Emerson CT5100 Quick Start Guide

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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

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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

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Description Quick Start Guide

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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.

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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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Description

Quick Start Guide

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Figure 2-5: Signal Cable Outputs

A. To mains input fuses

B. Mains input filter C. To enclosure earth stud D. To digital modules

E. To analog modules

F. To status relays G. Digital output terminals H. Analog output terminals

I. Status output terminals J. Mains input terminals

Note

Purge solenoid fitted can be either for 5500-MAN-EX01 for ATEX/IEC applications or 5500MAN-CD01 for North American applications.

Note

Maximum number of user terminals shown. These may be reduced depending on number and type of analog/digital outputs required.

Two sources of electrical power are applied to the analyzer through power entry points (see Figure 2-4 Items A and B).

1. A purge electrical supply that is used to power the overpressure facility in the

electrical compartment of the analyzer entry point (A).

2. An instrumentation electrical supply that is used to power all other functions of the

analyzer entry point (C).

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Both power supplies are 110 to 230 Vac, 50/60 Hz ± 10%. AC to DC power converters inside the analyzer automatically adjust in response to the input voltage level and ensure that the correct DC voltage is available inside the unit. The analyzer is electrically protected by an internal 5 A, 250 VA fast acting fuse on the instrumentation electrical supply line and an internal 2 A, 250 VA fuse on the purge electrical supply line.

The wiring diagram (Figure 2-6) for the purge electrical supply is in accordance the with the latest Pepperl+Fuchs 5500 Series Installation Manual Purge and Pressurization System documentation (www.Pepperl-fuchs.com). It is recommended that these instructions are verified from the Pepperl+Fuchs website to ensure the latest wiring instructions for the purge controller have been followed during installation. The complete wiring diagram used during the manufacture of the Rosemount CT5100(Ex) is included for reference in

Engineering drawings.

Figure 2-6: Pepperl +Fuchs Wiring Diagram (External Mount)

Figure 2-7: Pepperl +Fuchs Wiring Diagram (Internal Mount)

Figure 2-8: Pepperl +Fuchs Wiring Diagram (Terminal Block Connections)

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Description Quick Start Guide

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General wiring instructions for the Pepperl+Fuchs 5500 series purge control power connection are as follows:

• All applicable local and national wiring codes MUST be followed when wiring the

system. Also see IEC60079-14.

• The power supply to this device shall have a separate customer installed external

disconnect. If placed in the hazardous area, it shall be rated for the area it is being installed in. Placing the disconnect into the purged enclosure is not an option as power needs to be applied to the control unit before the purge cycle is complete.

• PE ground wire to be same size as largest wire used to bring power into the enclosure.

Terminate using ring lug properly crimped at grounding stud in bottom of enclosure.

• All wire shall be copper only, rated 176 °F (80 °C) minimum.

• The minimum wire strand in a stranded wire shall have a diameter of 0.004-in.

(0.1 mm) or greater.

• Wire strip length into fixed terminal block is 0.315 in. (8 mm).

• Terminal torque is 0.5 Nm to 0.6 Nm.

• There shall be only one wire per terminal.

• It is recommended to leave a bit of extra wire loop in housing to allow for any re-

termination.

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3 Specifications

3.1 Detailed system specifications

Table 3-1 gives the physical characteristics for the analyzer while Table 3-2 gives the

general characteristics. Schematic diagrams of the analyzer are shown in Figure 3-1, Figure

3-2, and Figure 3-3.

Table 3-1: Physical Characteristics

Rosemount CT5100(Ex) Value Comment

External dimensions 22.68 x 11.7 x 30.94 in.

575 x 298 x 786 mm

Weight 121 lb

55 kg

Length x width x height Nominal dimensions

Approximate weight

Table 3-2: General Characteristics

Rosemount CT5100(Ex) Value Units Comment

Instrumentation supply voltage 110 or 230 Vac 50/60 HZ ±10%

Purge supply voltage 110 or 230 Vac 50/60 Hz ±10%

Peak power consumption 500 W Max consumption per gas analyzer

Continuous steady-state power consumption

Electrical compartment enclosure N/A N/A Stainless steel

Optical compartment enclosure N/A N/A Stainless steel

Measurement technique N/A N/A Mid IR absorption spectroscopy

Operating conditions

Mid IR source N/A N/A Quantum Cascade Laser

Near IR source N/A N/A Interband Cascade Laser

300 W Once the gas analyzer has stabilized and

the analysis cell has reached the temperature set point

Diode Laser

Laser classification Class 1 N/A BS EN 60825-1: 2007 safety of laser

products. Equipment classification and requirements (identical to IEC 60825-1

2007)

Inlet gas port connector ¼

Outlet (exhaust) gas port connector ¼

Purge connector ⅜

Purge air pressure 2 Barg N/A

Quick Start Guide 29

in. mm

Swagelok® type, factory-configured, specify on order

Swagelok type, factory-configured, specify on order

Purge inlet (certified system only)

Specifications Quick Start Guide

February 2020 00825-0100-4512

Table 3-2: General Characteristics (continued)

Rosemount CT5100(Ex) Value Units Comment

Measurement result signals 4 to 20 mA 4 or 8 channel outputs, specify on order

Communication 10/100 Mbps Ethernet

Warm-up time 90 minutes N/A

Figure 3-1: Rosemount CT5100(Ex) Dimensions - Front View

A. Ventilation

B. Lifting eyelet C. User interface D. Purge control panel

Dimensions are in inches (mm)

