Emerson CT5100 Quick Start Guide

Rosemount™ CT5100(Ex)

Continuous Gas Analyzer

Quick Start Guide

00825-0100-4512, Rev AA

February 2020

Preface

Published by Emerson. All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no

liability for any inaccuracies that may be found. This quick start guide reflects the state of the product at the issue date below, but further enhancements while in service may mean that the manual does not reflect your particular system.

Emerson reserves the right to make changes without notice both to this publication and the products which it describes. Document number: 00825-0100-4512 Rev AA, February 2020

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording, or otherwise without the express prior written permission of the copyright holder.

If you require additional technical assistance, request help from cascade.support@emerson.com or Emerson distribution partners. Send general inquiries to cascade.support@emerson.com. All trademarks used within this document are the property of their respective owners.

Rosemount CT5100(Ex) preliminary information

This section details important user information for the Rosemount CT5100(Ex) Continuous Gas Analyzer.

This article is in accordance with IEC 60079-0: 2011 Clause 30.

This article must not be changed amended or removed.

Important

Users must read, understand, and comply with the following information before proceeding.

All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain, and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The following information are also available and/or referenced in Rosemount CT5100(Ex) Reference Manual.

Save all instructions for future use. Contact your local service center or sales office when missing documents.

Authorized personnel

In-depth specialist knowledge is an absolute requirement for working with and on the analyzer. Personnel installing, operating, servicing, and maintaining the analyzer must be instructed, trained, qualified, and authorized personnel of the operating company for hazardous areas and the manufacturer. It is the responsibility of the operating company to:

• Train staff

• Observe safety regulations

• Follow the safety instructions and procedures in the product manual

Operators must:

• Have been trained

• Have read and understand all relevant sections of the product manual before commencing work

• Know the safety mechanisms and regulations

WARNING

To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate, maintain, or service this analyzer before reading and understanding this reference manual and receiving appropriate training.

Safety Precautions

Operators, maintenance personnel, and authorized users must observe the following safety precautions and warnings.

Safety precautions are in accordance with IEC 60079-0: 2011 Clause 30. The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and maintenance personnel, must observe the following safety precautions and warnings.

DANGER

ELECTRIC SHOCK

In accordance with IEC 60079-0: 2011 Clause 30. The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Confirm that the circuit breakers

are set to Off and locked out and tagged out off before removing the top cover or opening the front cover. The analyzer must be earthed.

Death, personal injury, and/or damage to persons and/or property may result if this is not observed.

DANGER

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the

analyzer during start-up. The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes 30 seconds at a minimum flow

rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance. Purge the sample gas in accordance with the safe working procedures for this site. Allow the analyzer and the system for returning the sample gas to run for five minutes to allow any sample gas in the analyzer to

be returned to the exhaust. Failure to observe this precaution will cause death, personal injury, and/or damage to persons.

DANGER

FLAMMABLE SUBSTANCES

Some parts of the analyzer may reach temperatures of 320 °F (160 °C ) and may present an ignition source. Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer. A fire may result if this precaution is not observed. The interior of a analyzer is always hot unless it has been switched off and allowed to cool down.

WARNING

TRANSPORTATION HAZARD

Handle the analyzer with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet, or other body parts.

The analyzer weighs 121 lb (55 kg) and should always be lifted and moved using suitable lifting/moving equipment. Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard the analyzer against movement or break-away during transport by securely strapping it in place.

WARNING

FIRE AND EXPLOSION

In accordance with IEC 60079-0: 2011 Clause 30. Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable

concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in accordance with NFPA 496 and ISO60079-1/2 and 28.

Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

WARNING

FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or

service. Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

COMBUSTIBLE GASES

In accordance with IEC 60079-0: 2011 Clause 30. The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable

concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in accordance with NFPA 496.

Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Always lock out the gas handling system when shutting down the analyzer. Unauthorized performance on the analyzer or its

associated pipes/hoses may result in highly flammable gas being released, causing fire or explosion. Failure to lock out gas handling system may cause death.

