alarm on the Status Summary page MeterLink Logs Reports Menu Power failure If this was a known power fail or restart ...

Page 30: ... in Section 3 6 8 in the Installation Manual 00825 0100 3812 External ground wiring Transmitter Electronics Enclosure ground lug Inspect ground lug wiring and make sure the wiring is tightly secured Conduit seals Transmitter Electronics Enclosure Inspect the conduit sealant and follow your standard operating procedure to report tampering with the conduit sealant Your operating procedures may requi...

Page 31: ...g through a hub verify that the computer and meter are connected to the hub with straight through patch cables 2 2 5 Direct serial connections Verify the switch settings on the CPU Module Also verify your wiring between the meter and the computer running MeterLink using the Field Wiring drawing DMC 004946 Verify the Comms Address and Baud rate are correct in the Meter Directory record If unsure of...

Page 32: ...ually have to exist or be connected to the PC If you install a local printer you can configure MeterLink to temporarily change your Windows default printer over to this local printer while running MeterLink Do this by selecting this local printer for the Override system default printer selection in the Program Settings dialog MeterLink will automatically change the Windows default printer to the s...

Page 33: ...rs Select the Trusted Sources tab 3 Click the Trust access to Visual Basic Project radio button and click OK to apply your selections Maintenance and Troubleshooting Manual Troubleshooting 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 33 ...

Page 34: ... To enable Excel 2007 to work with MeterLink customize the Ribbon to include the Developer tab Figure 2 7 Excel 2007 Tools Menu Procedure 1 Select Macro Security to access the Trust Center Troubleshooting Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 34 Emerson com Rosemount ...

Page 35: ...soft com downloads en details aspx FamilyID 2354406c c5b6 44ac 9532 3de40f69c074 Additionally it may take longer to validate a workbook when you attempt to add it to the Workbooks to trend list This is a known issue documented in the Microsoft Knowledge Base Article 824136 Windows Explorer Quits Unexpectedly or You Receive an Error Message When You Right Click a File For Windows XP simply install ...

Page 36: ...Troubleshooting Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 36 Emerson com Rosemount ...

Page 37: ... latched band shrouds Re wet the transducers Common procedure for all meters Re wet the transducers Replace the transducer housing Common procedure for all meters Replace transducer housing and seals Replace the transducers Replace the transducers Direct mount electronics Remote mount electronics Transducers replacement Replace transducers for direct mount electronics Replace transducers remote mo...

Page 38: ...ety information Follow these safety message instructions to avoid injury and equipment damage 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 t...

Page 39: ...ng to remove the transducer housing If fluid leaks at the joint of the transducer housing and the body as the transducer housing is unscrewed immediately reinstall it Failure to comply may cause serious injury to personnel or equipment damage A Transducer housing and meter body joint CAUTION ESCAPING FLUIDS HAZARD The purchaser of the meter is responsible for the selection of Rosemount components ...

Page 40: ...eter options Figure 3 1 Direct mount transmitter electronics options A Bolted band shroud design 2 3 sizes B Split shroud design 4 to 10 150 300 ANSI sizes C Latched shroud design 4 to 10 150 300 ANSI sizes D Clamped band shroud design 12 and larger sizes Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 40 Emerson com Rosemount ...

Page 41: ...t at one end and the transducer cable at the other end Meters are supplied with transducers which are extractable while the line is pressurized The transducer assembly shown below is a one piece capsule that can be easily installed or removed from the meter without depressurizing the unit using the tool list provided in Table 3 9 LT 10 transducers are designed for 2 through 10 inch meter sizes LT ...

Page 42: ...1 P N 1 504 90 183 E Spring LT 10 P N 1 504 90 046 LT 11 P N 1 504 90 047 F Transducer capsule and cable assembly LT 10 P N 1 360 01 624 or LT 11 P N 1 360 01 823 G O ring part numbers vary with service conditions H Transducer housing LT 10 P N 1 360 01 632 for 900 ANSI 316L SS or P N 1 360 01 633 Inconel LT 11 P N 1 360 01 819 for 900 ANSI 316L SS or P N 1 360 01 818 Inconel Meter maintenance Mai...

Page 43: ...ter Failure to comply may cause serious injury Table 3 2 Band shroud removal tool list Tools required Standard inch socket or a standard inch wrench Appropriate personal protective equipment Figure 3 4 Bolted band shroud meter assembly top view A Bolted band shroud Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 43 ...