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Figure 3-2: Rosemount CT5100(Ex) Dimensions - Top View

A. Ventilation

B. Lifting eyelet C. Sample return D. Sample inlet

Dimensions are in inches (mm)

Figure 3-3: Rosemount CT5100(Ex) Dimensions - Bottom View

A. Atmospheric pressure refer plug

B. Earth point C. Purge pressure set D. Air supply

E. Cable glands

F. Purge vent

Dimensions are in inches (mm)

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Specifications Quick Start Guide

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Table 3-3: Environmental Characteristics

Environmental characteristic Value Units Comment

Operating temperature range -4 to 131

-20 to 55

Sample gas temperature range (Condition for safe use Europe)

Sample gas temperature range (Condition for safe use North

America)

Sample gas particulate density 5 mg/m

Sample gas particulate size 10 µm Maximum

IP code 66 N/A IP to IEC 60529

Sensor humidity range 10 to 95 % Relative humidity (non-

122 to 329 50 to 160

122 to 176 50 to 80

°F °C

Ambient temperature

Factory set, specify on order

Maximum

condensing) at 113 °F (45 °C)

3.2 Safety and system labels and annotation

The labels and annotation applied to the analyzer are specified in the table below.

Label type

Identification label (including serial number and model number

Example Location

Front panel

Fuse identification label 1. Back plate

2. Top right inside of door

IECEx and ATEX ratings label Enclosure side panel

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Label type Example Location

North America/Canada ratings label Enclosure side panel

Universal ratings label Enclosure side panel

Laser radiation CAUTION label Baseplate

Laser module identification label On each laser module housing

Intrinsically safe label 1. HMI

2. Intrinsically safe sensor barrier

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Label type Example Location

Terminal label (typical layout) Top left inside of door

Earth identification label Back plate

Manufacturer's label On analysis cell heater block

Electrical safety label On inside of electrical compartment

door

AC power supply danger label 1. On outside of electrical

compartment door

2. On manifold block of air overpressure system

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4 Install

4.1 Site selection

The Rosemount CT5100(Ex) has a T3 temperature classification. The user must ensure that no combustible gas concentrations will be present, whether on a continual or occasional basis, which have an ignition temperature below the T3 rating of the analyzer.

DANGER

FIRE AND EXPLOSION

The analyzer's electrical compartment must not be opened 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 NFPA496.

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

DANGER

ELECTRIC SHOCK

The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Ensure 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.

Failure to observe this precaution will cause death, personal injury, and/or damage to persons and/or property.

The analyzer is intended to be installed in a suitable Division 2 shelter to protect it from the elements.

Provide sufficient space around the analyzer to allow the maintenance and servicing of the unit.

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Figure 4-1: Clearance with Door Open

A. Door open

B. Door closed

C. Door opening arc

Dimensions are in inches (mm)

4.2 Unpacking

This procedure requires a minimum of two people to safely remove the equipment from the shipping container.

WARNING

HEAVY INSTRUMENT - LIFTING 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. Emerson recommends that a minimum of two people using suitable tools for transportation and lifting are employed.

Wear suitable protective gloves and protective footwear.

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Install

CAUTION

EQUIPMENT DAMAGE

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.

Failure to observe may cause damage to the equipment.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30.

Installing and wiring the analyzer must comply with all relevant national legislative requirements and regulations.

Consider all safety instructions within this manual and all associated analyzer instruction manuals.

WARNING

EXPLOSION HAZARD

In accordance with IEC 60079-0: 2011 Clause 30.

Installing the analyzer requires opening the enclosure and working at the open unit. This is permitted only when both the analyzer and connected external circuitry are de-energized.

Depending on the local regulation, this may require a competent hot work supervisor to issue a hot work permit.

CAUTION

SHOCK AND VIBRATION

The analyzer contains sensitive electronic equipment. It MUST NOT be subjected to any shock and or vibration.

Damage to the analyzer may result from a failure to follow this caution.

Procedure

1. On receipt of goods, look for any visible damage to the analyzer and verify that all items noted to be shipped were received. Record on the goods receipt note any damage or missing items, noting both the item(s) and quantity missing.

2. Visually inspect the exterior of the analyzer for signs of damage, corrosion, gas leaks, or signs of previously overheating.

3. Report anything found to the maintenance organization.

4. Attach suitably rated and tested lifting slings to the safety engineered lifting eye bolts mounted on top of the analyzer.

5. One person should carefully guide the equipment from the horizontal to vertical position while the other person lifts the equipment.

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6. Use safety approved and tested lifting equipment to remove the analyzer from the shipping container and place it on a solid, level surface.

7. Ensure that the analyzer is stored in its protective plastic cover until installation.

4.3 Mounting the analyzer

This procedure requires two people to safely move and mount the Rosemount CT5100(Ex).

Procedure

1. Ensure that there is free space around the analyzer to allow ventilation of the upper part of the analyzer.

WARNING

HEAVY ITEM

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.

2. Attach suitably rated and tested lifting slings to the safety engineered lifting eye bolts (see Figure 4-2, items A and D) mounted on top of the analyzer.

