Emerson Rosemount CT5100 Operation Manual

Operations Manual

D-7010-0046, Rev A

Rosemount CT5100 Continuous Gas Analyzer

May 2016

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 manual 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: D-7010-0046

Rev A, May 2016

©

Emerson 2016. All rights reserved.

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 Technical Support ([e-mail]) or
Emerson distribution partners.

General inquiries about this or other Cascade Technologies products should be sent to [e-mail].

All trademarks used within this document are the property of their respective owners.

Preliminary Information

Regulations and Standards

Regulations / Standards Description

2014/35/EU The Low Voltage Directive

2014/30/EU The Electromagnetic Compatibility Directive

2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive

USA 21 CFR 1040.1 Laser products

NEC 505 National Electrical Code (issued by ANSI: American National Standards

Institute and NFPA 70: National Fire Protection Association)

EN 6223: 2008 EMC Safety Standard

BS EN 60825-1:2007 Safety of laser products. Equipment classification and requirements

(identical to IEC 608250-1 2007)

BS EN 61010-1 2010 IEC 61010-1 2010 Safety requirements for electrical equipment for measurements, control,

and laboratory use. General requirements

BS EN 61326-1: 2013 Electrical equipment for measurement, control, and laboratory use. EMC

requirements. General requirements

Associated publications

Maintenance Manual (D-7010-0009)

Quick Start Guide (D-7010-0052)

Compliance approvals

This product complies with USA 21 CFR 1040 .10. It is also designed and manufactured under an approved
quality management system to ISO 9001:2008.

CE marking

Emerson and the CT5100 Continuous Gas Analyzer have satisfied the requirements for applying the CE
marking to the CT5100 Continuous Gas Analyzer.

This equipment meets all requirements of the EMC and Low Voltage directives.

Waste disposal

Do not dispose of measuring tools into household waste!

Only for EC countries

In accordance with European Directive 2012/19/EU for Waste Electrical and Electronic Equipment and its
implementation into national right, measuring tools that are no longer usable must be collected separately
and disposed of in an environmentally correct manner.

Safety and information notices

The following notices are used throughout this publication:

DANGER!

MAY CAUSE DEATH

Failure to follow this warning will result in death or serious injury to personnel.

WARNING!

DANGER TO PERSONNEL

Failure to follow this warning may result in injury to personnel.

CAUTION!

MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT

Failure to follow this warning may result in injury to personnel or cause damage to the equipment.

NOTICE

Important or tip messages will appear in this format.

Safety Precautions

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

DANGER!

ELECTRIC SHOCK

The CT5100 Continuous Gas Analyzer (CT5100 CGA) operates using mains voltage, which may cause death or serious injury to
personnel. Make sure 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.

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

WARNING!

FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD

Operators and service personnel do not have access to the laser/electrical and the upper cell compartments for maintenance or
service.

Electrical shock or thermal burns may occur.

WARNING!

FLAMMABLE SUBSTANCES

Some parts of the CT5100 CGA may reach temperatures of 190 °C (374 °F) and may present an ignition source. Exercise care when
using oil, paint, cleaning rags, or other flammable substances near the CT5100 CGA. A fire may result if this precaution is not
observed. The interior of a CT5100 CGA is always hot unless it has been switched off and allowed to cool down.

WARNING!

EXPLOSION HAZARD

Always lock out the gas handling system when shutting down the CT5100 CGA. Unauthorized performance on the CT5100 CGA 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!

EXPLOSION HAZARD

The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the CT5100
CGA during startup.

The sample gas in the pipes leading to the CT5100 CGA must be purged to prevent hazards to personnel during maintenance. You
must purge the sample gas in accordance with the safe working procedures for this site.

Allow the CT5100 CGA and the system for returning the sample gas to run for five minutes to allow any sample gas in the instrument
to be returned to the exhaust.

Failure to vent sample gas may cause death.

WARNING!

BURNS

Some parts of the CT5100 CGA may be heated to 190 °C (374 °F). To prevent burns, do not touch any of the hot parts. All parts of a
CT5100 CGA are always hot unless it has been switched off and allowed to cool down.

Before fitting, removing, or performing any maintenance on the CT5100 CGA, make sure 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 CT5100 CGA to
cool for at least twelve hours as the analysis cell is insulated against heat loss.

When handling the CT5100 CGA, always use 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 a burn is received, seek medical treatment immediately.

WARNING!

OPTICAL RADIATION EXPOSURE HAZARD

The CT5100 CGA contains lasers. Opening the CT5100 CGA and attempting to perform adjustments and procedures other than those
specified in this manual may result in hazardous optical radiation exposure.

All lasers used within the CT5100 CGA are Class 1. 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.

Failure to follow the correct procedures may cause damage to the eye. Do not look at the lasers with any kind of magnifier or optical
measuring device.

There are three types of laser that may be included in the CT5100 CGA: Quantum Cascade Lasers (QCLs), Interband Cascade Lasers
(ICLs), and diode lasers. The lasers within the CT5100 CGA are Class 1. The characteristics of the lasers contained within the CT5100
CGA are given in the table below.

Parameter QCL ICL Diode Comment

Operation mode Pulsed Pulsed Pulsed

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

Wavelength 4 - 10 µm 2- 5 µm Approximately 760 nm

Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first accessible

aperture: < 9.62mW

Pulse duration < 1 µs < 1 µs < 5 µs

Pulse repetition

< 100 kHz < 100 kHz < 100 kHz

frequency

Duty cycle < 5% < 5% < 25%

The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW.

The CT5100 Continuous Gas Analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of
laser safety labels on the CT5100 Continuous Gas Analyzer is specified in Section 4.3.

The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation
exposure.

WARNING!

HAZARDOUS SUBSTANCES

The CT5100 CGA may contain hazardous substances. Always handle CT5100 CGA assemblies and components with extreme caution.
Wear personal protective equipment (PPE) when handling the equipment.

Gas handling components within the CT5100 CGA contain particulate matter residue from the sample gases. Over the life of the
CT5100 CGA, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the CT5100 CGA:

• 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.

• Keep food and beverages away from the CT5100 Continuous Gas Analyzer.

• 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 in accordance with applicable local, national, or international health

and safety regulations and pollution regulations.

WARNING!

TRANSPORTATION HAZARD

Handle the CT5100 CGA with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet,
or other body parts.

The CT5100 CGA weighs 50.3 kg (111 lb.) and should always be lifted and moved using suitable lifting/moving equipment. Wear
suitable protective gloves and protective footwear. When preparing the CT5100 CGA for transport by air, road, or rail, safeguard the
CT5100 CGA against movement or break-away during transport by securely strapping it in place.

WARNING!

HAZARDOUS GAS

The product stream that the CT5100 CGA is examining may be hazardous even at low concentrations. Special care should therefore
be taken 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
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 CT5100 CGA.

CAUTION!

EQUIPMENT DAMAGE

Do not power up or try to operate the CT5100 CGA unless it is physically secure and all electrical and pneumatic connections to the
CT5100 CGA are in place.

Before commencing the startup process, it is important to ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the CT5100 CGA.

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

CAUTION!

EQUIPMENT DAMAGE

Always follow the startup procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.

CAUTION!

EQUIPMENT DAMAGE

Always follow the shutdown procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.

CAUTION!

LASER RADIATION

Invisible laser radiation. Do not stare into beam. Class 1 laser.