WARNING

BURNS

Some parts of the analyzer may be heated to 320 °F (160 °C). To prevent burns, do not touch any of the hot parts. All parts of a analyzer are always hot unless it has been switched off and allowed to cool down.

Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been switched off and allowed to cool for at least two hours. Before performing any maintenance on, or in the vicinity of, the analysis cell, allow the analyzer to cool for at least 12 hours as the analysis cell is insulated against heat loss.

When handling the analyzer, always wear suitable protective gloves. Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly

important when working at heights. If you receive a burn, seek medical treatment immediately.

WARNING

LASER

The analyzer contains lasers. Opening the analyzer and attempting to perform adjustments or procedures other than those specified in this manual may result in hazardous optical radiation exposure.

All lasers used within the analyzer are Class 1. The emitted laser light is invisible (mid-infrared), and the combined laser powers are sufficiently low at the first accessible aperture that the unprotected eye will not be damaged. This class is eye safe under all operating conditions.

It is, however, possible to cause damage to the eye through not following correct procedures. Do not look at the laser with any kind of magnifier or optical measuring device.

WARNING

HAZARDOUS SUBSTANCES

The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution. Wear personal protective equipment (PPE) when handling the equipment.

Gas handling components within the analyzer contain particulate matter residue from the sample gases. Over the life of the analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing repairs and maintenance on the analyzer:

Handle used gas handling components with extreme caution. Avoid direct skin contact with used gas handling components. Do not smoke, drink, or eat in the work area. Wear goggles or eye shields. Wear a suitable face mask to protect against inhalation of particulate matter. Do not wet fingers, eyes, or any exposed skin. Pack used gas handling components for disposal in sealed packaging and label them Contaminated. Dispose of contaminated items as hazardous material according to the applicable local, national, or international health and

safety regulations and pollution regulations.

Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

WARNING

OPTICAL RADIATION EXPOSURE HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. There are three types of laser that may be included in the Rosemount CT5100(Ex) : Quantum Cascade Lasers (QCLs), Interband

Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are Class 1. The characteristics of the lasers contained within the analyzer are given in the table below.

Parameter QCL ICL Diode Comment

Operation mode Pulsed Pulsed Pulsed N/A

Lasers per system 1 - 6 1 - 6 1 - 6 Maximum of 6 lasers per

Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A

Power < 5 mW < 5 mW < 5 mW Combined power of QCL

Pulse duration < 1 µs < 1 µs < 5 µs N/A

Pulse repetition frequency

Duty cycle < 5 % < 5 % < 25 % N/A

The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW. The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of laser safety labels on

the analyzer is specified in Safety and system labels and annotation. The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous

radiation exposure.

< 100 kHz < 100 kHz < 100 kHz N/A

system

at first accessible aperture: < 9.62 mW

WARNING

HAZARDOUS GAS

In accordance with IEC 60079-0: 2011 Clause 30. The product stream that the analyzer is examining may be hazardous even at low concentrations. Therefore, take special care to

ensure that the sample gas return port either returns the sample gas to the product stream or discharges the sample gas to a location that will not cause a hazard.

WARNING

HIGH PRESSURE GAS AND AIR

The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g., damage to eyes and skin or punctures from debris blown by the high pressure gas or compressed air. Always lock off or tag out the calibration gas supply and compressed air supply when shutting down the analyzer.

WARNING

HEAVY ITEM

In accordance with IEC 60079-0: 2011 Clause 30. Failure to propery handle the analyzer may cause injury to personnel. Ensure the wall the analyzer is mounted on is solid, stable, and of suitable material to hold the weight of the analyzer. Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or

other body parts. The analyzer weighs 121 lb (55 kg). Emerson recommends that a minimum of two people move and lift the analyzer. Wear suitable protective gloves and protective footwear.

WARNING

EXPLOSION HAZARD / ELECTRIC SHOCK HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Only trained, qualified personnel may install and connect power and signal cables. The installation/connection must be in

accordance with all legislative requirements and applicable standards. Failure to follow may cause warranty invalidation, property damage, and/or personal injury or death. Only qualified personnel, familiar with potential risks, should install the analyzer. Analyzers providing screw terminals for electrical connections may require working near live parts. Failure to observe this warning

and or follow safety instruction could cause an explosion or potentially hazardous situation, which if not avoided, could result in death or serious injury.

