Rosemount CT4400 Gas Analyzer Installation, Operation, and Maintenance Manual Manuals & Guides
Rosemount™ CT4400
Continuous Gas Analyzer
Reference Manual
00809-0100-4244, Rev AA
January 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 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 00809-0100-4244 Rev AA, January 2020.
©
Emerson 2020. 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.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.
Important instructions
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 instruction manuals shipped with the analyzer.
The following instruction manual(s) are available and/or referenced within this manual:
• Rosemount CT4400 Quick Start Guide
All instructions must be saved for future use. Contact your local service center or sales office if you are missing documents.
User information
Important
All users must read this page before proceeding!
Rosemount designs, manufactures, and tests its products to meet many national and international standards. The Rosemount
CT4400 is a sophisticated technical product, and to ensure it continues to operate as designed and within normal specifications, it
MUST be installed, used, and maintained correctly. The following instructions MUST be adhered to and integrated into your safety
program when installing, using, and maintaining Rosemount products.
• Failure to follow the proper instructions may cause:
— Loss of life.
— Personal injury
— Damage to property
— Damage to the analyzer
— Warranty invalidation
• Read all instructions prior to installing, operating, and servicing the analyzer.
• If you do not understand any of the instructions, contact your Rosemount Customer Care Representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the analyzer.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the analyzer.
• Install the analyzer as specified in the Installation Instructions of the manual and in accordance with all applicable local and
national codes.
• Connect the analyzer to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the analyzer.
• When replacement parts are required, ensure that only qualified people install replacement parts specified by Rosemount.
• Unauthorized parts and procedures can affect the analyzer’s performance, placing the safe operation of your process at risk,
and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
2
• To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except
when maintenance is being performed by qualified personnel.
• The information contained in this document is subject to change without notice.
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 to the emission of
gases hazardous to health when all gas connections have been made correctly.
To avoid exposure to the dangers, care must be taken when installing, operating, maintaining, and servicing the analyzer.
Authorized personnel
NOTICE
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 and qualified with the operating company and the
manufacturer. 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
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 instruction manual and receiving appropriate training.
Regulations and standards
Regulations / Standards
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 - CFR - Code of Federal Regulations Title 21 part
NEC® 505 National Electrical Code (issued by ANSI: American National
BS EN 61326-1: 2013
EN 61326-1: 2013
IEC/EN 60825-1: 2014 Safety of laser products part 1, equipment classification and
BS EN 61010-1 2010 IEC 61010-1 2010 Safety requirements for electrical equipment for measurements,
N/A Electrical equipment for measurement, control, and laboratory use.
Description
1040.1
Standards Institute and NFPA 70: National Fire Protection
Association)
Electrical equipment for measurement, control, and laboratory use
- EMC requirements. General requirements.
requirements.
control, and laboratory use. General requirements.
EMC requirements. General requirements.
3
Associated publications
Quick Start Guide
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 9001:2015.
Emerson and the Rosemount CT4400 Gas Analyzer have satisfied the requirements
for applying the CE marking to the Rosemount CT4400 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
DANGER
WILL 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 serious injury to personnel.
WARNING
SAFETY COMPLIANCE
Repairs or alterations are not permitted on any flame-proof paths, features, or joints.
Failure to follow this warning may compromise the product’s safety protection method and void the product certification.
NOTICE
Important messages will appear in this format.
Safety information
All authorized users, including installation, operation, and maintenance personnel, MUST observe the following safety
precautions and warnings.
DANGER
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power ON/OFF switch at the rear of the
panel is set to OFF and the power cable plug is removed BEFORE removing the top cover.
THE ANALYZER MUST BE EARTHED USING A GROUNDED THREE CORE CABLE suitable for the rating defined in the General
Characteristics (Table 1-3).
Failure to observe this precaution will cause death, personal injury, and/or damage to persons and/or property.