Failure to follow the correct procedures may cause damage to the eye.

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.

Abbreviations

The following abbreviations are used in this manual.

©

Copyright

% Percent

< Less than

° Degree

AC Alternating current

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

BS British Standard

C Celsius

CE European Conformity

CFR Code of Federal Regulations

CGA Continuous Gas Analyzer

CH

4

Methane

CO Carbon monoxide

CO

2

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

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

ISO International Organisation for Standardisation

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

3

m

Cubic meter

mA Milliamp

Max Maximum

mBar milli-Bar

mbps Megabits per second

mg Milligram

3

mg/m

Microgram/cubic meter

Mid IR Mid Infrared

min Minute

mm Millimeter

O

2

N

2

Oxygen

Nitrogen

NEC National Electrical Code

NFPA National Fire Protection Association

nm Newton meter

NO Nitric oxide

NO

2

Nitrogen dioxide

N2O Nitrous oxide

NH

3

Ammonia

No. Number

O

2

Oxygen

PC Personal computer

PM Preventative maintenance

ppm Parts per million

psi Pounds per square inch

QCL Quantum Cascade Laser

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

UKAS United Kingdom Accreditation Service

USA United States of America

USB Universal serial bus

V Volt

VA Volt-ampere

Vac Volt alternating current

W Watt

WEEE Waste electrical and electronic equipment

μm Micro-meter

Contents

Contents

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

1.1 Description .................................................................................................................................. 1

1.2 Customer information ................................................................................................................. 1

1.3 Safety precautions ....................................................................................................................... 2

1.4 Qualified personnel ......................................................................................................................2

1.5 Software version .......................................................................................................................... 2

Chapter 2 Theory of Operation ....................................................................................................... 3

2.1 Overview ......................................................................................................................................3

2.2 Quantum Cascade Laser ..............................................................................................................3

2.3 Measurement process ..................................................................................................................3

Chapter 3 Description .................................................................................................................... 5

3.1 Equipment purpose and role ........................................................................................................5

3.2 System overview ..........................................................................................................................6

3.3 Gas inputs and outputs ................................................................................................................ 8

3.4 Electrical/electronic inputs and outputs .....................................................................................10

3.5 Controls and indicators ..............................................................................................................12

3.6 Optical description .....................................................................................................................12

Chapter 4 Specifications ...............................................................................................................15

4.1 Gas detection .............................................................................................................................15

4.2 Detailed system specifications ...................................................................................................15

4.3 Safety and system labels and annotation ................................................................................... 18

Chapter 5 Controls and display controller .....................................................................................23

5.1 Introduction ...............................................................................................................................23

5.2 Operating states ........................................................................................................................ 23

5.3 Startup procedure ......................................................................................................................23

5.4 Shutdown procedure ................................................................................................................. 24

5.5 Front panel controls and indicators ............................................................................................24

5.6 Display controller .......................................................................................................................26

5.7 Gas sensor main screen ..............................................................................................................27

5.8 Pressure and Temperature screen ................................................................................................ 29

5.9 Help system ...............................................................................................................................29

5.10 Calibration ................................................................................................................................. 30

5.11 BACK button ...............................................................................................................................30

Chapter 6 Startup procedure ........................................................................................................33

6.1 Introduction ...............................................................................................................................33

6.2 Preparation for use .....................................................................................................................33

6.3 Startup .......................................................................................................................................34

Chapter 7 Operation .....................................................................................................................37

7.1 Introduction ...............................................................................................................................37

7.2 Normal operation ...................................................................................................................... 37

Chapter 8 Shutdown procedure ................................................................................................... 39

8.1 Introduction ...............................................................................................................................39

8.2 Shutdown procedure ................................................................................................................. 40

Operations Manual i

Contents

Chapter 9 Gas Calibration Procedures ...........................................................................................45

9.1 Required tools ............................................................................................................................45

9.2 Main menu .................................................................................................................................45

9.3 Zero Calibration ......................................................................................................................... 47

9.4 Span gas calibration ................................................................................................................... 52

Chapter 10 Preventative Maintenance ........................................................................................... 59

10.1 Maintenance ..............................................................................................................................59

10.2 Schedule ....................................................................................................................................59

ii Rosemount CT5100

1 Introduction

Topics covered in this chapter:

• Description

• Customer information

• Safety precautions

• Qualified personnel

• Software version

1.1 Description

The CT5100 Continuous Gas Analyzer, referred to hereafter as CT5100 CGA, is an
electronic sensor that uses laser spectroscopy to perform analysis of process gas streams.
The function of the CT5100 CGA is to detect and measure up to ten different types of gas
at concentrations ranging from parts per million (ppm) to percentage levels in the process
gas stream.

Introduction

This Operations Manual is intended for the personnel who operate and maintain the
equipment.

1.2 Customer information

This manual contains all the important information that must be followed to ensure the
correct operation and safety of personnel when operating the CT5100 CGA.

Operators and maintenance personnel must read this manual carefully before
commencing any work on the CT5100 CGA.

The manual is divided into chapters, which will allow you to easily find the information
required.

For information regarding maintenance, installation, and spare parts, contact your local
service representative.

Emerson is committed to continuously improving its products and documentation. Every
effort will be made to include in the documentation any modifications by the
manufacturer. However, it should be noted that this document reflects the supplied
sensor at the revision date on the front cover.

Should you require further information, or should particular problems arise that are not
covered in this Manual, then additional help can be requested from Cascade Technical
Support ([e-mail]) or Cascade Technologies Ltd distribution
partners. Further contact details for Cascade technologies Ltd can be found in the
preliminary material of this manual.

Operations Manual 1

Introduction

1.3 Safety precautions

WARNING!

Before installing or performing any maintenance on the CT5100 CGA, read and understand the
safety information given in the preliminary material of this manual.

The CT5100 CGA described in this manual 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 instrument 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 instrument has warning labels at appropriate
positions in accordance with USA 21 CFR 1040.10.

1.4 Qualified personnel

This manual provides operation and maintenance personnel with the level of knowledge
required to safely start, operate, and switch off the CT5100 CGA.

The installation, advanced operation, switching off, and servicing of the CT5100 CGA must
only be performed by technically qualified personnel in the field of instrumentation and
control who are familiar with this manual and have been specially trained on the CT5100
CGA. Only qualified and trained persons have the required specific knowledge to correctly
interpret the general safety information, warnings, and procedures given in this manual
and apply them to this particular application. Emerson or its distribution partners can
provide this training on request.

Knowledge of the safety information within this manual and its technically correct
implementation are prerequisites for danger-free operation, installation, and maintenance
of the CT5100 CGA.

1.5 Software version

The CT5100 CGA includes software that is used to control the operation of the instrument.
This manual describes software version 4.4.1-1.

2 Rosemount CT5100

2 Theory of Operation

Topics covered in this chapter:

• Overview

• Quantum Cascade Laser

• Measurement process

2.1 Overview

The CT5100 CGA is a gas sensor system that can be configured to measure the
concentrations of multiple small molecules carried in the gas sample. The types of
molecules that are measured depend on the system configuration.

The CT5100 CGA can be configured to detect and measure up to ten gases, with ranges
varying from parts per million (ppm) to percent (%) levels. A detailed description of the
system is given in Chapter 3 of this manual.

Theory of Operation

2.2 Quantum Cascade Laser

The CT5100 CGA uses up to six Quantum Cascade Lasers to detect and measure the gases.
Each QCL measures between one and three gases.

