Rosemount CT5100 Manuals & Guides

Rosemount™ CT5100

Continuous Gas Analyzer

Reference Manual

00809-0100-4511, Rev AA

May 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: 00809-0100-4511

Rev AA, May 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 [e-mail] or Emerson distribution partners.

Send general inquiries to [e-mail].

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

Preliminary information

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

Important

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

All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain,
and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The
following information is also available and/or referenced in the Rosemount CT5100 Quick Start Guide: 00825-0100-4511.

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

Authorized personnel

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

• Train staff

• Observe safety regulations

• Follow the safety instructions and procedures in the product manual

Operators must:

• Have been trained

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

• Know the safety mechanisms and regulations

WARNING

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

2

Important instructions

Important

All users must read this page before proceeding!

Emerson designs, manufactures and tests its products to meet many national and international standards. The Rosemount
CT5100 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 Emerson products.

• Failure to follow the proper instructions may cause:
— Loss of life

— Personal injury

— Damage to property

— Damage to this analyzer

— Warranty invalidation

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Emerson representative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

• Install your equipment as specified in the installation instructions of the appropriate Reference Manual and in accordance with

applicable local and national codes.

• Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.

• Unauthorized parts and procedures can affect the product’s performance; place the safe operation of your process at risk, and

VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

3

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

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

BS EN 61010-1 2010
IEC 61010-1 2010

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

Associated publications

Rosemount CT5100 Quick Start Guide

Compliance approvals

Important

The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.

This product complies with USA 21 CFR 1040.10.
This product is designed and manufactured under an approved quality management

system to ISO 9001: 2015.

Institute and NFPA 70: National Fire Protection Association)

(identical to IEC 608250-1 2007)

Safety requirements for electrical equipment for measurements,
control, and laboratory use. General requirements

EMC requirements. General requirements

Waste disposal

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

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

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.

4

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 death or serious injury to personnel.

CAUTION

MAY CAUSE DAMAGE TO EQUIPMENT

Failure to follow this warning may result in damage to the equipment.

NOTICE

Important or tip messages will appear in this format.

Safety precautions

Important

The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and
maintenance personnel, must observe the following safety precautions and warnings.
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.

WARNING

ELECTRIC SHOCK

The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Death, personal injury, and/or
damage to persons and/or property may result if this is not observed.

Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the top cover or opening the front
cover. The analyzer must be earthed.

Only trained, qualified personnel may install and connect power and signal cables. The installation/connection must be in
accordance with all legislative requirements and applicable standards.

Only qualified personnel, familiar with potential risks, should install the analyzer.

DANGER

EXPLOSION HAZARD

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

The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during prolonged shutdowns.

The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes and 30 seconds at a minimum
flow rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance.

Purge the sample gas in accordance with the safe working procedures for this site.

5

WARNING

FLAMMABLE SUBSTANCES

Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition source. The interior of a
analyzer is always hot unless it has been switched off and allowed to cool down. A fire may result if this precaution is not observed.

Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.

WARNING

TRANSPORTATION HAZARD

The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/moving equipment.

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

Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard
the analyzer against movement or break-away during transport by securely strapping it in place.

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

WARNING

FIRE AND EXPLOSION

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

Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized .

The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials or unless all equipment within the protected enclosure is de-energized.

Always lock out the gas handling system when shutting down the analyzer.

After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes and 30
seconds at a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar.

DO NOT operate the analyzer with doors or covers open.

Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit.

When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to
external equipment MUST be shut off.

This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.

Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up
the analyzer.

Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test.

Use only replacement parts and components authorized by Emerson.

All replacement parts and components must be certified and approved for use in hazardous areas.

The analyzer contains a battery for data backup purposes.

Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement
MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.

6

WARNING

FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD

Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially
hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

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

WARNING

BURNS

Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly
important when working at heights.

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

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

When handling the analyzer, always wear suitable protective gloves.

If you receive a burn, seek medical treatment immediately.

WARNING

HAZARDOUS SUBSTANCES

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

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 the
analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the 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.

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.

7

WARNING

OPTICAL RADIATION EXPOSURE HAZARD

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

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

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

Parameter QCL ICL Diode Comment

Operation mode Pulsed Pulsed Pulsed N/A

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

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

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

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

Pulse repetition
frequency

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

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

The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of laser safety labels on
the analyzer is specified in Safety and system labels and annotation.

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

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

aperture: < 9.62 mW

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 analyzer.

The maximum gas pressure valve must not exceed 100 psig (690 kPa).

WARNING

EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE

In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Failure to
observe this warning and or follow safety instructions could cause an explosion or potentially hazardous situation, which if not
avoided, could result in death or serious injury.

Take suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area.

Clean the device surface by gently wiping it with a damp or antistatic cloth only.

8

WARNING

HAZARD BY WRONG INPUT VOLTAGE

Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the
installation. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.

This type of analyzer is always setup for a specific rated input voltage; see nameplate label.

Ensure the voltage at site of installation meets the rated analyzer input voltage.

WARNING

LOOSE ITEMS

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

Do not place any loose items on top of the system or inside the compartments when doors / covers are open.

Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers.

WARNING

MAINTENANCE/MODIFICATIONS

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

On completion of any maintenance and or modifications verify:

— All tools and equipment are removed.