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Figure 4-2: Front View Dimensions

A. Lifting eye bolt B. Sample gas input port C. Sample gas return port

D. Lifting eye bolt

E. 0.413-in. (10.5 mm) diameter mounting points F. Purge compressed air supply port

Dimensions are in inches (mm)

3. One person should carefully guide the equipment while the other person operates the lifting equipment.

4. Use safety approved and tested lifting equipment to lift the analyzer from the stable platform.

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5. Mount the analyzer using four M8 (⅜-in.) fasteners to attach the wall mount brackets.

The bolts must be positioned in such a way to allow maximum use of all thread length.

The installer must ensure that the fasteners used are suitable for the load and surface that the analyzer is mounted on.

In case you need to thread lock the fittings for extra security, only do this with compounds compatible with the zone classification of the installation location.

The four wall fixing points must be 0.413-in. (10.5 mm) diameter mounting holes. Ensure that the wall fixing points are capable of supporting a load of 242 lb (110 kg)

each; this includes a x 2 factor of safety. Figure 4-4 shows the locations of the mounting points on the analyzer. All mounting points are 0.413-in. (10.5 mm) diameter holes.

Confirm the bolts are secure. Do not overtighten the fasteners. The analyzer must be mounted using the four off factory fitted and predrilled holes

on the brace bars. Refer to Figure 4-2.

6. Remove the lifting eyes and retain them for future use. Threads must be protected with a suitable grease and plastic grommets. After mounting, do not place any additional load on the analyzer. Do not place or leave loose items on flat surfaces. For transportation, the purge vent (D) located on the base of the analyzer is fitted

with a temporary protector cap (C). This protector cap MUST remain in place until the analyzer is commissioned. Refer to Figure 4-3.

The vent cap (A), O-ring (E) and grub screws (B) are shipped loose in the crate. Refer to Figure 4-3.

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Figure 4-3: Connecting the Purge Vent Cap

A. Vent cap B. 3/32-in. socket grub screws C. Protector cap

D. Purge vent

E. O-ring

7. To complete the installation, remove the protector cap from the purge vent and the O-ring (E). Install the vent cap, locking it in position with the grub screws.

Refer to Figure 4-2. An Allen key is provided for the grub screws. The protector cap (C) must be retained as it will need to be refitted whenever the

analyzer is being shutdown for a prolonged period to seal the purge vent from fluid ingress.

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Figure 4-4: Mounting Details

A. Mounting points

Dimensions are in inches (mm)

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Figure 4-5: Clearance with Door Open

A. Door open B. Door closed C. Door opening arc

Dimensions are in inches (mm)

4.4 Connecting the electrical/electronic inputs and outputs

4.4.1 AC power

Power is connected to the analyzer instrumentation through the power entry point (B) and the purge controller through the purge power and alarm entry point (A) fitted to the base of the analyzer. Refer to Figure 4-6.

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Figure 4-6: Power Gland

A. Purge power and alarm entry point

B. Power entry point

• A purge electrical and alarm supply that is used to power the overpressure facility in the

electrical compartment of the analyzer. Refer to Figure 4-6 (Item A).

• An instrumentation electrical supply that is used to power all other functions of the

analyzer. See Figure 4-6 (Item B).

The customer supplied circuit breakers must be in accordance with ATEX / IECEx / North American protection concepts. The main power isolator controls the application of electrical power to the purge controller with the secondary power isolator controlling the application of electrical power to the remaining analyzer functions.

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Figure 4-7: Power Entry Point Connections

A. To mains input fuses

B. Mains input filter

C. To enclosure earth stud

Table 4-1: Mains Input Terminal

Terminal Function

1 Sensor system supply (L)

2 Sensor system supply (N)

3 Earth

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Figure 4-8: Purge Power and Alarm Entry Point Connections

A. SV1

B. Power C. Bypass D. To purge solenoid

E. To be run separately from other cables looms

F. To PT100 sensor

Note

Purge control system power and alarm contact to be directly wired into purge control unit by end user. The cables must use cable glands suitable for the zone of application of the analyzer for entry into the analyzer enclosure and the purge control unit.

Terminal

L Purge control supply (live)

N Purge control supply (neutral)

K1 (normally open) Alarm contract

K2 (normally closed) Alarm contract

Function

Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 4-9.

The customer supplied power cable for the analyzer instrumentation will be connected to terminals 1 - 3.

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Table 4-2: Electrical Power Requirements

4.4.2

Electrical supply Power

consumption

Instrumentation supply voltage

Purge supply voltage 100 to 230 Vac, 2.3

400 W 100 to 230 Vac, 50/60 Hz ±10% 3.15 A

VA (without digital valve)

Voltage Fuse

internal fuses F1 and F2

100 to 240 Vac, 48/62 Hz ± 10%, single phase Overvoltage category 2

AC: 2.0A

For the electrical power wiring use 16 AWG stranded, three conductor copper or tin-plated copper power wire, rated for at least 250 Vac, of the required length. Cables must be terminated in the power entry points in accordance with local electrical codes. The full electrical wiring diagram is provided in Engineering drawings.

Fuses

Figure 4-9 shows the location of the fuses.