Inside the QCL, which is about the size of a pin head, electrons cascade down a series of
quantum wells, producing a photon at each step. This cascade of electrons can produce
between 20 and 100 photons per electron, giving QCLs higher output power than
traditional semi-conductor lasers.

The lasing wavelength of a QCL is determined by adjusting the physical thickness of the
semiconductor layers, giving access to high power lasers covering the mid-infrared
spectral region. A QCL has no need for cryogenic cooling, has excellent spectral quality in
chirped mode, and good tunability.

2.3 Measurement process

In the CT5100 CGA, gas concentrations are measured using mid-infrared optical
absorption spectroscopy. The light sources are QCLs, which are operated to produce
wavelength sweeps that cover the absorption lines of the gases to be measured.

Sample gas, which may contain impurity gases that are to be detected and measured, is
conditioned and drawn into the CT5100 CGA. Inside the CT5100 CGA, the sample gas is
fed into an analysis cell, where the beams from the QCLs are passed through the gas. The
analysis cell contains a set of mirrors that bounce the light back and forth many times,

Operations Manual 3

Theory of Operation

which lengthens the path of the lasers through the gas. On exiting the analysis cell, the
light is detected by a receiver unit. The variation in the intensity of light in the vicinity of
absorption lines for the gases being detected is measured, and the concentration is
determined using a comprehensive spectral fitting routine.

4 Rosemount CT5100

3 Description

Topics covered in this chapter:

• Equipment purpose and role

• System overview

• Gas inputs and outputs

• Electrical/electronic inputs and outputs

• Controls and indicators

• Optical description

3.1 Equipment purpose and role

The CT5100 CGA shown in Figure 3-1 is a gas sensor system that can be configured to
measure the concentrations of multiple small molecules contained in a gas sample that is
provided to the CT5100 CGA via a sample line. The types of molecules that are measured
depend on the system configuration.

Description

Operations Manual 5

Description

CT5100 Continuous Gas AnalyzerFigure 3-1:

The CT5100 CGA can be configured to detect and measure up to ten different gases,
depending on the combination of laser modules fitted.

3.2 System overview

A complete CT5100 CGA, as shown in Figure 3-2, consists of a gas handling system, the
CT5100 CGA, and the associated interconnecting wiring and gas piping. Measurement
data from the CT5100 CGA can be displayed in the process control center.

The CT5100 CGA 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 CT5100 CGA, the interconnecting
wires, and gas piping are provided by you. In Figure 3-2, the items supplied by us are
colored blue; the items supplied by you are colored purple. The green Gas Handling
System may be provided by you or us. Table 3-1 lists the main items of the system.

6 Rosemount CT5100

Description

CT5100 CGA installationFigure 3-2:

The CT5100 CGA contains an optical system with multiple lasers and a series of optical
components that provide an optical path, a heated multi-pass analysis cell, sample and
outlet ports that can be connected to a gas handling system, and control and analysis
electronics. The number of lasers installed depends upon customer requirements. The
complete system operates from either 100 or 240 Vac 50/60 Hz supply. You must specify
whether you want 100 or 240 Vac on your order.

Gas concentrations are measured using mid-infrared optical absorption spectroscopy. The
light sources are QCLs, which are operated to produce wavelength sweeps that cover the
absorption lines of the gases. The light from each laser is routed through an optical path to
the analysis cell, which provides measurement of low concentrations of the subject gases.
The sample gas is conditioned and drawn through the analysis cell by an external sample
handling system. The light exits the multi-pass analysis cell and is directed to a receiver in
the CT5100 CGA. The variation in the intensity of light in the vicinity of the absorption lines
is measured, and the concentration is determined using a comprehensive spectral fitting
routine.

There is no sample conditioning provided within the CT5100 CGA; the sampled gas must
be brought within the parameters shown in Table 4-3 before entering the CT5100 CGA.
Detailed characteristics of the CT5100 CGA are also given in Section 4.2.

Main items of the CT5100 CGA installationTable 3-1:

Item Name or description Supplied by Part number Quantity Notes

1 CT5100 CGA Emerson CT5100 1

2 CT5100 CGA software

package, version 4.0

Emerson N/A.

Software is
embedded in the
system.

1 Version

described
in manual

Operations Manual 7

Description

Main items of the CT5100 CGA installation (continued)Table 3-1:

Item Name or description Supplied by Part number Quantity Notes

3 Gas handling system Customer

(optionally by
Emerson)

4 Heated gas sample line

hose

5 Exhaust line hose (for

sample gas)

6 Reference gas cylinders

(instrument gas) for
calibration purposes

7 Pressure regulator Customer Customer choice 1 per gas

8 Pneumatic T-piece Customer Customer choice 1 Required

9 Excess flow line Customer Customer choice 1 Required

10 Power cables to

CT5100 CGA

11 Cables from CT5100

Continuous Gas
Analyzer to control
center

12 Main circuit breaker Customer Customer choice

Customer Customer choice 1

Customer Customer choice 1

Customer Customer choice Dependent

Customer Customer choice 1

Customer Customer choice 1

Customer choice
or Emerson

1

upon
number of
gases being
measured

cylinder

Required
for
calibration

for
calibration

for
calibration

3.3 Gas inputs and outputs

The CT5100 CGA has one gas input and one gas output (Figure 3-3).

1. The gas sample that is to be measured for impurities enters the instrument through
the sample gas input port (A) located on top of the CT5100 CGA.

2. Once the gas sample has been examined for impurities, it is expelled from the
instrument through the sample gas return port (B).

8 Rosemount CT5100

Description

Gas inlet and outlet connectorsFigure 3-3:

A. Sample gas input port
B. Sample gas return port
C. Top cover of CT5100 CGA (cell compartment)
D. Laser/electrical compartment

3. The sample supply line must be heated all the way to the sample gas input port on
the CT5100 CGA to prevent condensation forming at any point in the sample supply
line.

DANGER!

HAZARDOUS GASES

The product stream that the CT5100 CGA is examining may be hazardous even at low
concentrations. Special care should be taken 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. Hazardous gases may cause death.

Operations Manual 9

Description

3.4 Electrical/electronic inputs and outputs

Electrical / electronic connectorsFigure 3-4:

A. Analog/digital conduit
B. Analog/digital conduit
C. Power conduit

Electrical/electronic connections to the CT5100 CGA are made through three electrical
conduits located on the underside of the instrument, as shown in Figure 3-4. Use the wiring
diagram to make the electrical user connections as shown below.

10 Rosemount CT5100

Note: Maximum number of user terminals shown. These
may be reduced dependant on number and type of
Analog/Digital outputs required.

Description

Terminal Function

1 SENSOR SYSTEM SUPPLY (L)

2 SENSOR SYSTEM SUPPLY (N)

3 EARTH

4 PURGE ALARM CONTACTS (Not used)

5 PURGE SYSTEM SUPPLY (L) (Not used)

6 PURGE SYSTEM SUPPLY (N) (Not used)

7 EARTH

8 PURGE SOLENOID (L) (Not used)

9 PURGE SOLENOID (N) (Not used)

10 EARTH

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

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)

Electrical power is applied to the instrument through the power conduit (C).

Operations Manual 11

Description

The power supply is 110 to 240 Vac, 50/60 Hz ± 10%. AC to DC power converters inside the
instrument automatically adjust in response to the input voltage level and ensure that the
correct DC voltage is available inside the instrument. The instrument 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.