WARNING

HIGH PRESSURE HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. The maximum inlet purge gas pressure at the inlet valve must not exceed 690 kPa (6.9 bar). Higher pressure may damage the

analyzer enclosure in case of failure of the inlet valve. Failure to observe this warning could cause a potentially hazardous situation which if not avoided, could result in death or serious

injury.

WARNING

EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE

In accordance with IEC 60079-0: 2011 Clause 30. In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Take

suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area. Clean the device surface by gently wiping it with a damp or antistatic cloth only. Failure to observe this warning and or follow safety instruction could cause an explosion or potentially hazardous situation, which

if not avoided, could result in death or serious injury.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes 30 seconds at

a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

POSSIBLE EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. DO NOT operate the analyzer with doors or covers open. Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit. Failure to observe this warning and or follow safety instruction could cause an explosion or potentially hazardous situation, which

if not avoided, could result in death or serious injury.

WARNING

HAZARD BY WRONG INPUT VOLTAGE

In accordance with IEC 60079-0: 2011 Clause 30. Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the

installation. Pressurized analyzers for hazardous locations DO NOT provide wide range power supplies. This type of analyzer is always setup for a specific rated input voltage; see nameplate label. Ensure the voltage at site of installation meets the rated analyzer input voltage. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to

external equipment MUST be shut off. This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up

the analyzer. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. During the pre-purge phase, all inputs and outputs connected to external equipment MUST be shut off. This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized. The internal backup battery is still connected and associated circuitry remains powered. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Do not open while an explosive atmosphere may be present. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30. Use only replacement parts and components authorized by Emerson. All replacement parts and components must be certified and approved for use in hazardous areas. Failure to comply will void certification and may cause an explosion or potentially hazardous situation, which if not avoided, may

cause death, personal injury, and/or damage to persons and/or property.

WARNING

EXPLOSION HAZARD BY BATTERY

In accordance with IEC 60079-0: 2011 Clause 30. The analyzer contains a battery for data backup purposes. Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement

MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.

Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

WARNING

LOOSE ITEMS

Do not place any loose items on top of the system or inside the compartments when doors / covers are open. Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers. Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious

injury.

WARNING

MAINTENANCE/MODIFICATIONS

In accordance with IEC 60079-0: 2011 Clause 30. On completion of any maintenance and or modifications verify:

All tools and equipment are removed. No contamination (water/dust) is in the compartments. Analyzer is wiped clean. Vents are clear and not obstructed. Verify that system is in a safe state for operation.

Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious injury.

WARNING

TRANSPORTATION HAZARD

Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings for the weight of the equipment, and is in good operational condition.

Failure to verify equipment meets the lifting ratings and is in good operational condition may cause injury to personnel or damage the analyzer.

WARNING

PHYSICAL ACCESS

Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could be intentional or unintentional and needs to be protected against.

Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.

CAUTION

EQUIPMENT DAMAGE

Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the analyzer are in place.

Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any calibration gases that are required are available to the analyzer.

Failure to perform pre-system start-up checks may cause damage to equipment.

CAUTION

EQUIPMENT DAMAGE

Always follow the start-up procedure. Damage to the analyzer may result from a failure to follow this procedure.

CAUTION

EQUIPMENT DAMAGE

Always follow the shutdown procedure. Damage to the analyzer may result from a failure to follow this procedure.

CAUTION

UNSERVICEABLE EQUIPMENT

If the pressure and temperature screen does not display measurements similar to those shown in Gas sensor main screen and

Pressure and temperature screen. Refer to Troubleshooting and System Diagnostic section of Rosemount CT5100(Ex) Reference Manual.

CAUTION

EMC

This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures.

CAUTION

EMC

As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical components requires the use of special optical test/calibration equipment and procedures.

Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this manual, then the fault must be repaired by Emerson.