Page 44: ...s are loosened remove both end shrouds and place on a flat surface 5 Repeat Steps 1 through 4 to remove the other band shroud 6 Move the shroud parts bolts and lock washers out of your immediate work area This completes the bolted band shroud removal procedure 3 4 2 Remove clamped band shrouds WARNING CUTTING HAZARD Sharp edges may be present on the band shrouds Wear appropriate personal protectiv...

Page 45: ...d Figure 3 7 Clamped top end shroud assembly A Top end shroud B Top end shroud bolts Procedure 1 Remove top end band shroud security seals if installed Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 45 ...

Page 46: ... part of the worm screw clamp from the screw part of the worm screw clamp and remove them from the shroud Figure 3 8 Clamped shroud worm screw disassembly A Worm screw clamp threaded part B Worm screw clamp screw part C Guide pin holes 5 While holding the shroud end engaged with the guide pins against the body OD raise the other shroud end edge enough to unlock the threaded part of the worm screw ...

Page 47: ... end without the guide pins back band shroud close to the body OD and raise the shroud end engaged with the guide pins enough to disengage the band shroud from the guide pins Remove the nut part of the worm screw clamps following the same procedure described above Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 47 ...

Page 48: ...With the clamped band shroud assembly on its side edge on a flat surface locate the hem bend joint of the band shroud assembly half way from each end Move each part of the assembly away from each other freeing the sheet metal hem bend joint Place the band shroud assembly on its side edge on a flat surface Move the back band shroud with respect to the front band shroud freeing the sheet metal hem b...

Page 49: ...crew clamps out of your immediate work area This completes the clamped band shroud removal procedure 3 4 3 Remove split shrouds WARNING SHARP EDGES CUTTING HAZARD Equipment may have sharp edges Wear safety approved gloves eye protection and shoes when disassembling the shrouds Failure to comply may cause serious injury Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April ...

Page 50: ...hex nuts with integral tooth lock washers and shroud clamps see Figure 3 12 2 Remove the shroud clamps from each of the four studs by pulling the clamp off of the stud at each location 3 Slide the lower split shroud down to remove it from the meter body 4 Move the shroud assembly and bolts out of your immediate work area This completes the split shroud removal procedure 3 4 4 Remove latched band s...

Page 51: ...ment Required Band shrouds may have sharp edges Wear safety approved gloves eye protection and shoes when disassembling the shrouds Procedure 1 If installed remove the security wires and shroud latch retainers 2 Lift the one of the shroud latches and slowly disengage the latch from the strike Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid ...

Page 52: ...hes re wet the transducers to improve the signal strength Table 3 5 Transducer maintenance tools and shop supplies list Tools required Dow Corning Silicone 200 1 Oil Retaining ring pliers Rosemount P N 1 504 90 043 or or Stanley Proto J371 or 371L MeterLink or AMSTM Device Manager or a Field Communicator 1 Dow Corning 200 is a trademark of Dow Corning Corporation U S A Procedure 1 Disassemble the ...

Page 53: ...lide the feed thru cable seal down the cable Figure 3 16 Feed thru cable seal removal A Feed thru cable seal 4 Use the Retaining Ring pliers and remove the retaining ring shoulder washer and spring from the transducer housing 5 Pull the transducer capsule from the housing Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter...

Page 54: ...p of Dow Corning 200 Silicon Oil 1 12 500 Centistokes P N 1 360 01 650 on the face of the transducer Make sure the oil is evenly distributed across the transducer face 7 Wipe excess oil from the transducer sides 1 Dow Corning 200 is a trademark of Dow Corning Corporation U S A Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 54 Emerson com Rosemount ...

Page 55: ...ble seal into the housing groove with the retaining ring pliers 11 Repeat Step 3 through Step 10 for re wetting the other pair of transducers on the meter 12 Insert the feed thru cable seal into the housing groove with the Retaining Ring Pliers 13 Apply electrical power to the meter 14 Connect to the meter with MeterLink and run the Zero Flow Calibration Wizard Then collect and save a Maintenance ...

Page 56: ...unt or remote mount Transmitter Electronics Enclosures WARNING CUTTING HAZARD Sharp edges may be present on the meter Wear appropriate personal protective equipment when working on the meter Failure to comply may cause serious injury WARNING FLUID CONTENTS MAY BE UNDER PRESSURE When the meter is under pressure DO NOT attempt to remove or adjust the transducer housing Attempting to do so may releas...