— No contamination (water/dust) is in the compartments.

— Analyzer is wiped clean.

— Vents are clear and not obstructed.

— Verify that system is in a safe state for operation.

WARNING

Physical access

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

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

CAUTION

EQUIPMENT DAMAGE

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

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

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

Always follow the Start-up procedure.

Always follow the Shutdown procedure.

9

CAUTION

UNSERVICEABLE EQUIPMENT

If the pressure and temperature screen does not display measurements similar to those shown in Figure 8-1 and Figure 8-2, refer
to Troubleshooting and diagnostics.

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.

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

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

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Contents

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

1.1 Description................................................................................................................................ 15

1.2 Customer information............................................................................................................... 15

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

1.4 Qualified personnel....................................................................................................................16

1.5 Software version........................................................................................................................16

1.6 Glossary and abbreviations........................................................................................................ 17

Chapter 2 Theory of operation................................................................................................. 21

2.1 Overview................................................................................................................................... 21

2.2 Laser measurement principle.....................................................................................................21

2.3 Gas concentration measurements............................................................................................. 21

Chapter 3 Description.............................................................................................................. 23

3.1 Equipment purpose and role......................................................................................................23

3.2 System overview........................................................................................................................23

3.3 Gas inputs and outputs.............................................................................................................. 25

3.4 Connecting the electrical/electronic inputs and outputs............................................................27

3.5 Optical description.................................................................................................................... 31

Chapter 4 Specifications...........................................................................................................33

4.1 Gas detection............................................................................................................................ 33

4.2 Detailed system specifications...................................................................................................33

4.3 Safety and system labels and annotation................................................................................... 39

Chapter 5 Install.......................................................................................................................41

5.1 Site selection............................................................................................................................. 41

5.2 Unpacking................................................................................................................................. 43

5.3 Mounting the analyzer...............................................................................................................44

5.4 Connecting the electrical/electronic inputs and outputs............................................................49

Chapter 6 Controls and display controller.................................................................................57

6.1 Front panel controls and indicators............................................................................................57

6.2 Display controller.......................................................................................................................58

6.3 Gas Sensor Main screen............................................................................................................. 58

6.4 Pressure and Temperature screen..............................................................................................60

6.5 Help system...............................................................................................................................61

6.6 Main menu................................................................................................................................ 62

6.7 BACK button..............................................................................................................................62

Chapter 7 Start-up procedure...................................................................................................63

7.1 Introduction.............................................................................................................................. 63

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7.2 Preparation for use.................................................................................................................... 63

7.3 Start-up procedure.................................................................................................................... 64

7.4 Front panel controls and indicators............................................................................................67

Chapter 8 Operating the analyzer.............................................................................................69

8.1 Introduction.............................................................................................................................. 69

8.2 Normal operation...................................................................................................................... 69

Chapter 9 Shutdown procedure............................................................................................... 71

9.1 Safety precautions .................................................................................................................... 71

9.2 Shutdown procedure................................................................................................................. 72

Chapter 10 Gas calibration......................................................................................................... 77

10.1 Required tools......................................................................................................................... 77

10.2 Main menu calibration routines............................................................................................... 78

Chapter 11 Troubleshooting and diagnostics............................................................................. 99

11.1 Use the Built-in-Self-Test (BIST) fault diagnostics..................................................................... 99

11.2 Use the Faults menu.............................................................................................................. 103

11.3 Failure diagnosis principles.................................................................................................... 104

11.4 Repairable faults.................................................................................................................... 105

11.5 Tools and test equipment...................................................................................................... 106

11.6 General troubleshooting and diagnostics information........................................................... 106

11.7 Navigate the Diagnostics menu............................................................................................. 106

11.8 Visually examine the analyzer................................................................................................ 109

11.9 Functional failure diagnostics................................................................................................ 109

Chapter 12 Repair and replacement......................................................................................... 115

12.1 Repair policy.......................................................................................................................... 115

12.2 Open the electrical compartment door..................................................................................115

12.3 Close the electrical compartment door..................................................................................117

12.4 Replace the fuses...................................................................................................................117

12.5 Replace the TEC board........................................................................................................... 121

12.6 Replace the peripheral board................................................................................................. 123

12.7 Replace the motherboard......................................................................................................125

12.8 Replace the Ethernet in/out relay modules............................................................................ 127

12.9 Lower (main) DIN rail electronic components........................................................................ 128

12.10 Replace a DC power supply..................................................................................................129

12.11 Replace the 10 Amp solid state relay....................................................................................131

12.12 Replace the Ethernet connector...........................................................................................131

12.13 Replace the laser module.....................................................................................................132

12.14 Replace the detector module...............................................................................................134

12.15 Replacing the O2 detector................................................................................................... 135

12.16 Replace the main terminal board......................................................................................... 138

12.17 Replace the mains power filter.............................................................................................139

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12.18 Remove the top cover..........................................................................................................140

12.19 Replace the pressure sensor.................................................................................................141

12.20 Replace the PT100 cell temperature sensor......................................................................... 142

12.21 Cleaning the cell mirrors...................................................................................................... 145

12.22 Spare parts list..................................................................................................................... 150

Chapter 13 Preventative maintenance..................................................................................... 153

13.1 Cleaning the analyzer............................................................................................................ 153

13.2 Maintaining the analyzer........................................................................................................154

13.3 Scheduled maintenance........................................................................................................ 154

Appendix A Engineering drawings............................................................................................ 155

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Introduction

1 Introduction

1.1 Description

The Rosemount CT5100 Continuous Gas Analyzer, referred to hereafter as the Rosemount
CT5100, is an electronic sensor that uses laser spectroscopy to perform analysis of process
gas streams.