Quick Start Guide Contents

00825-0100-4512 February 2020

Chapter 1 Introduction.................................................................................................................15

1.1 Safety precautions and conditions for safe use............................................................................... 15

1.2 Qualified personnel........................................................................................................................ 17

1.3 Glossary and abbreviations.............................................................................................................17

Chapter 2 Description.................................................................................................................. 21

2.1 Equipment purpose and role.......................................................................................................... 21

2.2 System overview............................................................................................................................ 22

2.3 Gas flow through analyzer.............................................................................................................. 23

2.4 Connecting the electrical/electronic inputs and outputs.................................................................25

Chapter 3 Specifications...............................................................................................................29

3.1 Detailed system specifications........................................................................................................29

3.2 Safety and system labels and annotation........................................................................................ 32

Chapter 4 Install...........................................................................................................................35

4.1 Site selection.................................................................................................................................. 35

4.2 Unpacking...................................................................................................................................... 36

4.3 Mounting the analyzer....................................................................................................................38

4.4 Connecting the electrical/electronic inputs and outputs.................................................................43

Chapter 5 Controls and display controller.....................................................................................53

5.1 Front panel controls and indicators.................................................................................................53

5.2 Display controller........................................................................................................................... 56

5.3 Gas sensor main screen.................................................................................................................. 56

5.4 Pressure and temperature screen................................................................................................... 58

5.5 Help system....................................................................................................................................59

5.6 Main menu..................................................................................................................................... 60

5.7 BACK button...................................................................................................................................60

Chapter 6 Start-up procedure.......................................................................................................61

6.1 Introduction................................................................................................................................... 61

6.2 Preparation for use......................................................................................................................... 61

6.3 Start-up..........................................................................................................................................62

6.4 Front panel controls and indicators.................................................................................................66

Chapter 7 ATEX/IECEX assessment report summary..................................................................... 69

7.1 Certification overview.....................................................................................................................69

7.2 Applicant's name and address.........................................................................................................69

7.3 Manufacturer's name and address.................................................................................................. 69

7.4 Trademark......................................................................................................................................69

7.5 Product name/model number........................................................................................................ 69

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7.6 Rating.............................................................................................................................................69

7.7 Assessment standards.................................................................................................................... 70

7.8 Markings........................................................................................................................................ 70

7.9 Conditions of certification/special conditions for safe use...............................................................73

7.10 Conditions of certification for the replacement of simple devices.................................................75

Appendix A Engineering drawings.................................................................................................. 77

xiv Rosemount CT5100(Ex)

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Introduction

1 Introduction

1.1 Safety precautions and conditions for safe use

WARNING

Before installing or performing any maintenance on the analyzer, read and understand the safety information given in the preliminary information of this manual.

The analyzer described in this guide has been quality control tested and left the manufacturer in pristine condition. To achieve the correct and safe operation of this product, it must be transported, installed, operated, and maintained as described by the manufacturer.

All lasers used within the analyzer are Class 1. The emitted laser light is invisible (midinfrared) and the pulse duration so short that the unprotected eye will not be damaged.

The nature of the laser beam path and beam width further ensures that it should be impossible to cause any eye damage. The analyzer has warning labels at appropriate positions in accordance with USA 21 CFR 1040.10.

Conditions for safe use (Europe)

• The maximum sample gas temperature that the analyzer can operate with is 320 °F

(160 °C).

• The purge controller keypad mounted on the front of the equipment shall not be

exposed to direct UV light sources or direct sunlight. Example methods of protection include, but are not limited to, indoor applications away from UV sources and outdoor locations under shading. As part of regular inspections, if damage to or deterioration of the membrane keypad is detected, take the unit out of service for repair or replacement.

• The purge controller bypass function shall only be enabled during setup or

maintenance and only when the area is known to be non-hazardous.

• The equipment shall be installed in an area of not more than pollution degree 2 as

defined in IEC 60664-1.

• The cable glands used in the equipment are only suitable for use in areas with a low risk

of mechanical damage and must be suitably protected.

• The purge controller automatically monitors the internal pressure of the enclosure and

will output any fault conditions onto contact K2. It is the end user's responsibility to connect this contact to a suitable facility such as an alarm or an automatic shutdown system.