Page 57: ...ench 7 15 inch wrench 11 mm Retaining ring pliers Rosemount P N 1 504 90 043 or Stanley Proto J371 or 371L MeterLink or AMS Device Manager or a HART Field Communicator 3 6 1 Replace transducer housing and seals Procedure 1 Disable electrical power to the meter 2 Before removing the transducer housing drain the meter of fluid and ensure the pressure inside the meter is at atmospheric pressure If fl...

Page 58: ...hru cable seal removal B Retaining ring pliers 5 Slide the feed thru cable seal down the cable Figure 3 21 Feed thru cable seal removal A Feed thru cable seal 6 Use the Retaining Ring pliers and remove the retaining ring shoulder washer and spring from the transducer housing 7 Pull the transducer capsule from the housing Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 010...

Page 59: ...surizing the meter if necessary Once assured all pressure is vented and fluid within the meter is drained continue to unscrew and remove the transducer housing from the meter body 9 Prepare to install the a new transducer housing Note Rosemount recommends replacing the O ring seals each time the transducer housing is replaced a If replacing the o ring seal remove the used seal and discard Apply Mo...

Page 60: ...nge Ft lb N m Transducer housing LT 10 40 43 49 53 LT 11 90 99 122 134 11 Place one drop of Dow Corning 200 Silicon Oil 4 12 500 Centistokes P N 1 360 01 650 on the face of the transducer Make sure the oil is evenly distributed across the transducer face 12 Wipe excess oil from the transducer sides 13 Insert the re wetted transducer capsule into the transducer housing port inside the meter body 14...

Page 61: ...d run the Zero Flow Calibration Wizard select the Calibrate Zero Calibrate menu and generate the report Then collect and save a Maintenance log to show the as left condition of the meter Or use AMSTM Device Manager or a HART Field Communicator and select Overview Zero Calibration Start menu or Service Tools Maintenance Zero Calibration Start 19 Close your application connection MeterLink AMS Devic...

Page 62: ...irs Average delay and delta times are based on the transducer housing so they will not change in the meter configuration when transducer capsules are replaced WARNING CUTTING HAZARD Sharp edges may be present on the meter Wear appropriate personal protective equipment when working on the meter Failure to comply may cause serious injury WARNING FLUID CONTENTS MAY BE UNDER PRESSURE When the meter is...

Page 63: ...osure and remove the transducer capsule from the housing This includes removing the Transmitter Electronics Enclosure the Acquisition Module the Base Enclosure and the Shroud assembly Table 3 7 Transducer removal tool list Tools required LT 10 or LT 11 transducer pair Crescent wrench or channel lock pliers for cable glands and electrical conduit 7 16 inch wrench 11 mm 3 8 inch drive ratchet wrench...

Page 64: ...d loosen the hex nuts on the Transmitter Electronics Enclosure This should allow enough slack to remove the Transmitter Electronics Enclosure from the Base Enclosure If the installation uses flexible conduit you may not need to disconnect it from the Transmitter Electronics Enclosure Figure 3 24 Conduit removal A Transmitter electronics enclosure B Conduit gland fitting 4 Use a 7 16 inch 11mm wren...

Page 65: ...nsducer terminal blocks 6 Use a 1 8 inch 3mm flat blade screw driver to remove the Acquisition cable terminal block screws Unplug the Acquisition cable terminal block 7 Use a 1 8 inch 3mm flat blade screw driver and remove the transducer wire terminal blocks screws Disconnect the transducer cable wires from the terminal blocks so that the cables can be removed from the meter NOTICE Ensure the tran...

Page 66: ... and remove the three Acquisition Module flat head screws split lock washers and flat washers then remove the Acquisition Module from the Base Enclosure 9 Remove the three Base Enclosure hex head bolts shoulder washers flat washers and split lock washers with a 7 16 inch 11 mm socket wrench Then remove the Base Enclosure from the meter body Meter maintenance Maintenance and Troubleshooting Manual ...

Page 67: ...shroud meter pull cable through the top hole in top shroud Figure 3 28 Figure 3 28 Split shroud transducer cable seal and gasket A Base Enclosure B Feed thru Cable seal C Base cover gasket D Nylon flat washers 12 If it is a band shroud meter remove all foil tape from the body top and circular grooves and remove the cable from the grooves Repeat this procedure for each transducer pair you are remov...