CAUTION!

You must ensure that the mains supply cable used is of a suitable rating for the unit power
requirements. Failure to do so may result in personal injury and/or damage to persons and/or
property.

The digital outputs conduit (B) provides an Ethernet output from the instrument that may
be used for downloading data for failure diagnosis purposes or for downloading data to the
process control center.

The results of the gas analysis are output from the instrument through the 4-20 mA analog
or Modbus outputs and sent to your process control center.

The optional digital outputs provide fault indications to your process control center. Each
digital output is connected to a normally closed relay, located inside the CT5100 CGA,
which will open in response to the detection of a specific fault. The possible causes of a
fault indication are:

1. The sample gas concentration is outside of specification, i.e., the sample gas
concentration has exceeded the measurement range of the instrument.

2. The CT5100 CGA is out of specification or has developed a fault.

NOTICE

The installation of the gas analyzer shall be in accordance with National Electrical Code (NEC).

3.5 Controls and indicators

The controls and indicators on the CT5100 CGA are described in Section 5.5 of this manual.

3.6 Optical description

The laser modules are located in the core of the CT5100 CGA. Each laser module produces
a separate light beam, and these beams are combined linearly as the modules are aligned
in the system. The combined beams are closely coupled, parallel, and coaxial about a
virtual line. The laser light beams pass through a baseplate onto an optical steering
assembly, which directs the laser beam through the sample cell.

The sample cell contains a set of mirrors to create a path through the sample gas that is
between 2 m and 5 m through multiple reflections along the length of the cell. The laser
beams exit the cell at the opposite end from where they entered and are directed using a
second optical block to a receiver.

12 Rosemount CT5100

Description

By measuring and analyzing the light detected by the receiver unit, it is possible to
accurately determine the concentrations of the target molecules within the gas sample
cell.

Operations Manual 13

Description

14 Rosemount CT5100

4 Specifications

Topics covered in this chapter:

• Gas detection

• Detailed system specifications

• Safety and system labels and annotation

4.1 Gas detection

The CT5100 CGA is highly configurable in the gases that can be detected and their range of
concentrations.

4.2 Detailed system specifications

Specifications

Table 4-1 gives the physical characteristics of the CT5100 CGA. Schematic diagrams of the

sensor and mounting points are shown in Figure 4-1and Figure 4-2. Table 4-2 gives the
general characteristics of the instrument.

Physical characteristicsTable 4-1:

CT5100 CGA Value Units Comment

Gas analyzer
dimensions

Gas analyzer weight 50.35

General characteristicsTable 4-2:

CT5100 CGA Value Units Comment

Instrumentation supply
voltage

Peak power consumption 500 W Max consumption per gas analyzer

Continuous steady-state
power consumption

Electrical compartment
enclosure

Optical compartment
enclosure

Measurement technique - - Mid IR absorption spectroscopy

Mid IR source - - Quantum Cascade Laser

575 x 286 x 641

22.64 x 11.25 x 25.24

111

110 or240 V AC 50/60 HZ ± 10%

300 W Once the gas analyzer has stabilized and the analysis cell

- -

- - Stainless steel

mm

in.

kg

lb.

has reached the temperature set point

Stainless steel

Length x Width x Height

Operations Manual 15

Specifications

General characteristics (continued)Table 4-2:

CT5100 CGA Value Units Comment

Near IR source - - Interband Cascade Laser

Diode Laser

Laser classification Class 1 BS EN 60825-1: 2007 safety of laser products. Equipment

classification and requirements (identical to IEC 60825-1

2007)

Inlet gas port connector 6 mm or 1/4 in. Swagelok type, factory-configured, specify on order

Outlet (Exhaust) gas port
connector

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

6 mm or 1/4 in. Swagelok type, factory-configured, specify on order

10/100 Mbps Ethernet

16 Rosemount CT5100

Specifications

CT5100 Continuous Gas Analyzer dimensions - front viewFigure 4-1:

Operations Manual 17

Specifications

CT5100 Continuous Gas Analyzer dimensions - top viewFigure 4-2:

Table 4-3 gives the environmental characteristics of the CT5100 CGA.

Environmental characteristicsTable 4-3:

Environmental characteristic Value Units Comment

Operating temperature range 5 to 45

41 to 113

Sample gas temperature range 50 to 195

122 to 383

Sample gas moisture content 20 % Maximum

Sample gas particulate density 5 mg/m

Sample gas particulate size 10 μm

IP code 66 IP to IEC 60529

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

Operating altitude 0 to 2,000 m

°C

°F

°C

°F

Ambient temperature

Factory set, specify on order

3

condensing) at 45 °C (113 °F)

4.3 Safety and system labels and annotation

The labels and annotation applied to the CT5100 CGA are specified in Table 4-4.

18 Rosemount CT5100

Safety and system labelsTable 4-4:

Label type Example Location

Identification label
(including serial
number and model
number

Front panel

Specifications

Fuse identification
label

Ratings label Enclosure side panel

Laser radiation
CAUTION label

1. Back plate

2. Top right inside of
door

Baseplate

Laser module
identification label

On each laser module
housing

Operations Manual 19

Specifications

Safety and system labels (continued)Table 4-4:

Label type Example Location

Intrinsically safe label 1. HMI

2. Intrinsically safe
sensor barrier

Terminal label Top left inside of door

Earth identification
label

Back plate

20 Rosemount CT5100

Specifications

Safety and system labels (continued)Table 4-4:

Label type Example Location

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

Operations Manual 21

Specifications

22 Rosemount CT5100

5 Controls

Topics covered in this chapter:

• Introduction

• Operating states

• Startup procedure

• Shutdown procedure

• Front panel controls and indicators

• Display controller

• Gas sensor main screen

• Pressure and Temperature screen

• Help system

• Calibration

• BACK button

Controls

5.1 Introduction

This chapter describes the controls, displays, and indicators on the CT5100 CGA and how
to use the display controller located on the front panel of the instrument.

5.2 Operating states

The CT5100 CGA has two operating states: Work Mode and Off.

1. As the CT5100 CGA is designed for long term continuous operation, it is usually in
Work Mode.

2. The CT5100 CGA is normally only placed in the Off state for maintenance.

5.3 Startup procedure

The startup procedure described in Chapter 6 must be followed or damage to the CT5100
CGA may result. The description of normal operation provided in Chapter 7 of this manual
assumes that the startup procedure has been followed and completed correctly.

CAUTION!

EQUIPMENT DAMAGE

Always follow the startup procedure. Damage to the CT5100 CGA may result from a failure to
follow the startup procedure.

Operations Manual 23

Controls

5.4 Shutdown procedure

To switch off the instrument, the shutdown procedure described in Chapter 8 must be
followed or damage to the CT5100 CGA may result.

CAUTION!

EQUIPMENT DAMAGE

Always follow the shutdown procedure. Damage to the CT5100 CGA may result from a failure
to follow the shutdown procedure.

5.5 Front panel controls and indicators

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

24 Rosemount CT5100

Controls

Front panelFigure 5-1:

A. Display controller

NOTICE

On/Off circuit breakers

There are no On/Off switches on the CT5100 CGA. The application of electrical power to the
instrument is controlled through an external circuit breaker.