Figure 4-9: Fuses

A. Fuse F4 (24 Vdc supply)

B. Fuse F3 (12 Vdc supply) C. Fuse F1 (mains supply – live) D. Fuse F2 (mains supply – neutral)

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Table 4-3: Fuse Requirements

Fuse Function Rating Schurter part number

1 Live line 110/230 Vac

(following mains filter)

2 Neutral line 110/230

Vac (following mains filter)

3 Analyzer 12 Vdc supply

rail

4 Analyzer 24 Vdc supply

rail

3.15 A, 250 V, fast acting ceramic

5 A, 250 V, fast acting ceramic

3.15 A, 250 V, fast acting ceramic

0001.1009

0001.1011

0001.9011

4.4.3 Connecting the sample supply and return line

Sample gas supply and sample return connections are ¼-in. (6 mm) ”Hamlet” compression tube fittings. To avoid the risk of gas leaks, confirm that these connections are made correctly and tightly. Both the sample gas supply pipe and the sample return pipe should be thermal insulated.

The maximum sample gas supply pressure is 2 BarG.

4.4.4

Connecting the signal cables

The signal cables are connected to the system through an entry point outlet C, as shown in

Figure 4-10. All signal cables are to be minimum 20 AWG tri-rated switchgear cable.

Customer supplied conduit and cables are to be terminated in the entry point provided in accordance with local electrical codes.

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Figure 4-10: Signal Cable Outputs

A. To digital modules

B. Digital output terminals C. To analog modules D. Analog output terminals

E. To status relays

F. Status output terminals

Table 4-4: User Connections

Terminal Function

11 Digital output 1

12 Digital output 2

13 Digital output 3

14 Digital output 4

15 Digital output 5

16 Digital output 6

17 Digital output 7

18 Digital output 8

19 Digital output 9

20 Digital output 10

21 Digital output 11

22 Digital output 12

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Table 4-4: User Connections (continued)

Terminal Function

23 Analog output 1

24 Analog output 2

25 Analog output 3

26 Analog output 4

27 Analog output 5

28 Analog output 6

29 Analog output 7

30 Analog output 8

31 Status output 1 (check function)

32 Status output 2 (maintenance required)

33 Status output 3 (out of specification)

34 Status output 4 (failed)

Quick Start Guide

4.4.5 Power input cables and circuit breakers

WARNING

FLAMMABLE/EXPLOSIVE GASES

The purge/pressurization cycle expels any flammable or explosive gases from the electrical compartment and MUST be completed before applying electrical power to the rest of 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.

The power input cable/purge power cable circuit breakers can be tested as follows:

• Set the Purge circuit breaker to ON. The purge / pressurization process will start ONLY

when the K1 LED on the purge control panel comes on indicating the purge process is complete can you proceed to the next step. Refer to Figure 5-4.

• The main power input circuit breaker can now be set to ON.

• Check that the display controller lights up. The analyzer will then begin to power-up.

4.4.6

Temperature sensor and cell heater

The sample cell is controlled to operate at a pre-set temperature. This involves a heater and a temperature sensor. To test these, check that a temperature reading is displayed against temperature on the display controller as described in Pressure and temperature

screen.

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Leave the analyzer operating and confirm that the temperature rises until the analysis cell reaches the pre-set operating temperature around 122 °F (50 °C). This will take approximately 90 minutes.

4.4.7 Pressure sensor

The pressure sensor monitors the pressure in the analysis cell. To test that it is functioning, check that a pressure reading is displayed under pressure on the Beka Display Controller as described in Pressure and temperature screen.

The reading will be approximately 760 Torr at atmospheric pressure. If desired, cap off the gas inlet and use an external pump to evacuate the cell. Verify that the pressure drops as expected.

NOTICE

A Torr is a non-SI unit of pressure, defined as 1/760 of standard atmospheric pressure, and is equal to the fluid pressure of 1 mm of mercury.

4.4.8

4.4.9

Analog output cables

In order to generate a 4-20 mA output, the analyzer must be left for 90 minutes to warm up, and the analysis cell must be at the correct pressure.

The 4-20 mA outputs will operate when the analysis cell temperature and pressure are within the required test range. It is not essential to flow sample gas through the system; nitrogen or atmospheric air will be adequate for this test.

With the analyzer at operating temperature and pressure, ensure that a current between 4 mA and 20 mA is generated on each 4-20 mA output. This can either be measured as a current with a multimeter, or as a gas concentration through the control station.

Ethernet

To test the Ethernet connection, connect a remote laptop to the Ethernet port and attempt to connect to the internal PC as described in the separate connection procedure. It is not necessary to run the gas sensor on the laptop; once connected, enter the command exit to disconnect again.

DANGER

FIRE AND EXPLOSION

The electrical compartment of the analyzer must not be opened 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.

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

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4.4.10 Seal glands

Where poured seal glands are a local industry requirement for cable termination, they should be made in accordance with the manufacturer’s instructions once acceptance tests have been made on the system to ensure that the analyzer does not need to be removed.

4.4.11 Commissioning

Once the sensor is fully installed as described above, it should be commissioned in accordance with the commissioning plan agreed between Emerson and the customer.

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5 Controls and display controller

5.1 Front panel controls and indicators

The Rosemount CT5100(Ex) is configured from the two control displays located on the front panel. Refer to Figure 5-1.