Page 68: ...e with foil tape C Transducer cable circular grooves D Feed thru cable seal 13 Use Retaining Ring pliers to pull the transducer feed thru cable seal from the transducer housing Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 68 Emerson com Rosemount ...

Page 69: ... 3 31 Feed thru cable seal removal A Feed thru cable seal 15 Use the Retaining Ring pliers and remove the retaining ring shoulder washer and spring from the transducer housing 16 Pull the transducer capsule from the housing Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 69 ...

Page 70: ...op of Dow Corning 200 Silicon Oil 5 12 500 Centistokes P N 1 360 01 650 on the face of the transducer to be installed 19 Insert the transducer capsule into the transducer housing in the meter body 20 Slide the spring and shoulder washer along the cable to the transducer capsule 5 Dow Corning 200 is a trademark of Dow Corning Corporation U S A Meter maintenance Maintenance and Troubleshooting Manua...

Page 71: ...nsducer pocket a Start placing the cable in the circular the body circular groove at the transducer b Use foil tape to hold the cable and loop in position c Continue positioning the cable in the body circular groove and securing with the tape At the meter top position the cable in the body top cable groove and tape to hold d Ensure that a flat surface will be available for the band shroud to be in...

Page 72: ...le B Meter body circular cable groove C Transducer cable D Meter body transducer pocket 23 For split shroud meters only feed the transducer cables through the hole in the upper split shroud on top of the meter body Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 72 Emerson com Rosemount ...

Page 73: ... shroud feed thru cable seal A Base enclosure B Cable Feed thru seal C Gasket nylon flat washers D Base electronics gasket 25 Repeat Step 23 and Step 24 for each transducer pair you are replacing 26 Using tape mark each transducer cable with the transducer location to identify which cable goes to which transducer e g A1 A2 B1 and B2 are the transducer location identity names Maintenance and Troubl...

Page 74: ...ex head bolts 3 B Split lock washers 3 C Flat washers 3 D Nylon shoulder washers 3 E O ring F Base enclosure 28 Apply Loctite nickel anti seize or equivalent to the three hex head bolts to prevent loosening due to vibration during operation 29 Place the Acquisition Module into the Base Enclosure align the thee holes of the Acquisition Module with the three holes in the base enclosure and secure wi...

Page 75: ... the insulation of the individual wires 31 The transducer cables have two wires and a bare drain wire that must be terminated on the connector on the Acquisition Module The red wire connects to the positive pin the black wire connects to the negative pin and the bare drain wire connects to the S pin Shield Reattach the transducer cables to the terminal blocks with a 1 8 inch 3mm flat blade screw d...

Page 76: ... blade screw driver Figure 3 41 Transducer wiring and Acquisition cable reassembled A Transducer wiring terminal blocks B Acquisition cable C Acquisition Module D Base enclosure O ring E Base Enclosure 34 When you have completed wiring the transducer cables to the Acquisition Module check the Base Enclosure O ring and reinstall it if necessary Meter maintenance Maintenance and Troubleshooting Manu...

Page 77: ...cer cables to be sure they will not be pinched as the lower shroud is assembled Make sure the transducer cables are moved out of the way and will not be pinched when the Shroud is reinstalled 42 Reinstall the shroud Install bolted band shrouds Install clamped band shrouds Install split shrouds Install latched band shroud 43 Reseal the meter electronics and shroud if required see Meter sealing This...

Page 78: ...e 3mm Rosemount P N 2 4 9200 501 Retaining ring pliers Rosemount P N 1 504 90 043 MeterLink or AMS Device Manager or a Field Communicator Procedure 1 Disable power to the meter 2 Remove security seals if installed 3 Remove the shrouds Refer to the appropriate sections below for your meter Remove bolted band shrouds Remove clamped band shrouds Remove split shrouds Remove latched band shrouds 4 Use ...

Page 79: ...e 3 43 Feed thru cable seal removal A Feed thru cable seal 6 Use the Retaining Ring pliers and remove the retaining ring shoulder washer and spring from the transducer housing 7 Pull the transducer capsule from the housing Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 79 ...

Page 80: ...ransducer capsule Figure 3 45 LT 10 Transducer and cable assembly removed from meter 8 Prepare to disassemble transducer cables from the terminal blocks inside the Junction Box Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 80 Emerson com Rosemount ...