• For correct operation, the on-site pressurizing air supply must be capable of providing

at least 25 L/min for leakage compensation.

• When using the analyzer variant fitted with the Elmess gas cell heater certified as BVS

14ATEXE155U and IECEx BVS 14.0106U, the equipment top compartment should be cooled with a source of compressed air at a minimum flow rate of 280 L/min.

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Introduction

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• The Elmess gas cell heater, certified as BVS 14ATEXE155U and IECEx BVS 14.0106U,

may only be used in combination with the ESI Technology gas cell pressure transducer, certified as TRAC12ATEX0060X and IECEx TRC 12.0025X.

Conditions for safe use (North America)

• The maximum sample gas temperature that the analyzer can operate with is

176 °F (80 °C).

• The purge controller keypad mounted on the front of the equipment shall not be

• The purge controller bypass function shall only be enabled during setup or

maintenance and only when the area is known to be non-hazardous.

• The cable glands used in the equipment are only suitable for use in areas with a low risk

of mechanical damage and must be suitably protected.

• The purge controller provided with this equipment provides alarm signals at various

contacts as described in the equipment instructions. The alarms relate to low-flow and loss of purged air supply, and must be connected to the end-user's remote, monitored alarm system.

• For correct operation, the on-site pressurizing air supply must be capable of providing

at least 25 L/min for leakage compensation.

• This assessment does not cover reliable function, performance, or other properties of

the equipment not related to safety.

• The equipment is to be installed using wire no larger than the protective earth wire.

• Equipment is only to be installed by manufacturer trained personnel.

• If at any time there is a conflict between the system safety provisions and any relevant

local (national or regional) requirements, the local requirements always take precedence.

• Equipment is not to be used with flammable liquids.

• The relief valve sealing cap must be fitted to maintain IP66 when the unit is in a non-

operational state.

• Equipment is subject to acceptance of the local inspection authorities having

jurisdiction.

• The equipment is intended for use only with air of instrument quality; all piping up to

and including the shut-off valve adjacent to the equipment must be protected against mechanical damage.

• The protective gas supply to the equipment must be marked with the warning as

detailed in NFPA496 Clause 4.12.5.

• When installing conduit for power and data connections, the end-user must select

suitably certified conduit.

16 Rosemount CT5100(Ex)

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General safety notice/residual risk

Installation, operation, and maintenance of the analyzer must be in accordance with these instructions.

When operated as intended and all applicable safety instructions are observed, an element of risk will remain, including, but not limited to, the following:

• Explosion protection measures may become ineffective on the occurrence of one

failure (for Category 3 analyzers).

• The emission of gases hazardous to health may be possible when all gas connections

have been correctly made.

• To avoid exposure to the dangers of residual risks, take particular care when installing,

operating, maintaining, and servicing the analyzer.

1.2 Qualified personnel

It is the operating company's responsibility to:

• Train staff

• Observe safety regulations

• Follow the safety instructions and procedures in the product manual

Operators must:

• Be trained

• Read and understand all relevant sections of the product manual before commencing

work

• Know the safety mechanisms and regulations

WARNING

1.3 Glossary and abbreviations

Abbreviation Description

% Percent

< Less than

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Introduction Quick Start Guide

February 2020 00825-0100-4512

Abbreviation Description

° Degree

AC Alternating current

Barg Pressure, in units of bars, above or below atmospheric pressure

BS British Standard

C Celsius

CDA Compressed dry air

CE European Conformity

Methane

Carbon dioxide

DC Direct current

Deg Degree (temperature)

e.g. For example

EC European Community

EMC Electromagnetic compatibility

EU European Union

Hrs Hours

Hz Hertz

H2O Water

ICL Interband Cascade Laser

IEC International Electro-technical Commission

in. Inches

IP Ingress protection

IPxx Ingress protection (xx are numbers that define the protection level)

