Upgrade kit instructions
00825-0200-3810, Rev AA
Rosemount™ Ultrasonic 3810 Series
Electronics
June 2022
Upgrade kit instructions June 2022
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..............................................................................................................................................3
Install......................................................................................................................................... 13
Operate......................................................................................................................................27
Mark III Wiring I/O and switch settings........................................................................................40
Summary table of communications/output settings.................................................................. 48
3810 Communication and Output settings................................................................................ 52
3810 Series engineering drawings..............................................................................................66
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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: Emerson.com/Rosemount
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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.
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 in
Appendix B. 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 in Appendix B:
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 3-4 for the 3810
Series electronics for board layout.
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Figure 1-3: Remove End Caps from the Upper Electronics
Enclosure
Figure 1-4: 3800 Series Electronics Assembly board layout
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 in Appendix
B 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 PiggyBacked 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 6mm 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
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 3-4).
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
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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.
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.
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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
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Figure 2-6: Acquisition Module Wiring
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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Figure 2-10: Install Cable and Secure Wires
17. Use the cable ties to dress the transducer cables. They should be
dressed in groups of two: A1 and C1, D1 and B1, A2 and C2, D2 and
B2. Install one cable tie at three inches from the base enclosure and
another about the point where the cables start to bend and separate
out to their respective port.
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Figure 2-11: Re-oriented and Secured Transducer Cables
18. Reconnect the acquisition cable connector to the acquisition module
and secure the cable connector by tightening the two screws.
19. Install the cable clamp on the Acquisition cable with the screw, lock
washer, flat washer to secure the cable to the final mounting hole of
the Acquisition module..
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Figure 2-12: Installing the Acquisition Cable and Module
A. Acquisition cable connector
B. Acquisition cable
C. Cable clamp and screw
20. Wrap the excess cable around the Acquisition Module and place the
electronics housing into position on the base enclosure.
21. Ensure the O-ring on the base of the upper enclosure is properly
seated. Position the upper enclosure housing so that it is in the
desired orientation for reattaching the electrical conduit.
22. Install the 3810 meter upper enclosure on the base enclosure once
the transducers are wired correctly.
23. Install the two screws with the 6 mm Allen wrench to secure the
upper enclosure to the base enclosure.
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Figure 2-13: Bolt the Upper Enclosure to Base Enclosure
24. Remove the end cap next to the conduit entries from the upper
enclosure. Figure 2-14 shows the layout of the 3810 electronics.
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Figure 2-14: 3810 Series Electronics Layout
A. End cap
B. CPU module
C. Optional I/O module
D. 3810 Series Transmitter electronics enclosure
E. I. S. Barrier module
F. Power supply
G. Backplane
H. Optional local display module
I. End cap
J. Acquisition module
K. Base electronics enclosure
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