4
DANGER
FAILURE TO LOCK-OUT THE GAS HANDLING SYSTEM
Always lock out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling system
when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being
released, causing fire or explosion.
Death or personal injury may result if this is not observed.
DANGER
FAILURE TO VENT SAMPLE GAS.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during startup.
The sample gas in the pipes leading to the analyzer 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 analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING
LASER OPTICAL RADIATION EXPOSURE HAZARD
The Rosemount CT4400 is a Class 1 laser product. The lasers are fully enclosed so that no hazardous radiation is accessible under
normal operating conditions.
Opening the analyzer and attempting to perform adjustments or procedures other than those specified in this manual may
result in hazardous optical radiation exposure to personnel.
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 in accordance with applicable local, national, or international health and
safety regulations and pollution regulations.
5
WARNING
HAZARDOUS GAS
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 operates 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 when shutting down the analyzer.
WARNING
EXPLOSION HAZARD
Always lock-out/tag-out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling
system when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas
being released, causing fire or explosion.
Failure to observe this precaution will cause death, personal injury, and/or damage to persons.
WARNING
EXPLOSION HAZARD
The sample gas in the system must be vented to prevent fire or explosion during maintenance or during startup.
The sample gas in the pipes leading to the analyzer 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 analyzer and the venting system to run for a minimum of five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack system. Rosemount recommends that
the analyzer is moved by a minimum of two people when lifting and transporting the equipment.
Failure to properly handle the analyzer may cause injury to personnel, wear suitable protective gloves and protective footwear.
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.
6
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 measurements are out of tolerance, refer to Troubleshooting and diagnostics for guidance.
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
EQUIPMENT DAMAGE
Ensure that the local power voltage where the unit is to be installed corresponds to the unit's nominal voltage as given on the
name plate label.
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, it is important to ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the analyzer.
Safety and system labels and annotation
Safety Labels
The labels and annotation applied to the analyzer are specified in the table.
7
Label type Example Location
Identification label (including
the Serial No. (S/N) Model,
Config No. and Date of
Manufacture (DoM).
Fitted on the rear panel
Identification ratings label for
the Half Rack System.
Identification ratings label
for the Full Rack System.
Earth identification label. Backplate
Fitted on the rear panel of the
unit
Fitted on the rear panel of the
unit
8
Label type Example Location
CAUTION Laser Radiation
Rear panel
safety statement
AC power supply voltage label Fitted on inside rear panel
next to power input socket.
Abbreviations
The following symbols and abbreviations are used in this manual.
Abbreviation Description
©
Copyright
% Percent
° Degree
AC Alternating current
BS British Standard
C Celsius
CE European Conformity
CFR Code of Federal Regulations
e.g. For example
EC European Community
EMC Electromagnetic compatibility
EU European Union
Hz Hertz
H2O Water
IEC International Electro-technical Commission
in. Inches
IP Internet Protocol
ISO International Organization for Standardization
k Thousand
kg Kilogram
L Liter
lb. Pounds
LCD Liquid crystal display
m Meter
mA Milliamp
9
Abbreviation Description
Max Maximum
mg Milligram
3
mg/m
Milligram/cubicmeter
Mid IR Mid Infrared
Min Minimum
mm Millimeter
NEC National Electrical Code
NFPA National Fire Protection Association
3
NH
Ammonia
nm Nanometer
NO Nitricoxide
N2O Nitrousoxide
No. Number
O
2
Oxygen
PC Personal computer
ppm Parts per million
QCL Quantum Cascade Laser
SELV Safety Extra Low Voltage (SELV) circuits.