The function of the analyzer is to detect and measure up to 10 different types of gas at
concentrations ranging from parts per million (ppm) to percentage levels in the process
gas stream.

Important

The Rosemount CT5100 is designed for use in Non Hazardous areas ONLY.

Note

This manual is intended for the personnel who install, 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 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
([e-mail]) or Emerson distribution partners. Further contact
details for Emerson can be found on the back page of this manual.

1.3 Safety precautions and conditions for safe use

WARNING

SAFE USE PRECAUTIONS

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

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

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Introduction

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

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

General safety notice/residual risk

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

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

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

have been correctly made.

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

operating, maintaining, and servicing the analyzer.

Reference Manual

1.4 Qualified personnel

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

It is the 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 reference manual and receiving appropriate training.

1.5 Software version

The analyzer includes software that is used to control the operation of the analyzer. This
manual describes the software version as: 5.7.13.

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1.6 Glossary and abbreviations

Abbreviation Description

©

% Percent

< Less than

° Degree

AC Alternating current

ATEX Explosive atmospheres

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

BS British Standard

C Celsius

CDA Compressed dry air

CE European Conformity

Copyright

CFR Code of Federal Regulations

CGA Continuous Gas Analyzer

CH

4

CO

2

DC Direct current

Deg Degree (temperature)

e.g. For example

EC European Community

EMC Electromagnetic compatibility

EU European Union

Hrs Hours

Hz Hertz

H2O Water

ICL Interband Cascade Laser

IEC International Electro-technical Commission

in. Inches

IP Ingress protection

Methane

Carbon dioxide

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

IS Intrinsically safe

ISO International Organization for Standardization

k Thousand

kg Kilogram

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Abbreviation Description

kHz Kilo hertz

L Liter

lb. Pound

LCD Liquid crystal display

LED Light emitting diode

L/min Liters per minute

m Meter

3

m

mA Milliamp

Max Maximum

mBar milli-Bar

mbps Megabits per second

Cubic meter

mg Milligram

3

mg/m

Milligram/cubic meter

Mid IR Mid Infrared

min Minute

mm Millimeter

N

2

NEC

®

Nitrogen

National Electrical Code

NFPA National Fire Protection Association

nm Nanometer

NH

3

Ammonia

NO Nitric oxide

NO

2

Nitrogen dioxide

N2O Nitrous oxide

No. Number

O

2

Oxygen

PC Personal computer

PM Preventative maintenance

ppm Parts per million

psi Pounds per square inch

QCL Quantum Cascade Laser

TDL Tunable Diode Laser

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

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Abbreviation Description

UKAS United Kingdom Accreditation Service

USA United States of America

USB Universal serial bus

V Volt

VA Volt-ampere

Vac Volt alternating current

Vdc Volt direct current

W Watt

WEEE Waste electrical and electronic equipment

µm Micro-meter

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Reference Manual Theory of operation

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2 Theory of operation

2.1 Overview

The Rosemount CT5100 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 analyzer can be configured to detect and measure up to 10 gases, with ranges varying
from volume to percent (%) volume levels. A detailed description of the system is given in

Detailed system specifications .

2.2 Laser measurement principle

The analyzer can use up to six lasers to detect and measure gases. Each laser can measure
between one and three gases. Inside the laser, 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
the layers a higher output power than traditional semi-conductor lasers.

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

2.3 Gas concentration measurements

In the analyzer, gas concentrations are measured using mid-infrared optical absorption
spectroscopy. The laser light sources 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 analyzer. Inside the analyzer, the sample gas is fed into an
analysis cell, where the beams from the Quantum Cascade Lasers (QCLs) are passed
through the gas. The analysis cell contains a set of mirrors that bounce the light back and
forth many times, 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.

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Description

3 Description

3.1 Equipment purpose and role

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

Figure 3-1: Rosemount CT5100 Continuous Gas Analyzer

The analyzer can be configured to detect and measure up to 10 different gases, depending
on the combination of laser modules fitted.

3.2 System overview

A complete Rosemount CT5100 system consists of a gas handling system, the analyzer,
and the associated interconnecting wiring and gas piping.

The customer MUST provide the gas handling system and interconnecting wiring and gas
piping.

The Rosemount CT5100 is supplied by Emerson. The gas handling system may be
provided by either the customer or Emerson, depending upon the specific installation. The

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circuit breaker used to control the application of electrical power to the analyzer, the
interconnecting wires, and gas piping are provided by the customer.

In Figure 3-2, the items supplied by Emerson are colored blue; the items supplied by the
customer are colored purple. The green gas handling system may be provided by Emerson
or the customer.

Table 3-1 lists the main items of the system.