The circuit breaker is a simple 2-pole on/off circuit breaker that must be set to On to permit the
safe operation of the CT5100 CGA.

Operation of the CT5100 CGA is controlled primarily through the display controller
(Figure 5-2).

Operations Manual 25

Controls

Display controllerFigure 5-2:

5.6 Display controller

Display controller buttonsFigure 5-3:

A. LCD display
B. Configurable button
C. Scroll button
D. Configurable button
E. Configurable button
F. Scroll button
G. Configurable button

Operation of the CT5100 CGA is controlled through the six buttons on the display
controller: Figure 5-3.

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

1. The gas concentration measurements obtained

26 Rosemount CT5100

2. The operating temperature and pressure

3. Help screens

4. Step-by-step calibration and diagnostics

The two scroll buttons (C and F) 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
(F) is used to scroll down.

The other four buttons (B, D, E, and G) are configured to perform different functions
according to which the software screen is shown on the LCD display.

5.7 Gas sensor main screen

When the CT5100 CGA is switched on, at the end of the startup procedure, the gas sensor
main screen (Figure 5-4) appears. The gas sensor main screen is the screen that is normally
displayed.

NOTICE

Controls

The gas concentrations shown in the following screenshots may be different from those shown
in your particular CT5100 CGA. They indicate the functionality of the software, which it the
same regardless of the gases or gas concentrations being measured.

Gas sensor main screenFigure 5-4:

The gas sensor main screen displays the gas concentration measurements obtained by the
CT5100 CGA. In the example shown in Figure 5-4, 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.

At the end of the startup 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.

Operations Manual 27

Controls

The gas sensor main screen also shows the status of the CT5100 CGA. In the example
shown in Figure 5-5, the instrument is Running and OK (i.e., 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.

Gas sensor main screen buttonsFigure 5-5:

A. MENU button
B. MENU text
C. PAGE text
D. PAGE button
E. HELP button
F. HELP text
G. STATUS button

PAGE (C) is a link between the gas sensor main screen and the Pressure and Temperature

screen (described in Section 5.8). Press the PAGE button (D) to toggle between these two
screens.

HELP (F)is a link to the Help system. Press the HELP button to go to the HELP screen
(described in Section 5.9).

MENU (B) is a link to the main menu of the software. Press the MENU button (A) to go to the
MAIN MENU screen (described in Section 5.10).

On the gas sensor main screen, the STATUS button (G) has no function when the CT5100
CGA is operating correctly. If, however, the software detects a fault, an error message is
displayed. Press the STATUS button to get further information on the error.

28 Rosemount CT5100

5.8 Pressure and Temperature screen

The Pressure and Temperature screen (Figure 5-6) shows pressure and temperature
measurements taken inside the CT5100 CGA.

Pressure and Temperature screenFigure 5-6:

Controls

The Cell reading is the temperature, in °C, of the analysis cell.

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

The Pres reading is the pressure, measured 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.

CAUTION!

UNSERVICEABLE EQUIPMENT

If the Pressure and Temperature screen does not display measurements similar to those shown
in Figure 7-2, contact your local service representative for guidance.

5.9 Help system

The CT5100 CGA software includes a context-sensitive help system. Press the HELP button,
which is available on most of the software screens, to open the help system.

The help system contains a number of different help screens, each conveying a different
message. As the help system is context-sensitive, when the HELP button is pressed, the
help screen that appears is the one that is most appropriate to the software function
engaged when the HELP button was pressed. Figure 5-7 shows an example of a help screen.

Operations Manual 29

Controls

Example of a help screenFigure 5-7:

5.10 Calibration

To access the Main menu (Figure 5-8), press the MENU button on either side of the gas
sensor main screen (Figure 5-4) or the Pressure and Temperature screen (Figure 5-6). The
Main menu is used for calibration, diagnostics, fault finding, downloading data, and
shutting down the CT5100 CGA.

Main menuFigure 5-8:

5.11 BACK button

On most of the software screens, the top left-hand button (Figure 5-9) is configured as a
BACK button. Press the BACK button to return to the previous screen.

30 Rosemount CT5100

BACK buttonFigure 5-9:

A. BACK button

Controls

Operations Manual 31

Controls

32 Rosemount CT5100

6 Startup Procedure

Topics covered in this chapter:

• Introduction

• Preparation for use

• Startup

6.1 Introduction

This section describes the startup procedure for the CT5100 CGA.

CAUTION!

EQUIPMENT DAMAGE

Always follow the startup procedure. Damage to the CT5100 CGA may result from a failure to
follow this procedure.

Startup Procedure

The CT5100 CGA normally operates continuously. It should only be necessary to start up
the instrument under the following circumstances.

• When the CT5100 CGA is first switched on following installation

• Following repair or maintenance of the CT5100 CGA

• When the CT5100 CGA has been switched off as part of a plant shutdown or

maintenance

6.2 Preparation for use

The CT5100 CGA must be installed and fully commissioned prior to startup.

CAUTION!

EQUIPMENT DAMAGE.

Do not power up or try to operate the CT5100 CGA unless it is physically secure and all electrical
and pneumatic connections to the CT5100 CGA are in place.

Before commencing the startup process, ensure that electrical power, sample gas handling
facilities, and any calibration gases that are required are available to the CT5100 CGA.

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

Operations Manual 33

Startup Procedure

WARNING!

BURN HAZARD
Some parts of the CT5100 CGA may be heated to 190 °C (374 °F). To prevent burns, do not touch
any of the hot parts. All components of a CT5100 CGA are hot unless it has been switched off
and allowed to cool down.

Before fitting, removing, or performing any maintenance on the CT5100 CGA, make sure 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 CT5100 CGA to cool for at least
twelve hours, as the analysis cell is insulated against heat loss.

When handling the CT5100 CGA, 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 a burn is
received, seek medical treatment immediately.

6.3 Startup

NOTICE

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

NOTICE

To stop the startup procedure at any time, set the main circuit breaker to Off.

To start up the CT5100 CGA, perform the following steps:

1. Visually inspect the exterior of the CT5100 CGA for signs of damage, corrosion, gas
leaks, or overheating. Report anything found to the maintenance organization.

2. Make sure that the top cover is fitted to the CT5100 CGA. If it is not, report it to the
maintenance organization and do not proceed further until the top cover has been
fitted.

3. Make sure 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.

4. Make sure that the gas handling system is turned off.

5. Make sure that the external main circuit breaker is set to Off.

6. Visually examine the gas ports (if necessary, refer to Figure 6-1) to make sure that
the sample supply line and the sample return line are correctly attached.

34 Rosemount CT5100

Startup Procedure

CT5100 CGA Gas Supply LinesFigure 6-1:

A. Sample gas input port
B. Sample gas return port
C. Top cover of CT5100 CGA (cell compartment)
D. Laser/electrical compartment
E. Power conduit
F. Analog/digital conduit
G. Analog/digital conduit

7. Visually check that the electrical connections have been made to the three conduit
hubs at the base of the instrument. See Figure 6-1.

8. Set the main circuit breaker to On.

Operations Manual 35

Startup Procedure

The CT5100 CGA commences its automatic startup. The control PC that forms part
of the instrument is configured to automatically load the necessary gas sensor
software and configuration files. The startup sequence commences automatically
under software control.

After a few seconds, the Gas Sensor main screen (Figure 6-2) appears on the display
controller. If it does not, report the fault to the maintenance organization.