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
10
Reference Manual Contents
00809-0100-4244 January 2020
Contents
Chapter 1 Plan............................................................................................................................. 13
1.1 Description.....................................................................................................................................13
1.2 Equipment purpose and role.......................................................................................................... 13
1.3 System overview............................................................................................................................ 15
1.4 Customer information....................................................................................................................16
1.5 Safety precautions and conditions for safe use............................................................................... 17
1.6 Qualified personnel........................................................................................................................ 17
1.7 Software version.............................................................................................................................17
1.8 Detailed system specifications........................................................................................................18
1.9 Unpacking the analyzer.................................................................................................................. 21
Chapter 2 Install...........................................................................................................................23
2.1 Site selection and rack mounting....................................................................................................23
2.2 Gas inputs and outputs...................................................................................................................25
2.3 Connecting the electrical/electronic inputs and outputs.................................................................26
Chapter 3 Start-up procedure.......................................................................................................29
3.1 Introduction................................................................................................................................... 29
3.2 Preparation for use......................................................................................................................... 29
3.3 Start-up procedure......................................................................................................................... 30
Chapter 4 Operating the analyzer.................................................................................................33
4.1 Introduction................................................................................................................................... 33
4.2 Normal operation........................................................................................................................... 33
4.3 Display controller........................................................................................................................... 35
4.4 Gas sensor main screen.................................................................................................................. 36
4.5 Pressure and temperature screen................................................................................................... 37
4.6 Help system....................................................................................................................................38
4.7 Main menu..................................................................................................................................... 38
4.8 BACK button...................................................................................................................................39
Chapter 5 Verifying gas concentrations........................................................................................41
5.1 Verification.....................................................................................................................................41
Chapter 6 Gas calibration............................................................................................................. 49
6.1 Required tools................................................................................................................................ 49
6.2 Gas service menu definitions.......................................................................................................... 49
6.3 Calibration......................................................................................................................................50
6.4 Reference gas - suggested concentration ranges............................................................................63
Chapter 7 Troubleshooting and diagnostics................................................................................. 65
7.1 Troubleshooting, repairs, and failure diagnostics............................................................................65
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January 2020 00809-0100-4244
7.2 Using the Built-In-Self Test (BIST) fault diagnostics......................................................................... 67
7.3 Configuring the 4-20mA outputs....................................................................................................73
7.4 Visual examination......................................................................................................................... 78
7.5 Failure diagnostics..........................................................................................................................78
7.6 Replacing the power socket fuses...................................................................................................83
7.7 Cleaning the analysis cell mirrors....................................................................................................85
Chapter 8 Shutdown procedure................................................................................................... 91
Chapter 9 Preventative maintenance........................................................................................... 97
Chapter 10 Recommended spare parts...........................................................................................99
Appendix A Engineering drawings................................................................................................ 101
xii Rosemount CT4400
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1 Plan
1.1 Description
The Rosemount CT4400 Continuous Gas Analyzer, referred to hereafter as Rosemount
CT4400 is a multi-component Quantum Cascade™ Laser (QCL)/Tuned Diode Laser (TDL)
analyzer designed for applications where processing gas streams is required.
Optimized for cold/dry applications running at ambient pressure with low maintenance,
low cost of ownership, and easy integration, it can hold up to five laser modules and
measure up to six components simultaneously with enhanced dynamic range from sub
parts per million (sub ppm) to percentage levels in a process gas stream.
The analyzer is designed to be mounted in a standard 19 in. (482.6 mm) rack width as
either a half rack or full rack system depending on the gas analysis configuration required.
WARNING
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and
transporting to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack
system. Rosemount recommends that the analyzer is moved by a minimum of two people
when lifting and transporting the equipment.
Failure to properly handle the analyzer may cause injury to personnel, wear suitable
protective gloves and protective footwear.
1.2 Equipment purpose and role
The analyzer is a multi-component QCL/TDL gas analysis system that can be configured to
measure concentrations of multiple small molecules in a gas sample that is provided to
the analyzer through a customer installed gas sample line.
The types of molecules that are measured depend on the system configuration.
Reference Manual 13
Plan Reference Manual
January 2020 00809-0100-4244
Figure 1-1: Rosemount CT4400 Half Rack System
Figure 1-2: Rosemount CT4400 Full Rack System
The analyzer can be configured to detect and measure up to six different gases
simultaneously.