Figure 3-2: Rosemount CT5100 Installation

A. Gas handling system

B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT5100

E. Electrical power

F. Two pole main isolator complete with RCD
G. Control center
H. Measurement data

The analyzer contains an optical system with multiple lasers and a series of optical
components that provide an optical path, a heated multi-pass analysis cell, and 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 at either 110 or 240 Vac 50/60 Hz supply.

The analyzer uses mid-infrared optical absorption spectroscopy to measure gas
concentrations. The light sources are Quantum Cascade Lasers (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. An external sample handling
system conditions the sample gas and draws it through the analysis cell. The light exits the
multi-pass analysis cell and is directed to a receiver in the analyzer. 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 analyzer; the sampled gas must be
brought within the parameters shown in Detailed system specifications before entering
the analyzer. Detailed characteristics of the analyzer are also given in in Table 4-1.

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Table 3-1: Main Items of the Rosemount CT5100 Installation

Item Name or description Supplied by Part number Quantity Notes

1 Rosemount CT5100 Emerson Rosemount CT5100 1 N/A

2 Rosemount CT5100 software

package, version 5.x.x.

3 Gas handling system Customer

4 Heated gas sample line hose Customer Customer choice 1 N/A

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 for

9 Excess flow line Customer Customer choice 1 Required for

10 Power cables to Rosemount

CT5100

11 Cables from Rosemount

CT5100 to control center

Emerson N/A. Software is

embedded in the
system.

Customer choice or
(optionally by
Emerson)

Customer Customer choice 1 N/A

Customer Customer choice Dependent upon

Customer Customer choice 1 N/A

Customer Customer choice 1 N/A

Emerson

1 Version

described in
manual

1 N/A

N/A
number of gases
being measured

Required for
cylinder

calibration

calibration

calibration

12 Main circuit breaker

complete with RCD

Customer Customer choice N/A N/A

3.3 Gas inputs and outputs

The analyzer has one gas input and one gas output. See Figure 3-3.

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Figure 3-3: Gas Inlet and Outlet Connectors

A. Sample gas return port

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

Procedure

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

the sample gas input port located on top of the analyzer (see Figure 3-3.).

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

analyzer through the sample gas return port.

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

on the analyzer to prevent condensation forming in the line.

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WARNING

HAZARDOUS GASES

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.

3.4 Connecting the electrical/electronic inputs and outputs

CAUTION

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

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Figure 3-4: Electrical/Electronic Connectors

A. Power entry point

B. Analog/digital entry point

C. Analog/digital entry point

Electrical/electronic signal connections to the analyzer are made through three electrical
entry points located on the underside of the analyzer, as shown in Figure 3-4. Use the
wiring diagram to make the electrical connections as shown in Engineering drawings and

Figure 3-5.

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Figure 3-5: Signal Cable Outputs

A. To mains input fuses

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

E. To digital modules

F. To analog modules
G. To status relays
H. Digital output terminals

I. Analog or digital output terminals
J. Analog output terminals

K. Status outpput terminals

L. Mains input terminals

Table 3-2: Rosemount CT5100 System Wiring User Connections

Terminal Function

1 Sensor system supply (L)

2 Sensor system supply (N)

3 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

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Table 3-2: Rosemount CT5100 System Wiring User Connections (continued)

Terminal Function

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)

01 Analog or digital input/output

02 Analog or digital input/output

03 Analog or digital input/output

04 Analog or digital input/output

05 Analog or digital input/output

06 Analog or digital input/output

Electrical power is applied to the analyzer through the power entry point, Figure 3-4.

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

WARNING

Failure to follow this warning may result in personal injury and/or damage to persons
and/or property.

Make sure that the mains supply cable used is of a suitable rating for the unit power
requirements and is of a three core earthed construction.

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The digital outputs conduit (B and C) 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 the 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 analyzer, 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 analyzer is out of specification or has developed a fault.

NOTICE

The installation of the gas analyzer shall be in accordance with all local and national
standards.

3.5 Optical description

The laser modules are located in the core of the analyzer. 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 0.66 ft. (0.2 m), 6.56 ft. (2 m), 16.4 ft. (5 m), and 19.2 ft. (15 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.

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.

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4 Specifications

4.1 Gas detection

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

4.2 Detailed system specifications

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

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

Table 4-1: Physical Characteristics

Rosemount CT5100 Value Comment

External dimensions 22.64 x 11.73 x 28.11 in.

575 x 298 x 714 mm

Weight 117 lb.

53 kg

Length x width x height
Nominal dimensions

Approximate weight

Table 4-2: General Characteristics

Rosemount CT5100 Value Units Comment

Instrument supply voltage 110 to 240 Vac 50/60 HZ ±10%

Peak power consumption 500 W Max consumption per gas

analyzer

Continuous steady-state power
consumption

Electrical compartment enclosure N/A N/A 304 stainless steel

Optical compartment enclosure N/A N/A Polyester TGIC free powder

Wetted materials N/A N/A AISI 316 (EN 1.4401 grade)

300 W Once the gas analyzer has

stabilized and the analysis cell
has reached the temperature
set point

coated 304 stainless steel

stainless steel tubing and
fittings including thermowell
and pressure diaphragm, PFA
coated aluminum cell body,
PTFE seals, protected gold
coated mirrors, CaF2 windows,
and FKM (typically Viton™) or
FFKM (typically Kalrez™) O-rings

Measurement technique N/A N/A Mid infrared (IR) absorption

spectroscopy

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

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Table 4-2: General Characteristics (continued)

Rosemount CT5100 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 ¼

6

Outlet (exhaust) gas port connector ¼

6

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

Communication 10/100 Mbps Ethernet

Warm-up time 90 minutes N/A

in.
mm

in.
mm

Swagelok® type, factory­configured, specify on order

Swagelok type, factory­configured, specify on order

on order

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Figure 4-1: Rosemount CT5100 Dimensions - Front View

Dimensions are in inches (mm).