Gas sensor main screenFigure 6-2:

9. Start up the system for returning the sample gas.

10. Start up the gas handling system that conditions the sample gas before it is fed into
the CT5100 CGA.

At the end of the startup 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 startup procedure is now complete.

36 Rosemount CT5100

7 Operating Procedure

Topics covered in this chapter:

• Introduction

• Normal operation

7.1 Introduction

This section describes the normal operation of the CT5100 CGA. Chapter 5 of this manual
describes how to use the display controller located on the front panel of the CT5100 CGA.

NOTICE

The gas concentrations shown in the following screenshots may be different from those shown
in your particular CT5100 CGA. The screenshots indicate the functionality of the software,
which is the same regardless of the gases or gas concentrations being measured.

Operating Procedure

7.2 Normal operation

The CT5100 CGA is designed for long term continuous operation, and therefore its normal
state is to be switched on and performing gas measurements. The CT5100 CGA is usually
only switched off for maintenance. The shutdown procedure used to switch of the CT5100
CGA is described in Chapter 8 of this manual.

Provided that the startup procedure described in Chapter 6 has been followed, the CT5100
CGA does not require any human intervention during normal operation other than
occasional calibration checks (described in Chapter 9 of this manual).

During normal operation, either the Gas Sensor main screen (Figure 7-1) or the Pressure and
Temperature screen (Figure 7-2) is shown on the display controller. To toggle between
these two screens, press the PAGE button.

Operations Manual 37

Operating Procedure

Gas Sensor main screenFigure 7-1:

Pressure and Temperature screenFigure 7-2:

CAUTION!

UNSERVICEABLE EQUIPMENT

If the Pressure and Temperature screen does not display measurements similar to those shown
in Figure 7-2, contact your local service representative for guidance.

On both the Gas Sensor main screen and the Pressure and Temperature screen, the STATUS
button has no function when the CT5100 CGA is operating correctly. If, however, the
software detects a fault, an error message is displayed; press the STATUS button to get
further information on the error.

38 Rosemount CT5100

8 Shutdown Procedure

Topics covered in this chapter:

• Introduction

• Shutdown procedure

8.1 Introduction

This chapter describes the shutdown procedure for the CT5100 CGA.

CAUTION!

EQUIPMENT DAMAGE

Always follow this shutdown procedure. Damage to the CT5100 CGA may result from a failure
to follow this procedure.

Shutdown Procedure

The CT5100 CGA normally operates continuously. It should only be necessary to shut
down the instrument in the following circumstances:

• In order to perform repairs or maintenance on the CT5100 CGA

• When the CT5100 CGA has to be switched off as part of a plant shutdown or plant

maintenance

• When the CT5100 CGA is switched off for re-calibration

Use the display controller to perform the shutdown procedure. Refer to Chapter 5 for the
display controller navigation instructions.

NOTICE

The gas concentrations shown in the following screenshots may be different from those shown
in your particular CT5100 CGA. The screenshots indicate the functionality of the software,
which is the same regardless of the gases or gas concentrations being measured.

Operations Manual 39

Shutdown Procedure

WARNING!

BURN HAZARD

Some parts of the CT5100 CGA may be heated to 329 °F (165 °C). To prevent burns, do not touch
any of the hot parts. All parts of a CT5100 CGA are hot unless it has been switched off and
allowed to cool down.

Before fitting, removing, or performing any maintenance on the CT5100 CGA, make sure 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 CT5100 CGA to cool for at least
twelve hours as the analysis cell is insulated against heat loss.

When handling the CT5100 CGA, always use suitable protective gloves.

Personal injury and/or damage to property may result if these safety precaution are not
observed. These precautions are particularly important when working at heights. If a burn is
received, seek medical treatment immediately.

8.2 Shutdown procedure

To shut down the CT5100 CGA, perform the following steps:

DANGER!

EXPLOSION HAZARD

Always lock out the gas handling system when shutting down the CT5100 CGA. Unauthorized
operation of the gas handling system when maintenance is being performed on the CT5100
CGA 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.

1. Shut down the gas handling system that conditions the sample gas and feeds it to
the CT5100 CGA. Always lock out the gas handling system to prevent its
unauthorized operation during maintenance, which may cause an escape of gas.

DANGER!

EXPLOSION HAZARD

The sample gas in the system must be vented to prevent fire or explosion during
maintenance and to prevent damage to the CT5100 CGA during shutdown.

The sample gas in the pipes leading to the CT5100 CGA must be purged to prevent
hazards to personnel during maintenance. Purging the sample gas must be done in
accordance with the safe working procedures for the site.

Allow the CT5100 CGA and system for returning the sample gas to run for five minutes to
allow any sample gas in the instrument to be returned to the exhaust.

Failure to vent sample gas may cause death.

40 Rosemount CT5100

Shutdown Procedure

2. Purge any sample gas in the pipe/hose from the gas handling system to the CT5100
CGA using factory air or nitrogen supply.

3. Allow the CT5100 CGA to run for five minutes with the purge gas connected, so that
any sample gas in the instrument is vented to the exhaust. On the display controller,
check that the gas concentrations read 0 ppm before stopping the purge flow.

WARNING!

HIGH PRESSURE GASES
The calibration gas supply and compressed air supply operate at a pressure that can
cause injury, e.g., damage to eyes and skin punctures from debris blown by the high
pressure gas or compressed air. Always lock out and tag out the calibration gas supply
when shutting down the CT5100 CGA.

4. Turn off the calibration gas supply to the CT5100 CGA. Lock out and tag out the
compressed air supply.

5. Press the MENU button on the display controller in either the Gas Sensor main screen
(Figure 8-1) or the Pressure and Temperature screen (Figure 8-2).

Gas Sensor main screenFigure 8-1:

Pressure and Temperature screenFigure 8-2:

Operations Manual 41

Shutdown Procedure

The Main menu (Figure 8-3) opens.

Main menuFigure 8-3:

A. BACK button
B. SELECT button
C. Scroll up button
D. HELP button
E. Scroll down button

6. On the display controller, use the scroll up (C) and scroll down (E) buttons to select
SERVICE as shown in Figure 8-3. Then press the SEL (select) button (B).

The Service screen (Figure 8-4) opens.

Service screenFigure 8-4:

A. BACK button
B. SELECT button
C. Scroll up button
D. HELP button
E. Scroll down button

7. Use the scroll up (C) and scroll down (E) buttons to select Shutdown as shown in

Figure 8-4. Then press the SEL (select) button (B).

The Shutdown screen (Figure 8-5) appears.

42 Rosemount CT5100

Shutdown Procedure

Shutdown screenFigure 8-5:

8. Press the YES button.

The CT5100 CGA shuts down.

9. Check that the screen of the display controller goes blank.

10. Set the external secondary circuit breaker to Off. Lock out and tag out the secondary
circuit breaker.

11. Set the external main circuit breaker to Off. Lock out and tag out the main circuit
breaker.

The shutdown procedure is now complete.

Operations Manual 43

Shutdown Procedure

44 Rosemount CT5100

9 Gas Calibration Procedures

Topics covered in this chapter:

• Required tools

• Main menu

• Zero Calibration

• Span gas calibration

The gas concentrations measured by the CT5100 CGA can be calibrated against a known
sample gas by using the following gas calibration procedures. The CT5100 CGA and its
installation have to be configured to allow zero and span calibration procedures to be
used. If you are unable to complete the steps below, contact Emerson for further
assistance.