Page 81: ...duit 9 Pull the transducer cable for the transducer to be replaced down through the foam feed thru cable seal on and the base cover gasket If a split shroud meter pull cable through the top hole in top shroud Figure 3 47 Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 81 ...

Page 82: ...oves Repeat this procedure for each transducer pair you are removing Figure 3 48 Bolted band shroud transducer removal A Junction Box B Transducer cable with foil tape C Transducer cable circular grooves D Feed thru cable seal 10 Use a 7 16 inch 11 mm wrench and remove the four hex head bolts and split lock washers securing the junction box cover Meter maintenance Maintenance and Troubleshooting M...

Page 83: ... the terminal block mounting plate from the junction box 14 Use a 7 16 inch 11mm socket wrench and remove the three hex head screws split lock washers flat washers shoulder washers and lift the Junction box off of the meter body 15 Prepare to install the new transducer and the cable assembly 16 Make sure the cables are labeled for the correct transducer A1 A2 B1 and B2 17 Place one drop of Dow Cor...

Page 84: ...meters only loop the transducer cable at the transducer a couple of turns The loop must fit within the body transducer pocket a Place the cable into the circular body groove at the transducer b Use foil tape to hold the cable and loop in position c Continue positioning the cable in the body circular groove and securing with the tape At the meter top position the cable in the body top cable groove ...

Page 85: ...body circular cable groove C Transducer cable D Meter body transducer pocket 22 For split shroud meters only feed the transducer cables through the hole in the upper split shroud on top of the meter body Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 85 ...

Page 86: ...arefully feed the transducer cables through the center of the Junction Box rubber gasket and the feed thru foam cable seal and gasket then into the hole in the bottom of the Junction Box Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 86 Emerson com Rosemount ...

Page 87: ... names NOTICE Feed thru foam seals tear easily Carefully pull the transducer cables through the seal to prevent ripping the feed thru cable seal 26 Ensure the nylon flat washers are in place between the junction box and the gasket 27 Reattach the Junction Box to the meter body with the three shoulder washers flat washers split lock washers and hex head bolts Tighten the bolts with a 7 16 inch 11 m...

Page 88: ...ction box cover and gasket C Terminal blocks D Terminal block mounting plate E Meter mount junction box F Junction Box rubber gasket and feed thru foam cable seal Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 88 Emerson com Rosemount ...

Page 89: ...ring terminations Strip back about 1 5 inches of the cable outer sheath and 1 4 inch of insulation from the wires Note When stripping the outer sheath of the transducer cable do not cut into the insulation of the individual wires The transducer cables have two wires and a bare drain wire that must be terminated on in the Junction box terminal blocks as marked The red wire connects to the positive ...

Page 90: ...r Or use AMS Device Manager or a HART Field Communicator and select Overview Zero Calibration Start menu or Service Tools Maintenance Zero Calibration Start 36 Close your application connection MeterLink AMS Device Manager or HART Field Communicator 37 Reinstall the shroud Install bolted band shrouds Install clamped band shrouds Install split shrouds Install latched band shroud 38 If required inst...

Page 91: ...mount P N 1 504 90 043 1 8 inch 3mm flat blade screw driver 3mm 1 4 inch 7 mm flat blade screw driver 3 8 inch drive ratchet wrench 3 8 inch drive extension at least 3 5 long 7 16 inch socket wrench 3mm Allen wrench Rosemount P N 2 4 9200 501 3 9 Transmitter electronics maintenance Should the meter require disassembly in the field i e check boards change switch settings or replace boards to preven...

Page 92: ...s on the Transmitter Electronics Enclosure loosen the end cap security latches using a 3 mm Allen wrench and remove both end caps from the Transmitter Electronics Enclosure 4 If replacing the CPU Module located closest to the terminal end of the enclosure or the Optional I O Module use a 3mm flat blade screw driver and disconnect the CPU Module terminal blocks or the Optional I O Module terminal b...

Page 93: ... Detailed view and verify the meter is acquiring data the transducers have good signals and flow profiles for the chords are displayed and run the Zero Flow Calibration Wizard select the Calibrate Zero Calibrate menu and generate the report Then collect and save a Maintenance log to show the as left condition of the meter Or use AMS Device Manager or a HART Field Communicator and select Overview Z...