A. Lifting eyelet

B. Ventilation

C. User interface

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Figure 4-2: Rosemount CT5100 Dimensions - Top View

Dimensions are in inches (mm).

A. Lifting eyelet

B. Sample return

C. Sample inlet

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Figure 4-3: Rosemount CT5100 Dimensions - Bottom View

Dimensions are in inches (mm).

A. Cable glands

B. Earth point

Table 4-3: Environmental Characteristics

Environmental characteristic Value Units Comment

Operating temperature range -4 to 131

-20 to 55

Sample gas temperature range 131 to 374

50 to 190

Sample gas moisture content 30 (dependent on gas

type. Customer must
confirm.)

Sample gas particulate density 5 mg/m

Sample gas particulate size 10 µm Maximum

IP code IP66 (electrical

compartment
enclosure)

IP20 (optical
compartment
enclosure)

°F
°C

°F
°C

% Maximum

3

N/A IP to IEC 60529

Ambient temperature

Factory set, specify on order

Maximum

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Table 4-3: Environmental Characteristics (continued)

Environmental characteristic Value Units Comment

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

condensing) at 113 °F (45 °C)

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4.3 Safety and system labels and annotation

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

Label type Example Location

Identification label (including serial
number and model number)

Fuse identification label 1. Back plate

Ratings label Enclosure side panel

Emerson.com/RosemountGasAnalysis Front panel

2. Top right inside of door

Laser radiation CAUTION label Baseplate

Laser module identification label On each laser module housing

Intrinsically safe label 1. HMI

2. Intrinsically safe sensor barrier

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Label type Example Location

Terminal label Top left inside of door

Earth identification label Back plate

Manufacturer's label On analysis cell heater block

Electrical safety label On inside of electrical compartment

door

AC Power Supply Danger label 1. On outside of electrical

compartment door

2. On manifold block of air
overpressure system

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5 Install

5.1 Site selection

The Rosemount CT5100 has a T3 temperature classification which specifies the maximum
surface temperature of the analyzer. Ensure that no combustible gas concentrations will
be present, whether on a continual or occasional basis, which have an ignition
temperature below the T-rating of the analyzer.

WARNING

FIRE AND EXPLOSION

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

The analyzer's electrical compartment must not be opened unless the atmosphere in the
area is known to be below the ignitable concentration of combustible gases or materials,
or unless all equipment within the protected enclosure is de-energized.

WARNING

ELECTRIC SHOCK

The analyzer operates using mains voltage, which may cause death or serious injury to
personnel. Failure to observe this precaution will cause death, personal injury, and/or
damage to persons and/or property.

Ensure that the circuit breakers are set to Off and locked out and tagged out off before
removing the top cover or opening the front cover.

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

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

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Figure 5-1: Clearance with Door Open

Dimensions are in inches (mm).

A. Door open

B. Door closed

C. Door opening arc

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5.2 Unpacking

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

WARNING

HEAVY INSTRUMENT - LIFTING HAZARD

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

The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable
lifting/moving equipment. Emerson recommends that a minimum of two people using
suitable tools for transportation and lifting are employed.

Wear suitable protective gloves and protective footwear.

CAUTION

EQUIPMENT DAMAGE

Failure to observe this caution may cause damage to the equipment.

When preparing the analyzer for transport by air, road, or rail, safeguard the analyzer
against movement or break-away during transport by securely strapping it in place.

WARNING

EXPLOSION HAZARD

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

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

WARNING

EXPLOSION HAZARD

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

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

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WARNING

HEAVY ITEM

Failure to propery handle the analyzer may cause injury to personnel.

Ensure the wall the analyzer is mounted on is solid, stable, and of suitable material to
hold the weight of the analyzer.

Handle the analyzer with caution during unpacking, installing, maintaining, and
transporting to prevent crushing of hands, feet, or other body parts.

The analyzer weighs 117 lb. (53 kg).
Emerson recommends that a minimum of two people move and lift the analyzer.
Wear suitable protective gloves and protective footwear.

CAUTION

SHOCK AND VIBRATION

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

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

Procedure

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

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

3. Report anything found to the maintenance organization.

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

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

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

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

5.3 Mounting the analyzer

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

Procedure

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

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WARNING

HEAVY ITEM

Failure to propery handle the analyzer may cause injury to personnel.

Ensure the wall the analyzer is mounted on is solid, stable, and of suitable material
to hold the weight of the analyzer.

Handle the analyzer with caution during unpacking, installing, maintaining, and
transporting to prevent crushing of hands, feet, or other body parts.

The analyzer weighs 117 lb. (53 kg).