9.1 Required tools

Gas Calibration Procedures

To calibrate the CT5100 CGA, you need the following items:

• Nitrogen gas of instrument gas purity for use as a zero calibration gas

• Suitable span calibration gases for each gas measured

• Gas bottle pressure regulators

• Interconnecting hoses to connect the gas bottles to the CT5100 CGA

• A T-piece and excess flow line

9.2 Main menu

Calibration is performed under the control of the CT5100 CGA software, using calibration
routines built in to the software. The calibration functions are accessed through the Main
menu (Figure 9-1). To get to the Main menu, press the MENU button on either the gas
sensor main screen or the Pressure and Temperature screen, as described in Chapter 5.

Operations Manual 45

Gas Calibration Procedures

A. Calibration and maintenance options
B. SEL text
C. SEL button
D. Scroll up button
E. Scroll up arrow
F. Scroll down arrow
G. Scroll down button

Main menuFigure 9-1:

The Main menu is used to access the software routines and screens that are used for
calibration and maintenance. Four options are presented (Figure 9-1, item A), which are:

• VERIFY: This option allows the operator to check the sensor readings against a known

gas source and then, if necessary, to calibrate the CT5100 CGA against the known
gas source.

• DIAGNOSTICS: This option displays various parameters used in the internal

calculations and compares desired and actual parameters, for example, the analysis
cell pressure and temperature. The diagnostics routines and screens are used to
perform fault diagnosis.

• FAULTS: This option takes you to a screen that lists any faults affecting the CT5100

CGA. This option is used as part of the failure diagnosis procedures.

• SERVICE: This option takes you to a screen from which you can shut down the

CT5100 CGA or download data from the instrument. The downloaded data is used
to diagnose faults. The data downloading is performed by maintenance and/or
management personnel.

On the Main menu, the up and down arrows (E and F) and the associated scroll buttons (D
and G) can be used to scroll between the menu options (A). When the option you want is
highlighted (VERIFY is the example shown in Figure 9-1), press the SEL (select) button (C) to
go to the first screen of that software routine.

46 Rosemount CT5100

9.3 Zero Calibration

Zero calibration is calibrating the CT5100 CGA so that when no sample gas is flowing
through it the gas concentrations measured by the instrument are zero. Zero calibration is
done by calibrating the CT5100 CGA measurements against a known sample gas using the
following procedure:

Run the CT5100 CGA at a stable temperature for at least thirty minutes prior to
commencing this procedure.

Use nitrogen gas of instrument gas purity as the zero calibration gas.

1. Make sure that a pressure regulator is connected to the nitrogen gas bottle.

2. Connect a hose from the nitrogen gas bottle through a T-piece to the sample supply
port on the rear of the CT5100 CGA. Connect an excess flow line to the unused port
on the T-piece and route the excess flow line to a suitable extractor.

3. On the display controller of the CT5100 CGA, browse to the Main menu as described
in Section 9.2.

4. Select VERIFY using the scroll up and scroll down buttons.

Gas Calibration Procedures

Refer to Figure 9-1.

5. Press the SEL button.

The Verify gas screen (Figure 9-2) opens.

CT5100 Verify gas screenFigure 9-2:

A. BACK button
B. SEL (select) button
C. Scroll up button
D. HELP button
E. Gas type
F. Scroll down button

6. Use the scroll up (C) and scroll down (F) buttons to move the cursor until the gas
that you wish to zero calibrate is selected. Press the SELECT button (B).

The Verify type screen (Figure 9-3) opens.

Operations Manual 47

Gas Calibration Procedures

7. Refer to Figure 9-3. Use the scroll up (C) and scroll down (E) buttons to move the

Verify type screenFigure 9-3:

A. BACK button
B. SEL (select) button
C. Scroll up button
D. Calibration options
E. Scroll down button

cursor until the ZERO calibration option is selected, as shown in Figure 9-3. Press the
SELECT button (B).

The Verify zero screen shown in Figure 9-4 opens.

Verify zero screenFigure 9-4:

A. BACK button
B. GO button
C. HELP button
D. CANCEL button

8. Flow the zero gas at a pressure of +.05 Bar Gauge from the nitrogen cylinder into the
CT5100 Continuous Gas Analyzer.

9. Refer to Figure 9-4. To proceed with the zero calibration, press the GO button (B).

48 Rosemount CT5100

Gas Calibration Procedures

NOTICE

To halt the zero calibration and return to the Main menu (Figure 9-1), press the CANCEL
button (D).

10. Allow the concentrations to stabilize and wait for two minutes after stabilization.

When the two minutes have elapsed, observe the display controller. It displays a
Verify zero measurement screen similar to that shown in Figure 9-5. This screen gives
a reading (C) of the concentration of the selected gas that is present as an impurity
in the nitrogen calibration gas as measured by the instrument. In the example
shown in Figure 9-5, the gas being measured is N2O (nitrous oxide), and the
instrument has detected a concentration of 0.411 ppm.

Verify zero measurement screenFigure 9-5:

A. BACK button
B. DONE button
C. Gas measurement
D. HELP button
E. CAL (Calibrate) button
F. RES (Reset) button

11. If the reading is within tolerance, no further action is required. Press the DONE
button (B) to end the zero calibration process.

The display controller proceeds to the calibration/verification complete screen.
Refer to Figure 9-7.

Operations Manual 49

Gas Calibration Procedures

12. If the reading is outside tolerance, press the RES (Reset) button (F).

Verify zero confirmation screenFigure 9-6:

A. BACK button
B. OK button
C. HELP button
D. CANCEL button

The CT5100 CGA returns to its factory set calibration.

13. Repeat steps 3-11 of this procedure to check that the CT5100 CGA is within
tolerance.

14. If the reading is within tolerance, no further action is required. Press the DONE
button (B) to end the zero calibration process.

The display controller proceeds to the calibration/verification complete screen.
Refer to Figure 9-7.

15. If the calibration of the CT5100 CGA remains outside of tolerance, press the CAL
button (E) to adjust the calibration.

This brings up the confirmation screen, an example of which is shown in Figure 9-6.

50 Rosemount CT5100

Gas Calibration Procedures

Calibration/verification complete screenFigure 9-7:

A. GAS button
B. DONEbutton
C. HELP button
D. TYPE button

16. Refer to Figure 9-7. To proceed with the automatic re-calibration, press the OK
button (B).

To halt the calibration and return to the Main menu (Figure 9-1), press the CANCEL
button (D).

When the calibration or verification is complete, the screen shown in Figure 9-7 is
displayed.

17. Refer to Figure 9-8. If you wish to perform a Span calibration on the same gas, press
the TYPE button (D).

The software proceeds to the Verify type screen. Refer to Figure 9-8.

Verify type screenFigure 9-8:

A. BACK button
B. SEL (Select) button
C. Scroll up button
D. Calibration options
E. Scroll down button

Operations Manual 51

Gas Calibration Procedures

18. If you wish to perform a zero calibration for another gas, press the BACK button (A).

The software returns to the Verify gas screen (Figure 9-2).

19. Repeat steps 7 - 17 for the next gas.

20. If you are finished calibrating the CT5100 CGA, press the DONE button.

The software returns to the Main menu shown in Figure 9-1.

The zero calibration procedure is now complete.