Figure 5-1: Front Panel

A. Display controller

B. Purge control panel C. Protector cap D. Purge vent

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Figure 5-2: Exploded View

A. Vent cap

B. 3/32-in. socket grub screws C. Protector cap D. Purge vent

E. O-ring

The protector cap (Figure 5-2, C) must be removed from the purge vent (D) and replaced with the vented cap (A) supplied with the unit.

NOTICE

On/Off circuit breakers There are no On/Off switches on the analyzer. The application of electrical power to the analyzer is controlled through two external circuit breakers.

Both external circuit breakers are simple two-pole on/off circuit breakers. Both must be set to On to permit the safe operation of the analyzer.

Operation of the analyzer is controlled primarily through the display controller. Refer to Figure 5-3.

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Figure 5-3: Display Controller

The purge control panel (Figure 5-4) is used to program the operation of the overpressure air system that prevents flammable and explosive gases from entering the analyzer's electrical compartment. Adjustment of the overpressure air system MUST ONLY be performed by maintenance personnel.

Five LEDs, identified as K1, K2, PSV, Bypass, and PT100, are located on the upper part of the purge control panel. These five LEDs indicate the status of the overpressure air system.

Figure 5-4: Purge Control Panel

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5.2 Display controller

Operation of the Rosemount CT5100(Ex) is controlled through the six buttons on the display controller: Figure 5-5.

Figure 5-5: Display Controller Buttons

A. LCD display

B. Configurable button C. Scroll up button D. Scroll down button

The LCD display (A) can be used to display:

• Gas concentration measurements obtained.

• Operating temperature and pressure.

• Help screens.

• Step-by-step calibration.

• Diagnostics.

The two scroll buttons (C and D) are used to scroll through the information on the LCD display. The right-hand scroll button (C) is used to scroll up, and the left-hand scroll button (D) is used to scroll down

5.3 Gas sensor main screen

When the analyzer is switched on at the end of the start-up procedure, the Gas Sensor Main screen (Figure 5-6) appears appears.

The Gas Sensor Main screen is the screen that is normally displayed.

NOTICE

The gas concentrations shown in the following screenshots may be different from those shown in your particular analyzer. The screenshots indicate the functionality of the software, which is the same regardless of the gases or gas concentrations being measured.

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Figure 5-6: Gas Sensor Main Screen

The Gas Sensor Main screen displays the gas concentration measurements obtained by the analyzer. In the example shown in Figure 5-6 the gases nitric oxide (NO), nitrogen dioxide (NO2), oxygen (O2), carbon monoxide (CO), and carbon dioxide (CO2) are being measured and, for each gas, the concentration detected is in parts per million (ppm) or percentage as applicable.

The NOx reading is the total nitrogen oxide reading, a combination of nitric oxide (NO) and nitrogen dioxide (NO2).

At the end of the start-up procedure, the gas measurements initially appear as 0.00 ppm until the first readings are taken. After a few seconds, the initial gas concentrations are

displayed. The Gas Sensor Main screen also shows the status of the analyzer. In the example shown

in Figure 5-6, the analyzer is Running and OK (e.g., no faults have been identified). This area of the display shows any errors detected by the software.

On the software screens, highlighted items are links to other screens in the software. To access a screen, press the button next to the highlighted item.

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Figure 5-7: Gas Sensor Main Screen Buttons

A. MENU button

B. MENU text C. PAGE text D. PAGE button

E. HELP button

F. HELP text

G. STATUS button

PAGE text is a link between the Gas Sensor Main screen and the Pressure and

Temperature screen (described in Pressure and temperature screen). Press the PAGE button to toggle between these two screens.

HELP text is a link to the Help system. Press to go to the Help screen (described in Help

system).

MENU text is a link to the Main Menu of the software. Press the MENU button to go to the MAIN MENU screen (described in Main menu).

On the Gas Sensor Main screen, STATUS button (Figure 5-7) has no function when the analyzer is operating correctly. If, however, the software detects a fault, an error message is displayed. Press to get further information on the error.

5.4 Pressure and temperature screen

The Pressure and Temperature screen (Figure 5-8) shows pressure and temperature measurements taken inside the analyzer.

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Figure 5-8: Pressure and Temperature Screen

The Gas Te reading is the temperature, in °C, of the gas within the analysis cell.

The Pres reading is the pressure, in Torr, inside the analysis cell.

NOTICE

A Torr is a non-SI unit of pressure defined as 1/760 of standard atmospheric pressure and is equal to the fluid pressure of 1 mm of mercury.

5.5 Help system

When the button is pressed it takes you to the home page. Figure 5-9 shows an example of a help screen.

Figure 5-9: Example of a Help Screen

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5.6 Main menu

To access the Main menu (Figure 5-10), press the MENU button on either side of the Gas Sensor Main screen (Figure 5-6) or the Pressure and Temperature screen (Figure 5-8).

The Main menu (Figure 5-10) is used for calibration, diagnostics, fault finding, downloading data, and shutting down the analyzer.

Figure 5-10: Main Menu

5.7 BACK button

On most of the software screens, (Figure 5-11) is configured as a BACK button. Press BACK (A) to return to the previous screen.

Figure 5-11: BACK Button

A. BACK button

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6 Start-up procedure

6.1 Introduction

CAUTION

EQUIPMENT DAMAGE

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

The analyzer normally operates continuously. It should only be necessary to start up the analyzer under the following circumstances:

• When the analyzer is first switched on following installation.