Emerson recommends that a minimum of two people move and lift the analyzer.

Wear suitable protective gloves and protective footwear.

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

Figure 5-2: Front View Dimensions

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

D. Lifting eye bolt

E. 0.413-in. (10.5 mm) diameter mounting bolts

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

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

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

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

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

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

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

each; this includes a x 2 factor of safety. Figure 5-3 shows the locations of the
mounting points on the analyzer. All mounting points are 0.413-in. (10.5 mm)
diameter holes.

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

on the brace bars. Refer to Figure 5-2.

6. Remove the lifting eyes and retain them for future use.
Threads must be protected with a suitable grease and plastic grommets.
After mounting, do not place any additional load on the analyzer.
Do not place or leave loose items on flat surfaces.

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Figure 5-3: Mounting Details

Dimensions are in inches (mm).

A. Mounting points

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Figure 5-4: Clearance with Door Open

Install

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

5.4 Connecting the electrical/electronic inputs and outputs

5.4.1 AC power

Power is connected to the analyzer instrumentation through the power entry point (A)
fitted to the base of the analyzer. Refer to Figure 5-5.

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Figure 5-5: Power Gland

A. Power and signal/exit points

B. M6 earth stud

The customer supplied circuit breaker, complete with RCD, must be in accordance with
local and national standards.

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Figure 5-6: Power Entry Point Connections

A. To mains input fuses

B. Mains input filter

C. To enclosure earth stud

Table 5-1: Mains Input Terminals User Connections

Terminal Function

1 Sensor system supply (L)

2 Sensor system supply (N)

3 Earth (E)

Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses
F1 and F2 located inside the analyzer. Refer to Figure 5-7.

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

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Table 5-2: Electrical Power Requirements

5.4.2

Electrical supply Power

consumption

Instrumentation supply
voltage

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

Voltage Fuse

internal
fuses
F1 and F2

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

Fuses

Figure 5-7 shows the location of the fuses.

Figure 5-7: Fuses

A. Fuse F4 (24 Vdc supply)

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

E. Industrial power supply

Table 5-3: Fuse Requirements

Fuse Function Rating Schurter part number

1 Live line 110/240 Vac

(following mains filter)

2 Neutral line 110/240

Vac (following mains
filter)

52 Emerson.com/Rosemount

3.15 A, 240 V, fast
acting ceramic

3.15 A, 240 V, fast
acting ceramic

0001.1009

0001.1009

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Table 5-3: Fuse Requirements (continued)

Fuse Function Rating Schurter part number

3 Analyzer 12 Vdc supply

rail

4 Analyzer 24 Vdc supply

rail

3.15 A, 240 V, fast
acting ceramic

3.15 A, 240 V, fast
acting ceramic

0001.1009

0001.1009

5.4.3 Connecting the sample supply and return line

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

The maximum sample gas supply pressure is 2 BarG.

5.4.4

Connecting the signal cables

The signal cables are connected to the system through conduit outlets (B and C as shown
in Figure 3-4). All signal cables are to be minimum 20 AWG tri-rated switchgear cable.
Customer supplied conduit and cables are to be terminated in the conduit outlets in
accordance with local and national electrical codes.

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Figure 5-8: Signal Cable Outputs

A. To mains input fuses

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

E. To digital modules

F. To analog modules
G. To status relays
H. Digital output terminals

I. Analog or digital output terminals
J. Analog output terminals

K. Status output terminals

L. Mains input terminals

Table 5-4: System Wiring

Terminal Function

1 Sensor system supply (L)

2 Sensor system supply (N)

3 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

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Table 5-4: System Wiring (continued)

Terminal Function

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)

01 Analog or digital input/output

02 Analog or digital input/output

03 Analog or digital input/output

04 Analog or digital input/output

05 Analog or digital input/output

06 Analog or digital input/output

5.4.5 Power input cables and circuit breaker

The power input cable circuit breaker can be tested as follows:

• Set the main power circuit breaker to ON.

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

5.4.6

Temperature sensor and cell heater

The sample cell is controlled to operate at a pre-set temperature when it leaves the
factory.

With the analyzer on, the cell will reach the pre-set operating temperature in
approximately 90 minutes.

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5.4.7 Pressure sensor

The pressure sensor monitors the pressure in the analysis cell.

To test that it is functioning, check that a pressure reading is displayed under pressure on
the Display Controller as described in Pressure and Temperature screen.

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

NOTICE

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

5.4.8

5.4.9

5.4.10

Analog output cable

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

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

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

Seal glands

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

Commissioning

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

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6 Controls and display controller

6.1 Front panel controls and indicators

The Rosemount CT5100 is configured from the control display located on the front panel.
Refer to Figure 6-1.

Figure 6-1: Front Panel

A. Display controller

NOTICE

ON/OFF circuit breaker

There is no ON/OFF switch on the analyzer. The external circuit breaker controls the
application of electrical power to the analyzer.

The external circuit breaker is a simple two-pole ON/OFF circuit breaker that must to set to
ON to permit the safe operation of the analyzer.

The display controller controls operation of the analyzer.Refer to Figure 6-2.

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6.2 Display controller

The six buttons on the display controller control operation of the Rosemount CT5100:

Figure 6-2.