14 Rosemount CT4400
Reference Manual
00809-0100-4244 January 2020
Plan
1.3 System overview
A complete Rosemount CT4400 system consists of the analyzer, and the associated
interconnecting wiring and gas piping.
Measurement data from the analyzer can be displayed in the process control center. You
must provide a stable gas handling system and interconnecting wiring and gas piping;
Rosemount will supply the analyzer.
In Figure 1-3, the items supplied by Rosemount are colored orange; the items supplied by
the Customer are colored blue. Table 1-1 lists the main items of the system.
Figure 1-3: Complete Rosemount CT4400 Gas Analysis System
A. Gas handling system
B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT4400 Gas Analyzer
E. Electrical power
F. Measurement data
G. Control center
The analyzer contains an optical system with a laser, components that provide an optical
path, sample inlet/outlet ports that can be connected to a customer provided gas
handling system and control/analysis electronics. The complete system operates from
either a 110 Vac 60Hz or a 230 Vac 50Hz supply.
Gas concentrations are measured using mid-infrared optical absorption spectroscopy. The
light source is provided by a quantum cascade laser or tuned diode laser, which produces
wavelength sweeps that cover the absorption lines of the gases. The light from the laser is
routed through an optical path to the analysis cell, which provides measurement of low
concentrations of the sample gas. An external sample handling system conditions the
sample gas and draws it through the analysis cell. The laser light exiting the multi-pass
analysis cell is directed to a receiver in the analyzer. The variation in the intensity of the
light in the vicinity of the absorption lines is measured, and the concentration is
determined using a spectral fitting routine.
There is no sample conditioning provided within the analyzer; this is the responsibility of
the Customer. The sample gas must be conditioned as detailed in Sample gas conditioning
requirements before entering the analyzer. Detailed characteristics of the analyzer are
given in Detailed system specifications.
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January 2020 00809-0100-4244
Table 1-1: Main Items of the Rosemount CT4400 System
Item Name or description Supplied by Part number Quantity Notes
1 Rosemount CT4400 Rosemount CT4400 1 N/A
2 Rosemount CT4400
software package,
version 5.7.8.0
minimum
3 Gas handling system Customer Customer
4 Exhaust line hose (for
sample gas)
5 Reference gas
cylinders (instrument
gas) for calibration
purposes
6 Pressure regulator Customer Customer
7 Pneumatic T-piece Customer Customer
8 Excess flow line Customer Customer
9 110/230 Vac
power cable
10 Cable from analyzer to
control center
Rosemount N/A 1 Software is embedded on
choice
Customer Customer
choice
Customer Customer
choice
choice
choice
choice
Rosemount Customer
choice
Customer Customer
choice
the PC board.
Version described in the
manual
1 Selected to provide steady
state conditions
1 N/A
Dependent
upon number
of gases
being
measured
1 per gas
cylinder
2 Required for calibration
1 Required for calibration
1 3 core cable MUST be
1 N/A
N/A
Required for calibration
earthed
11 482.6 mm (19 in.) rack
system
Customer Customer
choice
1 Holds the Rosemount
CT4400
1.4 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 analyzer.
For information regarding installation, consult Install and the Quick Start Guide.
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, this document reflects the supplied analyzer 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, you can request additional help from Cascade Technical Support
(cascade.support@emerson.com) or Emerson distribution partners. Further contact
details for Emerson can be found on the back page of this manual.
16 Rosemount CT4400
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1.5 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 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 analyzer are Class 1. The lasers are fully enclosed so that no
hazardous radiation is accessible under normal operating conditions. Opening the
analyzer and attempting to perform adjustments or procedures other than those specified
in this manual may result in hazardous optical radiation exposure to personnel.
The analyzer has warning labels at appropriate positions in accordance with USA 21 CFR
1040.10.