• Following repair or maintenance.

• When the analyzer has been switched off as part of a plant shutdown or maintenance.

6.2 Preparation for use

The Rosemount CT5100(Ex) must be installed and fully commissioned prior to start-up.

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 commencing the start-up process, 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.

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WARNING

BURN HAZARD

Some parts of the analyzer may be heated up to 320 °F (160 °C). To prevent burns, do not touch any of the hot parts. All components of the analyzer are 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 twelve hours, as the analysis cell is insulated against heat loss.

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

observed. These precautions are especially important when working at heights. If you receive a burn, seek medical treatment immediately.

6.3 Start-up

Note

The gases shown in the screenshots and the measurements thereof may be different from those shown in your particular Rosemount CT5100(Ex). They indicate the functionality of the software, which is the same regardless of the gases being measured.

Note

To stop the start-up procedure at any time, set the main circuit breaker to Off.

To start up the analyzer,

Procedure

1. Visually inspect the exterior of the analyzer for signs of damage, corrosion, gas

leaks, or overheating. Report anything found to the maintenance organization.

2. Verify that the analyzer has been correctly installed as described in Install.

3. Ensure that the top cover is fitted to the analyzer. If it is not, report it to the

maintenance organization and do not proceed further until the top cover has been fitted.

4. Confirm that the door to the electrical compartment is closed and locked. If the

door cannot be closed and locked, report it to the maintenance organization and do not proceed further until the door has been repaired.

5. Ensure that the gas handling system is turned off.

6. Verify that the external main and secondary circuit breakers are set to Off.

7. Visually examine the three gas ports.

If necessary, refer to Figure 6-1 to ensure that the sample supply line, the sample return line, and the compressed air line are correctly attached.

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Figure 6-1: Rosemount CT5100(Ex) Gas Inlet and Outlet and Electrical Connections

A. Sample gas return port B. Sample gas input port C. Top cover of analyzer (cell compartment)

D. Purge air supply

E. Laser/electrical compartment

F. Analog/digital power entry point G. Power entry point H. Purge power and alarm entry point

8. Visually check that the electrical connections have been made to the three power entry points, Figure 6-1, at the base of the analyzer.

9. Visually check that the vent cap is fitted to the purge vent (Figure 4-3). UNDER NO CIRCUMSTANCES may the analyzer be started with the protector cap

fitted as this will prevent the analyzer from venting during the purge process.

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WARNING

FLAMMABLE/EXPLOSIVE GASES

The purge/pressurization cycle expels any flammable or explosive gases from the analyzer's electrical compartment. 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 the startup process.

Only after the purge/pressurization cycle has been completed can electrical power be applied to the rest of the analyzer.

10. Turn on the compressed air supply to the analyzer.

11. Set the main circuit breaker to On. The air pressurization will begin its automatic start-up and begin to purge the air inside the analyzer.

Figure 6-2: Purge Control Panel

A. K1 LED B. P/SV LED C. PT100 LED

12. Observe the PT100 LED on the purge control panel (Figure 6-2). If the PT100 LED (C) illuminates red, the air pressurization system is unserviceable,

and the start-up procedure must be halted immediately. To halt the start-up procedure, set the external main circuit breaker to Off. Lock off or tag off the main circuit breaker, turn off the compressed air supply, and report the fault to the maintenance organization.

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13. Observe the P/SV LED (B) on the purge control panel. When the pre-set internal overpressure has been reached, the P/SV LED (B)

illuminates orange. If the P/SV LED (B) does not illuminate blue, the pressurization system is unserviceable, and the start-up procedure must be halted immediately. To halt the start-up procedure, set the external main circuit breaker to Off, lock off or tag off the main circuit breaker, turn off the compressed air supply, and report the fault to the maintenance organization.

WARNING

FLAMMABLE/EXPLOSIVE GASES

Only after the purge/pressurization cycle has been completed can electrical power be applied to the rest of the analyzer.

14. Wait until the purge cycle is performed. Do not switch on the secondary circuit breaker until the purge cycle is complete.

Observe the K1 LED (A) on the purge control panel, which will illuminate green when the purge cycle is complete.

15. When the purge/pressurization cycle is complete, set the secondary circuit breaker to On, which applies electrical power to the rest of the analyzer. The analyzer begins its automatic start-up. The control PC that forms part of the analyzer is configured to automatically load the necessary gas sensor software and configuration files. The start-up sequence commences automatically under software control.

After a few seconds, the Gas Sensor main screen (Figure 6-3) appears on the display controller. If it does not, report the fault to the maintenance organization.

Figure 6-3: Gas Sensor Main Screen

16. Start up the system for returning sample gas.

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17. Start up the gas handling system that conditions the sample gas before it is fed into the analyzer.

At the end of the start-up procedure, the gas measurements initially appear as 0.00 ppm until the first readings are taken. After a few seconds, the initial gas concentrations are displayed.

The start-up procedure is now complete.

6.4 Front panel controls and indicators

The is configured from the control display located on the front panel (Figure 6-4).

Figure 6-4: Front Panel

A. Display controller

B. Purge control panel

NOTICE

On/Off circuit breakers

There are no On/Off switches on the analyzer. The application of electrical power to the analyzer is controlled through a customer provided external circuit breaker.

The circuit breaker is a simple two-pole on/off circuit breaker that must be set to On to permit the safe operation of the analyzer.