Figure 6-2: Display Controller Buttons

A. LCD display

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

The LCD displaycan be used to display:

• Gas concentration measurements obtained

• Operating temperature and pressure

• Help screens

• Step-by-step calibration

• Diagnostics

Use the two scroll buttonsto scroll through the information on the LCD display. Use the
right-hand scroll button to scroll up and the left-hand scroll button to scroll down.

The other four buttons are configured to perform different functions according to the
software screen that is shown on the LCD display.

6.3 Gas Sensor Main screen

When the analyzer is switched on at the end of the start-up procedure, the Gas Sensor Main
screen (Figure 6-3) appears.

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

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NOTICE

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

Figure 6-3: Gas Sensor Main Screen

The Gas Sensor Main screen displays the gas concentration measurements obtained by the
analyzer. In the example shown in Figure 6-3 the gases nitric oxide (NO), nitrogen dioxide
(NO2), oxygen (O2), carbon monoxide (CO), and carbon dioxide (CO2) are being measured
and, for each gas, the concentration detected is in parts per million (ppm) or percentage
as applicable.

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

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

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

Figure 6-3, the analyzer is Running and OK (e.g., no faults have been identified). This area

of the display shows any errors detected by the software.

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

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Figure 6-4: Gas Sensor Main Screen Buttons

A. MENU button

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

E. HELP button

F. HELP text

G. STATUS button

PAGE

HELP

MENU

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

A link between the Gas Sensor Main screen and the Pressure and Temperature
screen (described in Pressure and Temperature screen). Press PAGE to toggle
between these two screens.

A link to the Help system. Press HELP to go to the Help screen (described in Help

system).

A link to the Main menu of the software. Press MENU to go to the Main menu
screen (described in Main menu).

6.4 Pressure and Temperature screen

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

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Figure 6-5: Pressure and Temperature Screen

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

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

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

NOTICE

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

6.5 Help system

The analyzer software includes a context-sensitive help system. Press HELP, 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, the Help screen that appears is the one
that is most appropriate to the software function engaged when HELP was pressed. Figure

6-6 shows an example of a Help screen.

Figure 6-6: Example of a Help Screen

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6.6 Main menu

To access the Main menu (Figure 6-7), press MENU on either side of the Gas Sensor Main
screen (Figure 6-3) or the Pressure and Temperature screen (Figure 6-5). The Main menu
(Figure 6-7) is used for calibration, diagnostics, fault finding, downloading data, and
shutting down the analyzer.

Figure 6-7: Main Menu

6.7 BACK button

On most of the software screens, the top lefthand button (Figure 6-8) is configured as a
BACK button. Press BACK to return to the previous screen.

Figure 6-8: BACK Button

A. BACK button

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7 Start-up procedure

7.1 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

7.2 Preparation for use

Install and fully commission the Rosemount CT5100 before starting it up.

WARNING

BURN HAZARD

Personal injury and/or damage to property may result if these safety precautions are not
observed.

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

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

When handling the analyzer, always use suitable protective gloves.

These precautions are especially important when working at heights. If a burn is received,
seek medical treatment immediately.

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CAUTION

EQUIPMENT DAMAGE

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

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

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

7.3 Start-up procedure

NOTICE

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

NOTICE

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

Procedure

1. Visually inspect the analyzer's exterior for signs of damage, corrosion, gas leaks, or

overheating. Report anything found to the maintenance organization.

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

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

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

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

cannot close and lock the door, report it to the maintenance organization and do
not proceed further until the door has been repaired.

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

6. Ensure that the external circuit breaker is set to OFF.

7. Visually examine the gas ports.

If necessary, refer to Figure 7-1 to ensure that the sample supply line and the
sample return line are correctly attached.

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Figure 7-1: Gas Inlet and Outlet and Electrical Connections

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

D. Laser/electrical compartment

E. Analog/digital power entry point
F. Power entry point

8. Ensure that the electrical connection has been made to the power entry point at the

base of the analyzer (Figure 7-1).

9. Start up the system that vents the sample gas exiting the analyzer.

10. Switch the circuit breaker to ON, applying electrical power to the analyzer.

The control PC that forms part of the analzyer is configured to automatically load
the necessary gas sensor software and configuration files.

The software automatically starts the start-up sequence. After a few seconds, the

Gas Sensor Main Screen appears on the display controller.

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Figure 7-2: Gas Sensor Main Screen

If the screen does not appear, report the fault to the maintenance organization.

11. Start up the system for venting the sample gas exiting the analyzer.

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

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

The start-up procedure is now complete.

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7.4 Front panel controls and indicators

Configure the analyzer from the control display located on the front panel (Figure 7-3).

Figure 7-3: Front Panel

A. Display controller

NOTICE

ON/OFF circuit breaker

There are no ON/OFF switches on the analyzer. A customer-provided external circuit
breaker controls the application of electrical power to the analyzer.

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

The display controller primarily controls operation of the analyzer (Figure 7-4).

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Figure 7-4: Display Controller

WARNING

Failure to follow these instructions may cause warranty invalidation, property damage,
and/or personal injury or death.

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

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

It is essential that only trained, qualified personnel operate the controls on the analyzer.

Figure 7-5: Default Program Screen

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8 Operating the analyzer

8.1 Introduction

This section describes the normal operation of the analyzer.