1.6 Qualified personnel
This manual provides installation, operation, and maintenance personnel with the level of
knowledge required to safely start, operate, and switch off the analyzer.
Only technically qualified personnel in the field of analysis and control who are familiar
with this manual and have been specially trained on the analyzer should install, operate,
switch off, and service the analyzer. 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 installation, operation, and maintenance
of the analyzer.
1.7 Software version
The analyzer includes software that is used to control the operation of the analyzer. This
manual describes the software version as: 5.7.8.0 minimum.
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1.8 Detailed system specifications
Table 1-2 gives the physical characteristics of the analyzer. Schematic diagrams of the
analyzers are shown in Figure 1-4 and Figure 1-5 with mounting points in Figure 2-1 and
Figure 2-2. General and environmental characteristics for the analyzer are provided in
Table 1-3 and Table 1-4.
Table 1-2: Physical Characteristics
Rosemount™ CT4400
External dimensions
(Half Rack)
Weight (Half Rack) 15
External dimensions
(Full Rack)
Weight (Full Rack) 30
Value
623 x 215 x 172
24.5 x 8.5 x 6.8
33
658 x 483 x 172
25.9 x 19 x 6.8
66
Units Comment
mm
in.
kg
lb
mm
in.
Kg
lb
Length x width x height
Nominal dimensions
Approximate weight
Length x width x height
Nominal dimensions
Approximate weight
Table 1-3: General Characteristics
Rosemount CT4400 Value Units Comment
Supply voltage 110/230 ± 10% Vac N/A
Supply Frequency 60/50 ± 5% Hz N/A
Peak power consumption 50 W Max. consumption
Frame and structure material N/A N/A Anodized and powder coated aluminum
Housing material N/A N/A Powder coated steel
Wetted materials N/A N/A PF Acoated aluminum, 316 stainless
steel, FKM and FFKM seals, CaF2 and
BaF2 windows, protected gold coated
aluminum mirrors
Measurement technique N/A N/A Mid IR absorption spectroscopy
Mid IR source N/A N/A Quantum Cascade™ Laser
Product Laser classification Class 1 N/A BSEN 60825-1: 2014 safety of laser
products. Equipment classification and
requirements (identical to IEC 60825-1
2014)
Inletgas port connector 6 or ¼ mm/in. Swagelok® type
Outlet (exhaust) gas
port connector
Measurement result signals 4 to 20 mA 4 or 8 channel outputs
Warm-uptime 30 minutes
18 Rosemount CT4400
6 or ¼ mm/in. Swagelok type
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00809-0100-4244 January 2020
Figure 1-4: Half Rack Dimensions
Figure 1-5: Full Rack Dimensions
Table 1-4: Environmental Characteristics
Environmental characteristic
Operating temperature range 5 ℃ to 50 ℃
Sample gas temperature range 15 ℃ to 50 ℃
Sample gas Pressure 0 - 1 atm (abs) Typically 1 atm (abs)
Sample gas flow rate 1 - 5 L/min N/A
Sample gas moisture content 2 % Ensure the dew point of the
Sample gas particulate density 5 mg/m
Sample gas particulate size 10 µm Maximum
Maximum operating altitude 2000 m N/A
Maximum relative humidity 80 @ 31 ℃ % Decreasing linearly to 50 %
Value Units Comment
41 ℉ to 122 ℉
59 ℉ to 122 ℉
℃
℉
℃
℉
3
Ambient temperature
N/A
gas is at minimum 18 ℉ (10
℃) below the ambient
temperature to avoid
condensate in the gas lines
Maximum
relative humidity at 104 ℉
(40 ℃)
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January 2020 00809-0100-4244
Table 1-4: Environmental Characteristics (continued)
Reference Manual
Environmental characteristic
Overvoltage category II N/A Numeral defining a transient
Pollution degree 2 N/A Numeral indicating the level
Note
The Rosemount CT4400 Continuous Gas Analyzer is suitable for indoor use only.