IS Intrinsically safe

ISO International Organization for Standardization

k Thousand

kg Kilogram

kHz Kilo hertz

L Liter

lb Pound

LCD Liquid crystal display

LED Light emitting diode

L/min Liters per minute

m Meter

18 Rosemount CT5100(Ex)

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Abbreviation Description

mA Milliamp

Max Maximum

mBar milli-Bar

mbps Megabits per second

mg Milligram

mg/m

Mid IR Mid Infrared

min Minute

mm Millimeter

NEC

NFPA National Fire Protection Association

Cubic meter

Milligram/cubic meter

National Electrical Code

nm Nanometer

No. Number

PC Personal computer

PM Preventative maintenance

ppm Parts per million

psi Pounds per square inch

QCL Quantum Cascade Laser

TDL Tunable Diode Laser

Torr Unit of pressure defined as exactly 1/760 of a standard atmosphere

USA United States of America

USB Universal serial bus

V Volt

Vac Volt alternating current

Vdc Volt direct current

W Watt

WEEE Waste electrical and electronic equipment

µm Micro-meter

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20 Rosemount CT5100(Ex)

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2 Description

2.1 Equipment purpose and role

The types of molecules that are measured depend on the system configuration.

Figure 2-1: Rosemount CT5100(Ex) Continuous Gas Analyzer

The analyzer can be configured to detect and measure up to different gases, depending on the combination of laser modules fitted.

Quick Start Guide 21

Description

February 2020 00825-0100-4512

Quick Start Guide

2.2 System overview

A complete Rosemount CT5100(Ex) system consists of the analyzer, and the associated interconnecting wiring and gas piping.

The Rosemount CT5100(Ex) is supplied by Emerson. The gas handling system may be provided by either you or Emerson, depending upon the specific installation. The circuit breakers used to control the application of electrical power to the analyzer, the interconnecting wires, and gas piping are provided by you.

In Figure 2-2, the items supplied by Emerson are colored blue; the items supplied by you are colored purple. The green gas handling system may be provided by Emerson or you.

Figure 2-2: Complete Rosemount CT5100(Ex) Installation

A. Gas handling system

B. Instrument air C. Sample supply line D. Sample return (exhaust) line

E. Rosemount CT5100(Ex)

F. Electrical power G. Two pole main isolator H. Purge power

I. Control center J. Measurement data

There is no sample conditioning provided within the analyzer; the sampled gas requirements for the analyzer to operate are defined in the Environmental Characteristics

22 Rosemount CT5100(Ex)

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(Table 3-3). Detailed characteristics of the analyzer are given in Rosemount CT5100(Ex)

Reference Manual.

Description

2.3 Gas flow through analyzer

The analyzer has two gas inputs and one gas output. See Figure 2-3.

Figure 2-3: Gas Inlet and Outlet Connectors

A. Sample gas return port

B. Sample gas input port C. Top cover of Rosemount CT5100(Ex) (cell compartment) D. Purge air supply

E. Laser/electrical compartment

Quick Start Guide 23

Description Quick Start Guide

February 2020 00825-0100-4512

Procedure

1. The gas sample that is to be measured for impurities enters the analyzer through

the sample gas input port located on top of the analyzer (see Figure 2-3, Items A and B).

2. Once the gas sample has been examined for impurities, it is expelled from the

analyzer through the sample gas return port (A).

3. A compressed air supply enters the analyzer through a port (D) on the underside of

the unit. The sample supply line must be heated all the way to the sample gas input port on

the analyzer to prevent condensation forming at any point in the sample supply line.

WARNING

AIR SUPPLY

The air supply must be clean, filtered, and free from moisture.

24 Rosemount CT5100(Ex)

Quick Start Guide

00825-0100-4512 February 2020

Description

2.4 Connecting the electrical/electronic inputs and outputs

CAUTION

If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

Figure 2-4: Electrical/Electronic Connectors

A. Purge power and alarm entry point

B. Power entry point

C. Analog/digital entry point

Electrical/electronic signal connections to the analyzer are made through three electrical entry points located on the underside of the analyzer, as shown in Figure 2-4. Use the wiring diagram to make the electrical connections as shown in Engineering drawings and

Figure 2-5.

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