9.4 Span gas calibration

The span gas concentrations measured by the CT5100 CGA when reference gas is flowing
can be verified and, if necessary, calibrated against the known reference gas by using the
following procedure.

Run the CT5100 CGA at a stable temperature for at least thirty minutes prior to
commencing this procedure.

1. Use a certified reference gas cylinder as the source of the span calibration gas.

2. Make sure that a pressure regulator is connected to the reference gas bottle.

3. Connect a hose from the reference gas bottle, through a T-piece, to the sample
supply port on the rear panel of the CT5100 CGA. Connect an excess flow line to the
unused port on the T-piece and route the excess flow line to a suitable extractor.

4. On the display controller of the CT5100 CGA, browse to the Main menu as described
in Section 9.2.

5. Refer to Figure 9-1. Select VERIFY using the scroll up (D) and scroll down (G) buttons.

6. Press the SEL button.

The Verify gas screen (Figure 9-9) opens.

52 Rosemount CT5100

Verify gas screenFigure 9-9:

A. BACK button
B. SEL (Select) button
C. Scroll up button
D. HELP button
E. Gas type
F. Scroll down button

Gas Calibration Procedures

7. Use the scroll up (C) and scroll down (F) buttons to move the cursor until the gas
that you wish to span calibrate is highlighted by the cursor. Press the SEL button (B).

The Verify type screen (Figure 9-10) opens.

Verify type screenFigure 9-10:

A. BACK button
B. SELECT button
C. Scroll up button
D. Calibration options
E. Scroll down button

8. Refer to Figure 9-10. Use the scroll up (C) and scroll down (E) buttons to move the
cursor until the SPAN calibration option is selected as shown in Figure 9-10.

The Span cylinder entry screen shown in Figure 9-11 opens.

Operations Manual 53

Gas Calibration Procedures

Span cylinder entry screenFigure 9-11:

A. BACK button
B. OK button
C. RIGHT button
D. DOWN button
E. Reference gas concentration
F. Cursor
G. UP button
H. LEFT button

9. Refer to Figure 9-11. Enter the gas concentration of the cylinder reference gas (E)
into the CT5100 CGA.

Initially, the default value 00000.000 appears on the screen.

10. Use the LEFT (H) and RIGHT (C) buttons to move the cursor (F) along the number to
select and highlight digits that need to be changed. For each digit that needs to be
changed, use the UP (G) and DOWN (D) buttons to respectively increase or decrease
the highlighted digit. Continue until the number on the screen is identical to the gas
concentration of the reference gas cylinder.

11. When the number on the screen is identical to the gas concentration of the
reference gas cylinder, press the OK button (B).

The Verify Span screen (Figure 9-12) appears.

54 Rosemount CT5100

Gas Calibration Procedures

Verify span screenFigure 9-12:

A. BACK button
B. GO button
C. HELP button
D. CANCEL button

12. Flow the reference gas, at a pressure of +.05 Bar Gauge, from the reference gas
cylinder into the CT5100 CGA.

13. Refer to Figure 9-12. To proceed with the verification/calibration, press the GO
button (B).

NOTICE

To halt the calibration and return to the Main menu, press the CANCEL button (D).

14. Allow the concentrations to stabilize and wait for two minutes after stabilization.

15. When the two minutes have elapsed, observe the display controller.

It displays a Verify span measurement screen similar to that shown in Figure 9-13. This
screen gives the actual concentration of the gas present as an impurity in the
reference gas cylinder (B), as manually entered in Step 9. The screen also displays
the gas concentration (G) as measured by the instrument and the percentage
difference (E) between the actual and measured concentrations.

Operations Manual 55

Gas Calibration Procedures

Verify span measurement screenFigure 9-13:

A. BACK button
B. Reference gas concentration
C. DONE button
D. HELP button
E. Difference between actual and measured concentrations
F. CAL (Calibrate) button
G. Measured gas concentration
H. RES (Reset) button

16. If the reading is within tolerance, no further action is required. Press the DONE
button (C) to end the span verification/calibration process.

The display controller proceeds to the Calibration/verification complete screen (refer
to Figure 9-14 and Step 20).

56 Rosemount CT5100

Gas Calibration Procedures

Calibration/verification complete screenFigure 9-14:

A. GAS button
B. DONE button
C. HELP button
D. TYPE button

17. If the reading is outside tolerance, press the RES (Reset) button (H).

The CT5100 CGA returns to its factory-set calibration.

18. Repeat steps 4-16 of this span calibration procedure to check that the CT5100 CGA
is within tolerance.

19. If the calibration of the CT5100 CGA remains outside of tolerance, the calibration
can be adjusted by pressing the CAL button (F).

This brings up a confirmation screen, an example of which is shown in Figure 9-15.

Span Calibrate screenFigure 9-15:

A. BACK button
B. OK button
C. HELP button
D. CANCEL button

20. Refer to Figure 9-15. To proceed with the automatic re-calibration, press the OK
button (B).

Operations Manual 57

Gas Calibration Procedures

21. Refer to Figure 9-14. If you wish to perform a zero calibration on the same gas, press

22. If you wish to perform a span calibration for another gas, press the GAS button (A).

23. If you are finished calibrating the CT5100 CGA, press the DONE button.

The automatic re-calibration of the instrument's span calibration starts, and the
offset shown on the screen is applied to the instrument. To halt the calibration and
return to the Main menu (Figure 9-1), press the CANCEL button (D).

When the calibration or verification is complete, the screen shown in Figure 9-14 is
displayed.

the TYPE button (D).

The software returns to the Verify type screen. Refer to Figure 9-10, Figure 9-11, and
steps 9 onwards.

The software returns to the Verify gas screen (Figure 9-9). Repeat steps 9-20 for the
next gas.

The software returns to the Main menu shown in Figure 9-1.

The span verification/calibration procedure is now complete.

58 Rosemount CT5100

10 Preventative Maintenance

Topics covered in this chapter:

• Maintenance

• Schedule

10.1 Maintenance

This section describes the preventative maintenance for the CT5100 CGA.

10.2 Schedule

This schedule lists the tasks required by the CT5100 CGA and the recommended
frequency. Variation in customer sites may require these activities to be performed more
or less often than indicated; however, the time between checks should not be increased by
more than 10%. Details of the tasks to be performed are contained in Table 10-1.

Preventative Maintenance

Scheduled checksTable 10-1:

Frequency Action

Monthly 1. Check the zero and span calibration of the CT5100 CGA.

2. Perform the calibration more frequently if necessary to meet quality
control or plant operation requirements.

Every three months 1. Perform the monthly check detailed in the previous row.

2. Purge the long path cell mirrors (as described in the Maintenance
Manual).

3. Check the X-Shift calibration of the lasers. Contact your local service
representative for guidance.

Annually 1. Perform the three-monthly check detailed in the previous row.

2. Perform a laser wavelength calibration. Contact your local service
representative for guidance.

Operations Manual 59

Preventative Maintenance

60 Rosemount CT5100

Preventative Maintenance

Operations Manual 61

D-7010-0046

Rev A

2016

Cascade Technologies

Emerson Process Management
Glendevon House
Castle Business Park
Stirling, FK9 4TZ
T [phone]
F [phone]

[e-mail]

©

2016 Rosemount. All rights reserved.

The Emerson logo is a trademark and service mark of Emerson
Electric Co. Rosemount is a mark of one of the Emerson Process
Management family of companies. All other marks are the property
of their respective owners.