Page 94: ...ower to the meter 2 Refer to Meter electronics replacement for the tools required to complete this procedure 3 Disconnect the Transmitter Electronics Enclosure security seals loosen the end cap security latch requires a 3 mm Allen wrench on the terminal end of the enclosure see Figure 3 56 and remove the end cap 4 Use a 1 4 inch 7mm standard flat head screw driver and remove the Fuse holder cap se...

Page 95: ...ll the security wire seals see Seal direct or remote mount transmitter electronics enclosure 12 If you are not replacing other electronics replace the end caps and security latches requires a 3 mm Allen wrench If required install the security seals through the hex bolts in the Junction box cover see Seal the Junction Box for remote mount electronics option This completes the fuse replacement proce...

Page 96: ...s the board to the Guide Plate 9 Attach the Acquisition Cable terminal block to the new Backplane Board and plug the Power Supply Board and I S Barrier board into the Backplane board 10 Insert the Backplane with the Power Supply and I S Barrier Boards attached to the Backplane into the enclosure 11 Fully seat the CPU Module and Optional I O Module onto the Backplane board 12 Install the four Phill...

Page 97: ...e your application connection MeterLink AMS Device Manager or HART Field Communicator 20 This completes the Backplane board replacement procedure If you encounter problems with this procedure see the Emerson Customer Support contact information on the back cover of this manual 3 9 4 Replace the I S Barrier board Procedure 1 If replacing the I S Barrier board remove power to the meter 2 Refer to Ta...

Page 98: ...nclosure standoffs with the four Phillips head screws 12 Reinstall the terminal blocks1 8 inch 3 mm flat head screw driver on the CPU Module Optional I O Module I S Barrier Board and the Power Supply 13 Recheck the connections wiring and switch settings before replacing the end caps 14 Connect to the meter with MeterLink Open the Meter Monitor Detailed view and verify the meter is acquiring data t...

Page 99: ...is procedure see the Emerson Customer Support contact information on the back cover of this manual 3 9 5 Replace the Power Supply Board Procedure 1 If replacing the Power Supply board disable electrical power to the meter 2 Refer to Table 3 9 for the tools required to complete this procedure 3 Disconnect the Transmitter Electronics Enclosure security seals loosen the end cap security latches with ...

Page 100: ...ptional I O Module 9 Attach the Backplane to the enclosure standoffs with the four Phillips head screws 10 Use a 1 8 inch 3 mm flat blade screw driver and install the terminal blocks on the CPU Module Optional I O Module I S Barrier Board and the Power Supply 11 Recheck the connections wiring and switch settings before replacing the end caps 12 Connect to the meter with MeterLink Open the Meter Mo...

Page 101: ...eter This completes the Power Supply Board replacement procedure If you encounter problems with this procedure see the Emerson Customer Support contact information on the back cover of this manual 3 9 6 Replace the Acquisition Module for direct or remote mount electronics Procedure 1 Disable electrical power to the meter 2 Refer to Table 3 9 for the tools required to complete this procedure 3 If t...

Page 102: ... Enclosure and Base Enclosure security seal removal A Transmitter electronics enclosure B Base enclosure bolts and security seals 5 For direct mount electronics Use a 7 16 inch 11mm wrench and remove the four hex head bolts and split lock washers securing the Transmitter Electronics Enclosure to the Base Enclosure Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 ...

Page 103: ...bolts C Base enclosure For remote mount electronics if necessary loosen the mounting bracket bolts and lower the Transmitter Electronics Enclosure and the Base Enclosure to a suitable working level Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 103 ...

Page 104: ...h 11mm wrench and remove the four hex head bolts and split lock washers securing the Base Enclosure 7 Use a 1 8 inch 3 mm flat head screw driver and disconnect the Acquisition cable terminal block and the transducer wire terminal blocks from the Acquisition Module inside of the Base enclosure Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 104 Emerson com Rosemo...

Page 105: ...es have good contact with the terminal block and the terminal block screws are tight 11 When you have completed attaching the terminal blocks to the Acquisition Module check the Base Enclosure or Junction Box O ring seal and reinstall if necessary 12 Reattach the Transmitter Electronics Enclosure to the Base Enclosure with the four hex head bolts and lock washers Tighten bolts with a 7 16 inch 11m...

Page 106: ...cement procedure 3 9 7 Acquisition cable replacement Replacing the Acquisition cable Rosemount P N 1 360 01 595 requires removing the Transmitter Electronics Enclosure from the Base Enclosure disconnecting the Acquisition cable terminal block from Backplane board disconnecting the CPU and Power Supply terminal blocks and disconnecting the Acquisition cable from the Acquisition Module in the Base E...