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Operation of the analyzer is controlled primarily through the display controller Figure 6-5.

Figure 6-5: Display Controller

CAUTION

DO NOT, under any circumstances, press the top two buttons on the display controller simultaneously. This will override the system code supplied with the analyzer and display the default program screen for the controller.

This will lock the software controlling the analyzer requiring the analyzer to shut down externally and restarted risking a possible corruption of the software and loss of the analyzer operation during the shutdown and restart process.

It is essential that only trained, qualified personnel operate the controls on the analyzer. Failure to follow these instructions may cause warranty invalidation, property damage

and/or personal injury or death.

Figure 6-6: Default Program Screen

The purge control panel (Figure 6-7) is used to program the operation of the overpressure air system that prevents flammable and explosive gases from entering the electrical compartment of the analyzer. Adjustment of the overpressure air system must only be performed by maintenance personnel.

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Five LEDs, identified as K1, K2, PSV, Bypass, and PT100 are located on the upper part of the purge control panel. These five LEDs indicate the status of the overpressure air system.

Figure 6-7: Purge Control Panel

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7 ATEX/IECEX assessment report

summary

7.1 Certification overview

This article is in accordance with IEC 60079-0: 2011 Clause 30. This article must not be changed amended or removed.

This report covers the assessment of the Rosemount CT5100(Ex) Continuous Gas Analyzer to the standards listed in Assessment standards, in order to support the issue of prime ATEX and IECEx certification.

7.2 Applicant's name and address

Cascade™ Technologies Ltd. Glendevon House Castle Business Park Stirling FK9 4TZ UK

7.3 Manufacturer's name and address

As applicant.

7.4 Trademark

7.5 Product name/model number

Rosemount CT5100(Ex) Continuous Gas Analyzer

7.6 Rating

110 V to 120 V, 60 Hz 220 V to 240 V, 50 Hz 1100 W

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7.7 Assessment standards

Table 7-1: Europe

IECEx ATEX

IEC 60079-0:2011 Ed 6 EN 60079-0:2012/A11:2013

IEC 60079-2:2014 Ed 6 EN 60079-2:2014

IEC 60079-28:2015 Ed 2 EN 60079-28:2015

(The requirements of the equivalent ATEX and IECEx standards are similar; therefore, any references in the following report can be regarded as referring to either format unless stated otherwise.)

This report may be issued against standards that do not appear on the UKAS Scope of Accreditation, but have been added through Sira's flexible scope of accreditation. Sira's flexible scope is available on request.

7.8 Markings

Table 7-2: IECEx and ATEX Markings

Detail IECEx ATEX

Certificate number IECEx SIR 16.0050X Sira 16ATEX1158X

Certification code EX ia d [ia Ga] op is pzc IIC T3 Gc Tamb

-20 to +55 ℃

Other marking N/A

Table 7-3: North American Markings

Detail CSA North American Marking

Certificate number 70044220

Marking class CLASS– 2258-02

Certification code Class I, Division 2, Groups A, B, C, D; T3. Tamb-20 °C to

+55 °C

Marking class CLASS– 2258-82

EX ia d [ia Ga] op is pzc IIC T3 Gc Tamb

-20 to +55℃

II 3 (1) G

Certification code Class I, Division 2, Groups A, B, C, D; T3. Tamb-20 °C to

+55 °C

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Table 7-4: Common Markings

Details

Model number Rosemount CT5100(Ex) Continuous Gas Analyzer

Manufacturer's name Cascade Technologies Ltd

Manufacturer's address Glendevon House

Castle Business Park Stirling FK9 4TZ UK

Ambient range -4 to 131 °F

-20 to 55 °C

Serial number As applicable

Year of manufacture As applicable

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Table 7-4: Common Markings (continued)

Details

Warnings (English/French)

WARNING Pressurized enclosure AVERTISSEMENT Envelope à suppression interne WARNING Do not open when an explosive atmosphere is present. AVERTISSEMENT Ne pas ouvrir si une atmosphère explosive est présente. WARNING Power shall not be restored after an enclosure has been

opened until enclosure has been purged for a minimum of two 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.

AVERTISSEMENT À la suite d’une ouverture, la mise sous tension ne doit pas

etre effectué avant que l’enveloppe n'ait été balayée pendant 2½ minutes sous un débit de 280 L/min.

WARNING This enclosure contains inert gas and may be an

asphyxiation hazard. AVERTISSEMENT Cette enveloppe contient un gaz inerte et peut constituer

un danger d'asphyxie. WARNING Batteries are located inside this enclosure. Do not open

when an explosive atmosphere is present. AVERTISSEMENT Présence de batteries à l'intérieur de cette enveloppe. Ne

pas ouvrir si une atmosphère explosive est présente. WARNING This pressurized enclosure contains a battery which

remains connected after the external power has been isolated. Consideration should be given to the removal of the battery if the enclosure is to remain unprotected by Ex for a significant time.

AVERTISSEMENT Cette enveloppe à surpression interne contient une

batterie qui reste connecté après que l'alimentation externe a été isolée. Il convient de retirer la batterie s’il faut que l'enveloppe reste sans protection ex pendant une durée prolongée.