1.8.1
Sample gas conditioning requirements
The sample gas temperature in Table 1-4 indicates the temperature range that the
analyzer can operate within.
Value Units Comment
overvoltage condition.
Overvoltage Category ll is
for equipment intended to
be supplied from the
building wiring.
of pollution that may be
present in the environment.
Pollution degree 2: only
non-conductive pollution
occurs except that
occasionally a temporary
conductivity caused by
condensation is expected.
1.8.2
The sample gas pressure in Table 1-4 shows the pressure range that the analyzer can
operate within. The sample gas pressure
ensure steady state conditions are being analyzed at all times. Sudden fluctuations in
pressure will affect the analysis being performed.
In the event of a power failure any residual sample gas should be purged from the analyzer
to ensure any corrosive gas elements are not left to contaminate/degrade the internal
components. Failure to do so could result in irreparable damage to the analyzer.
Sample filtration may be required to ensure the gas sample particulate size and density
does not exceed the requirements in Table 1-4.
MUST
not fluctuate more than -10 percent to
Optical description
The laser module is located in the core of the analyzer and the laser light beam passes
through the sample cell. The sample cell contains a set of mirrors to create a path through
the sample gas that is between 6.56 ft. (2 m) and 16.4 ft. (5 m) through multiple
reflections of the laser beam in the cell. The laser beam exits the cell at the opposite end
from where they entered and are directed using an optical block to a receiver.
By measuring and analyzing the light detected by the receiver unit, it is possible to
accurately determine the concentration of the target molecules within the gas sample.
20 Rosemount CT4400
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1.9 Unpacking the analyzer
WARNING
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and
transporting to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack
system. Rosemount recommends that the analyzer is moved by a minimum of two people
when lifting and transporting the equipment.
Failure to properly handle the analyzer may cause injury to personnel, wear suitable
protective gloves and protective footwear.
Procedure
1. Visually inspect the packaging to ensure there has been no damage in transit or
storage.
2. Open the packaging and visually inspect the exterior of the analyzer for signs of
damage, corrosion, gas leaks, or signs of previous overheating if returning from
storage.
3. Report anything found to the maintenance organization.
4. Carefully lift the analyzer from the shipping container (handles are provided on the
full rack system to aid this process).
5. Place the analyzer on a flat, stable surface that can accommodate the weight (up to
66 lb [30 kg]). This step requires two people to lift and transport the analyzer.
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Reference Manual
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Figure 1-6: Half Rack Front and Rear Views
A. Front panel
B. Display screen
C. User interface
D. Rear panel
E. Ethernet connection
F. Sample gas outlet
G. Sample gas inlet
H. Analog output (4-20 mA)
I. Mains power inlet
Figure 1-7: Full Rack Front and Rear Views
A. Front panel
B. Display screen
C. User interface
D. Rear panel
E. Ethernet connection
F. Sample gas outlet
G. Sample gas inlet
H. Analog output (4-20 mA)
I. Mains power inlet
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Install
2 Install
2.1 Site selection and rack mounting
WARNING
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and
transporting to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack
system. Rosemount recommends that the analyzer is moved by a minimum of two people
when lifting and transporting the equipment.
Failure to properly handle the analyzer may cause injury to personnel, wear suitable
protective gloves and protective footwear.
Procedure
1. The analyzer MUST be installed in an enclosed environment that is protected from
the elements, humidity, and temperature variations for optimum performance.
2. Site selection for analyzer installation MUST account for the handles on the front
face of the full rack system and rear entry for the cable and tube connections (see
Figure 2-1 and Figure 2-2).
3. Screw in rubber feet have been fitted to the base of the analyzer – if required these
can be removed to aid assembly into the rack system being provided.
4. The full rack system has additional slotted holes on the front face for securing the
analyzer to the rack system (see Figure 2-2).