Page 107: ...hroud by the end edges and bow the shroud with the brushed finish side of the shroud as the outside surface Position the bowed shroud center of the length over the top of meter body under the electronics enclosures and over the end of the meter body b Used bolted band shrouds previously installed bolted band shrouds will already be bowed Grasp the end edges and position the bowed shroud center of ...

Page 108: ...to cover the entire end surface aligning the two holes created by joining the edges of the two end shrouds with the tapped holes in the body end 8 While holding the end shrouds insert one shroud bolt with lock washer into the tapped hole and tighten wrench tight Repeat with the second shroud bolt with lock washer 9 Repeat Step 1 thru Step 8 to install the second bolted band shroud and two end shro...

Page 109: ...th a edge on a flat surface Position the parts to so they are circular with the ends with bent edges near each other Guide the bent edges to fit within each other completing the engagement of the sheet metal hem bend Be sure that full engagement is achieved and that the edges of both parts remain on the flat surface Figure 3 69 Band shroud assembly A Worm screw clamps B Guide pins C Clamped band s...

Page 110: ... clamp part into into the rectangular shaped hole and rotate the clamp part so the flat surface opposite of the nut is flat against the outside surface of the band shroud Extend the length of the clamp part threads beyond the end of the band shroud Secure the clamp part with tape to the band shroud Repeat to install a second worm screw clamp threaded part into the second rectangular hole on this e...

Page 111: ... Check to confirm that the band shroud assembly fully covers the body transducer pockets b Check to confirm that the hem bends assembly of the two shroud parts located at the bottom of the meter are fully engaged c If the shroud is misaligned use a flat blade screw driver and loosen both worm screw clamp assemblies by alternating between the two worm screw clamp screws turning each a few turns at ...

Page 112: ...11 If required install band shroud security seals Install the security seal wire into and through one of the two holes in the shroud bolts Shroud sealing This completes the clamped band shroud installation procedure 3 10 3 Install split shrouds WARNING CUTTING HAZARD Sharp edges may be present on the band shrouds Wear appropriate personal protective equipment when working on the meter Failure to c...

Page 113: ...one split shroud clamp onto a lower shroud stud Align the angled tabs of the clamps to fit over the angled tabs of the upper shroud Secure the clamp in place using a hex nut with attached external tooth lock washer 6 Tighten the nut with a 7 16 11 mm wrench Repeat this at each of the stud locations using additional nuts 7 If required attach the security wire seals on the Transmitter Enclosure end ...

Page 114: ... cause serious injury Use the following instructions to install the latched band shrouds covering the meter body and transducer assemblies If required install the latch security wires Before starting shroud assembly check around the body outside diameter to be sure all of the transducer cables are positioned so the shroud does not pinch or crimp the cables Meter maintenance Maintenance and Trouble...

Page 115: ...y shoulder see Figure 3 75 4 Hold the shroud snugly against the meter body and position the latch and strike so they are centered on the bottom of the meter body 5 Lift the latch and over the strike and press down firmly 6 Repeat Step 1 through Step 5 for the other band shroud 7 Visually inspect the shrouds covering for proper fit on the meter body Ensure the bands are flush against the body shoul...

Page 116: ...security seal wire into and through the holes in one of the shroud latches maximum wire diameter 078 inch 2 0 mm 9 Remove all slack and seal 10 Cut wire ends to remove excess wire 11 Repeat these steps for the other shroud latch This completes the split shroud security seal installation procedure Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 116 Emerson com Ro...

Page 117: ...structions to install the security seal wires on the Transmitter Electronics Enclosure Figure 3 77 Transmitter electronics enclosure security latch A Transmitter Electronics Enclosure end cap B Security latch Procedure 1 Rotate the end cap clockwise fully closing and compressing the end cap seal Install the Security latch using a 3 mm Allen wrench 2 Install the security seal wire into and through ...

Page 118: ...tter Electronics Enclosure security wire seals 3 11 2 Seal direct or remote mount Base electronics enclosure Use the following instructions to install the security seal wire on the Base Enclosure Procedure 1 Install security wire seal into and through two of the four the holes in the socket head screws on the Base Enclosure cover maximum wire diameter 078 inch 2 0 mm Meter maintenance Maintenance ...