Type of protective gas

Minimum overpressure 0.5 mbar

Maximum overpressure 10 mbar

72 Rosemount CT5100(Ex)

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Table 7-4: Common Markings (continued)

Details

Minimum purge flow rate 280 L/min

Leakage rate 25 L/min

Minimum purge supply pressure 1 Bar

Maximum purge supply pressure 2 Bar

Minimum purge time 2 minutes 30 seconds

Minimum supply pressure 1 Bar

Maximum supply pressure 2 Bar

7.9 Conditions of certification/special conditions for safe use

Europe

• 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, the unit is to be taken 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.

• Rosemount CT5100(Ex) purge controller automatically monitors the internal pressure

of the enclosure and will output any fault conditions onto contact K2. It is the responsibility of the end user 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 Rosemount CT5100(Ex) 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.

• 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.

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North America

• 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, the unit is to be taken 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 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-users 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 anytime 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.

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7.10 Conditions of certification for the replacement of simple devices

Approval for the PT100 temperature sensor as a simple device.

• To permit connection of a suitable temperature sensor, the following intrinsically safe

(IS) parameters have been declared.

• For the connections emerging from the purged enclosure:

Parameter IS

Voltage U

Current I

Power P

Capacitance C

Inductance L

12.4 V

17.4 mA

54 mW

• The capacitance and either the inductance or L/R of the load connected to hazardous

area terminals of the apparatus must not exceed the following values for Group IIC:

Capacitance Inductance L/R ratio

1.24 µF 117 mH 597 µH/ohm

The above parameters apply when one of the two conditions below is given:

• The total Li of the external circuit (excluding the cable) is < 1 percent of the Lo value or

• The total Ci of the external circuit (excluding the cable) is < 1 percent of the Co value.

The above parameters are reduced to 50 % when both of the two conditions below are given:

• The total Li of the external circuit (excluding the cable) is ≥ 1 percent of the Lo value or

• The total Ci of the external circuit (excluding the cable) is ≥ 1 percent of the Co value.

Note

The reduced capacitance of the external circuit (including cable) shall not be greater than 600 nF for Group IIC.

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A Engineering drawings

Use the wiring diagrams for the Rosemount™ CT5100(Ex) analyzer to assist with troubleshooting faults. These diagrams may be used to locate the position of a wiring connector should it become disconnected.

Table A-1: List of Engineering Drawings

Drawing number Description

W-2000-0034 (Sheets 1-5) Rosemount CT5100(Ex) heated

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2020

CASCADE TECHNOLOGIES

Glendevon House Castle Business Park Stirling FK9 4TZ Scotland

+44 1786 447 721 +44 1786 475 822 cascade.support@emerson.com

EUROPE REGIONAL OFFICE

Emerson Automation Solutions Neuhofstrasse 19a PO Box 1046 CH-6340 Baar Switzerland

+41 (0) 41 768 6111 +41 (0) 41 768 6300 cascade.support@emerson.com

Linkedin.com/company/Emerson-Automation-Solutions twitter.com/rosemount_news Facebook.com/Rosemount youtube.com/RosemountMeasurement

AMERICAS

Emerson Automation Solutions 10241 West Little York, Suite 200 Houston, TX 77040 USA

Toll Free 866 422 3683 +1 713 396 8880 (North America) +1 713 396 8759 (Latin America) +1 713 466 8175 cascade.support@emerson.com

MIDDLE EAST AND AFRICA REGIONAL OFFICE

Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai, United Arab Emirates, P.O. Box 17033

+971 4 811 8100 +971 4 886 5465 cascade.support@emerson.com

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.

ASIA-PACIFIC REGIONAL OFFICE

Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Republic of Singapore

+65 6 777 8211 +65 6 777 0947 cascade.support@emerson.com

Emerson CT5100 Quick Start Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Introduction

1.1 Safety precautions and conditions for safe use

1.2 Qualified personnel

1.3 Glossary and abbreviations

2 Description

2.1 Equipment purpose and role

2.2 System overview

2.3 Gas flow through analyzer

2.4 Connecting the electrical/electronic inputs and outputs

3 Specifications

3.1 Detailed system specifications

3.2 Safety and system labels and annotation

4 Install

4.1 Site selection

4.2 Unpacking

4.3 Mounting the analyzer

4.4 Connecting the electrical/electronic inputs and outputs

4.4.1 AC power

Fuses

4.4.3 Connecting the sample supply and return line

Connecting the signal cables

4.4.5 Power input cables and circuit breakers

Temperature sensor and cell heater

4.4.7 Pressure sensor

Analog output cables

Ethernet

4.4.10 Seal glands

4.4.11 Commissioning

5 Controls and display controller

5.1 Front panel controls and indicators

5.2 Display controller

5.3 Gas sensor main screen

5.4 Pressure and temperature screen

5.5 Help system

5.6 Main menu

5.7 BACK button

6 Start-up procedure

6.1 Introduction

6.2 Preparation for use

6.3 Start-up

6.4 Front panel controls and indicators

Quick Start Guide ATEX/IECEX assessment report summary

7.1 Certification overview

7.2 Applicant's name and address

7.3 Manufacturer's name and address

7.4 Trademark

7.5 Product name/model number

7.6 Rating

7.7 Assessment standards

7.8 Markings

7.9 Conditions of certification/special conditions for safe use

7.10 Conditions of certification for the replacement of simple devices

A Engineering drawings