5. The minimum tubing and cabling allowance defined in Figure 2-1 and Figure 2-2 at
the rear of the analyzer MUST be accounted for when installing the rack system.
Figure 2-1: Half Rack Installation Requirements
A. Four off M4 mounting holes for customer supplied mounting ears (if required)
B. Three off M4 mounting holes for customer supplied rail (if required)
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Install Reference Manual
January 2020 00809-0100-4244
Figure 2-2: Full Rack Installation Requirements
A. Four off ⌀5.5mm mounting slots
B. Four off M4 mounting holes for customer supplied mounting ears (if required)
C. Three off M4 mounting holes for customer supplied rail (if required)
6. If rigid tubing is being connected to the analyzer further clearance will be required
to allow full access to the connections for installation and maintenance.
7. With rigid tubing fitted the analyzer will not be capable of being slid out of the rack
on the slides.
8. Install the analyzer in a standard 19 in. (482.6 mm) rack system.
Note
Supply of the rack, telescopic slide rails, fitting and securing the analyzer into the
rack is the responsibility of the Customer. (Typical requirement - 2 off telescopic
slides, 24 in. (610 mm) long, 121.3 lb (55 kg) maximum load 2 in. (50.8 mm) over
travel 4 in. (9.6 mm) slide thickness Lock-out Front disconnect.).
9. Installation of telescopic slides on the analyzer will be in accordance with the
manufacturer’s procedure the locations for the slide fixing points are provided in
Figure 2-1 and Figure 2-2.
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Figure 2-3: Analyzer With Telescopic Slides
10. Due to the weight, care MUST be taken when installing the analyzer in the rack.
2.2 Gas inputs and outputs
The analyzer has provision for gas input and gas output, both of which are located on the
rear panel of the analyzer (Figure 2-4).
WARNING
HAZARDOUS GAS
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.
Procedure
1. The sample supply line provided by the Customer must provide gas at a constant
temperature to the sample gas input port on the analyzer to prevent condensation
forming at any point in the sample supply line within the analyzer, which could
reduce the accuracy of the gas analysis.
2. The gas sample enters the analyzer through the sample gas input port
(C) Figure 2-4.
3. Once the gas sample passes through the measurement cell and it is expelled from
the analyzer through the sample gas return port (B) Figure 2-4.
4. The Customer is responsible for ensuring that all expelled gases are disposed of in
accordance with all local and national regulations.
5. Connections for the full rack system where a single gas sample inlet requiring dual
cell analysis or two gas samples requiring separate analysis are shown in Figure 2-4.
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Install Reference Manual
January 2020 00809-0100-4244
Figure 2-4: Gas Inlet and Outlet Connections
A. Rear panel
B. Sample gas outlet
C. Sample gas inlet
2.3 Connecting the electrical/electronic inputs and outputs
This section discusses making the electrical connections to the analyzer.
DANGER
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the
power ON/OFF switch at the rear of the panel is set to OFF and the power cable plug is
removed.
The analyzer MUST be earthed using a grounded three core cable suitable for the rating
defined in the General Characteristics (Table 1-3).
Death or personal injury may result if this is not observed.
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Figure 2-5: Electrical/Electronic Inputs and Outputs
A. Rear panel
B. Ethernet connection
C. D sub connector type - 25 way
D. Mains power inlet
Procedure
1. Make electrical/electronic signal connections to the analyzer through connectors
located on the analyzer's rear panel (see Figure 2-5).
2. Use the wiring diagram to make the electrical connections as shown in Table 2-1,
Table 2-2, and Engineering drawings.
3. Power to the analyzer is connected through the Mains Power Inlet (Figure 2-5, D)
using the cable provided.
4. The Ethernet connector (Figure 2-5, B) provides an Ethernet output from the
analyzer that may be used for downloading data for failure diagnosis purposes.
5. The results of the gas analysis are output from the analyzer through the Analog
Output connection (Figure 2-5, C) and sent to your process control center.