Page 119: ...re 3 11 3 Seal the Junction Box for remote mount electronics option Use the following instructions to install the security seal wire on the junction box if required Procedure 1 Install security wire seal into and through two of the four the holes in the socket head screws on the Junction Box cover maximum wire diameter 078 inch 2 0 mm Maintenance and Troubleshooting Manual Meter maintenance 00809 ...

Page 120: ...es installing security seals on the Junction Box 3 11 4 Shroud sealing Security seals protect the integrity of the meter metrology and prevent tampering with transducer assemblies The following sections detail how to properly seal the Rosemount 3812 Liquid Allocation Ultrasonic Flow Meter after commissioning or maintenance procedures The security seal wires are commercially available Meter mainten...

Page 121: ...on the wire to prevent counterclockwise rotation of the screws when the seal wire is taut Figure 3 81 Bottom view band shroud security seals A Band shroud 1 4 20 bolts B End band shroud bolts 2 Adjust the security wire removing all slack and thread into the lead seal 3 Cut wire ends to remove excess wire This completes the bolted band shroud security seal installation procedure Clamped band shroud...

Page 122: ...the seal wire is taut 2 Remove all slack and seal 3 Repeat previous step for the other top end shroud 4 Cut wire ends to remove excess wire This completes the clamped band shroud security seal installation procedure Split shroud security seals Use the following instructions to install the security seal wires on the split shroud covering the meter body and transducer assemblies Meter maintenance Ma...

Page 123: ...0 mm 2 Remove all slack and seal 3 Cut wire ends to remove excess wire 4 Repeat these steps for the split shroud clamps This completes split band shroud security seal installation procedure Latched band shroud security seals Use the following instructions to install the security seal wires on the latched band shrouds covering the meter body and transducer assemblies Maintenance and Troubleshooting...

Page 124: ...recess for pop rivet allowance E Meter body shoulder F Shroud latch Procedure 1 Install the security seal wire into and through the holes in one of the shroud latches maximum wire diameter 078 inch 2 0 mm Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 124 Emerson com Rosemount ...

Page 125: ...security wires 2 Remove all slack and seal 3 Cut wire ends to remove excess wire 4 Repeat these steps for the other shroud latch This completes the latched shroud security seal installation procedure Maintenance and Troubleshooting Manual Meter maintenance 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 125 ...

Page 126: ...Meter maintenance Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 126 Emerson com Rosemount ...

Page 127: ...sion factors Unit of measurement F 32 x 5 9 C C 273 15 K 1 K C 5 9 C F 10 6 MPa Pa 0 006894757 MPa psi 0 1 MPa bar 0 101325 MPa atm 0 000133322 MPa mmHg 0 3048 m ft 0 0254 m in 103 dm3 m3 10 6 m3 cc m3 cm3 0 3048 3 m3 ft3 0 0254 3 m3 in3 3600 s h 86400 s day 103 g kg 0 45359237 kg lbm 231 in3 gal 42 gal bbl barrel 0 0037854 gal m3 6 289811 bbl m3 10 3 Pa s cPoise 1 488 Pa s lb ft s Maintenance and...

Page 128: ...llScale frequency full scale volumetric flow rate volume time unit Freq1FullScaleVolFlowRate and Freq2FullScaleVolFlowRate MaxFreq maximum frequency Hz pulses time unit Freq1MaxFrequency and Freq2MaxFrequency TimeUnit time conversion factor depends on the VolFlowRate Time Unit data point volume second 1 s s volume minute 60 s m volume hour 3600 s h volume day 86400 s d Volume where the volume is s...

Page 129: ...pendix contains the following engineering drawing s for the ultrasonic meter DMC 004936 Rosemount 3810 Liquid Ultrasonic Flow Meter System Wiring Diagram Maintenance and Troubleshooting Manual Engineering drawings 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 129 ...

Page 130: ...Engineering drawings Maintenance and Troubleshooting Manual April 2022 00809 0100 3812 130 Emerson com Rosemount ...

Page 131: ...Maintenance and Troubleshooting Manual Engineering drawings 00809 0100 3812 April 2022 Rosemount 3812 Liquid Ultrasonic Flow Meter 131 ...

Page 132: ... All rights reserved Emerson Terms and Conditions of Sale are available upon request The Emerson logo is a trademark and service mark of Emerson Electric Co Rosemount is a mark of one of the Emerson family of companies All other marks are the property of their respective owners ...

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