Table 2-1: Analog Outputs Half Rack System, 25 Way Socket
Pins Function Measurement (point
of display)
1 & 14 Analog channel 0, set in config file (4-20 mA, SELV) Sample gas
measurement 1
2 & 15 Analog channel 1, set in config file (4-20 mA , SELV) Sample gas
measurement 2
3 & 16 Analog channel 2, set in config file (4-20 mA, SELV) Sample gas
measurement 3
4 & 17 Analog channel 3, set in config file (4-20 mA, SELV) Sample gas
measurement 4
9 & 22 Status output 1 (check function), optional (dry contacts: 1A, 30 Vdc) N/A
10 & 23 Status output 2 (maintenance required), optional (dry contacts: 1A,
30 Vdc)
11 & 24 Status output 3 (out of specification), optional (dry contacts: 1A, 30
Vdc)
12 & 25 Status output 4 (failed), optional (dry contacts: 1A, 30 Vdc) N/A
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N/A
N/A
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January 2020 00809-0100-4244
Figure 2-6: Analog Connector 25-Way Socket
Table 2-2: Analog Outputs Full Rack System, 25-Way Socket
Pins Function Measurement
(position on display)
1 & 14 Analog channel 0, set in config file (4-20 mA, SELV) Sample gas
measurement 1
2 & 15 Analog channel 1, set in config file (4-20 mA, SELV) Sample gas
measurement 2
3 & 16 Analog channel 2, set in config file (4-20 mA, SELV) Sample gas
measurement 3
4 & 17 Analog channel 3, set in config file (4-20 mA, SELV) Sample gas
measurement 4
5 & 18 Analog channel 4, set in config file (4-20 mA, SELV) Sample gas
measurement 5
6 &.19 Analog channel 5, set in config file (4-20 mA, SELV) Sample gas
measurement 6
7 & 20 Analog channel 6, set in config file (4-20 mA, SELV) Sample gas
measurement 7
8 & 21 Analog channel 7, set in config file (dry contacts: 1A, 30 Vdc) Sample gas
measurement 8
9 & 22 Status output 1 (check function), optional (dry contacts: 1A, 30
Vdc)
10 & 23 Status output 2 (maintenance required), optional (dry contacts:
1A, 30 Vdc)
11 & 24 Status output 3 (out of specification), optional (dry contacts: 1A,
30 Vdc)
12 & 25 Status output 4 (failed), optional (dry contacts: 1A, 30 Vdc) N/A
N/A
N/A
N/A
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Reference Manual Start-up procedure
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3 Start-up procedure
3.1 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.
3.2 Preparation for use
The analyzer must be installed and fully commissioned prior to startup.
DANGER
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the
power ON/OFF switch at the rear of the panel is set to OFF and the power cable plug is
removed.
The analyzer MUST be earthed using a grounded three core cable suitable for the rating
defined in the General Characteristics (Table 1-3).
Death or personal injury may result if this is not observed.
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, it is important to ensure that the electrical
power, sample gas handling and any calibration gases that are required are available.
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Start-up procedure Reference Manual
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3.3 Start-up procedure
NOTICE
The gases shown in the screenshots and the measurements may be different from those
shown in your particular analyzer. They indicate the functionality of the software, which is
the same regardless of the gases being measured.
CAUTION
To stop the start-up procedure at any time, set the main circuit breaker to OFF.
To start the analyzer, perform the following steps:
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. Ensure that the analyzer has been correctly installed.
See Install.
3. Ensure that the On/Off switch at the rear of the analyzer is set to I (ON).
Figure 3-1: Rear Panel ON/OFF Switch
A. Rear panel
B. On/Off switch
4. The start-up sequence commences automatically under software control.
5. After a few minutes, the Gas Sensor Main screen (Figure 3-2) appears on the display
controller. If it does not, report the fault to maintenance.
30 Rosemount CT4400
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