NOTICE

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

WARNING

BURN HAZARD

Some parts of the analyzer may be heated to 374 °F (190 °C). All components of the
analyzer are hot unless it has been switched off and allowed to cool down. 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.

To prevent burns, do not touch any of the hot parts.

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

When handling the analyzer, always use suitable protective gloves.

If you receive a burn, seek medical treatment immediately.

8.2 Normal operation

The analyzer is designed for long term continuous operation, and therefore its normal
state is to be switched on and performing gas measurements. The analyzer is usually only
switched off for maintenance.

During normal operation, either the Gas Sensor Main screen (Figure 8-1) or the Pressure and
Temperature screen (Figure 8-2) is shown on the display controller. To toggle between
these two screens, press PAGE..

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Figure 8-1: Gas Sensor Main Screen

Figure 8-2: Pressure and Temperature Screen

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9 Shutdown procedure

9.1 Safety precautions

CAUTION

EQUIPMENT DAMAGE

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

Always follow the shutdown procedure.

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

• In order to perform repairs or maintenance on the analyzer

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

maintenance

• When the analyzer is switched off for re-calibration

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

NOTICE

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

WARNING

BURN HAZARD

Some parts of the analyzer may be heated up to 374 °F (190 °C). All parts of the analyzer
are hot unless it has been switched off and allowed to cool down. Personal injury and/or
damage to property may result if these safety precautions are not observed. These
precautions are particularly important when working at heights.

To prevent burns, do not touch any of the hot parts.

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

When handling the analyzer, always use suitable protective gloves.

If you receive a burn, seek medical treatment immediately.

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9.2 Shutdown procedure

WARNING

EXPLOSION HAZARD

Unauthorized operation of the gas handling system when maintenance is being
performed on the analyzer or on its associated pipes/hoses may result in gas being
released, causing fire or explosion. Failure to lock out the gas handling system may cause
death.

Always lock out the gas handling system when shutting down the analyzer.

Procedure

1. Shut down the gas handling system that conditions the sample gas and feeds it to

the analyzer. Always lock-out the gas handling system to prevent its unauthorized
operation during maintenance, which may cause an escape of gas.

WARNING

EXPLOSION HAZARD

Failure to vent sample gas may cause death.

Vent the sample gas in the system to prevent fire or explosion during
maintenance and to prevent damage to the analyzer during shutdown.

Purge the sample gas in the pipes leading to the analyzer to prevent hazards to
personnel during maintenance.

Purge the sample gas in accordance with 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 analyzer to be returned to the exhaust.

2. Purge any sample gas in the pipe/hose from the gas handling system to the analyzer

using factory air or nitrogen supply.

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).

3. Turn off the gas used to purge the analyzer.

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4. Press MENU on the display controller in either the Gas Sensor Main screen

(Figure 9-1) or the Pressure and Temperature screen (Figure 9-2).

Figure 9-1: Gas Sensor Main Screen

Figure 9-2: Pressure and Temperature Screen

The Main menu (Figure 9-3) opens.

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Figure 9-3: Main Menu

A. BACK button
B. SELECT button
C. Scroll up button

D. HELP button

E. Scroll down button

5. On the display controller, select System as shown in Figure 9-3.

6. Press SEL (select).

The System screen opens. Refer to Figure 9-4.

Figure 9-4: System Screen

A. BACK button
B. SELECT button
C. Scroll up button

D. HELP button

E. Scroll down button

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7. Use scroll up (C) and scroll down (E) to select SHUTDOWN as shown in Figure 9-4.

Then press SEL (select).
The Shutdown screen (Figure 9-5) opens.

Figure 9-5: Shutdown Screen

8. Press YES.

The analyzer shuts down.

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

secondary circuit breaker.

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

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10 Gas calibration

10.1 Required tools

The gas concentrations measured by the analyzer can be validated against a known
sample gas or calibrated to match it by using the following gas calibration procedure.

To calibrate the analyzer, 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 analyzer

• A T-piece and excess flow line

NOTICE

In the case of gases, such as H2O, for which it is not normally possible to obtain calibrated
gas cylinders, it will usually be measured by the same laser as some other gas. Validating
the other gases measured by the analyzer (particularly any which are measured by the
same laser as H2O) can demonstrate that the system is functioning correctly, meaning
there is no need to calibrate the water measurement directly.

If you need to calibrate (e.g., for legal requirements), you can use a water vapor generator
to supply a known concentration of water vapor.

The validation procedure is essentially the same as the calibration procedure, except that
it does not adjust the analyzer measurements to match the calibration standard.

WARNING

EQUIPMENT DAMAGE

Failure to follow may cause warranty invalidation, property damage, and/or personal injury
or death.

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

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

It is essential that only trained, qualified personnel operate the controls on the analyzer.

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Figure 10-1: Default Program Screen

10.2 Main menu calibration routines

Calibration is performed under the control of the analyzer software, using calibration
routines built into the software.

Access calibration functions through the Main menu (Figure 10-4).

Procedure

1. To get the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or
Pressure and Temperature screen (Figure 10-3).

NOTICE

Press BACK to cancel the procedure and return to the previous screen.

Figure 10-2: Gas Sensor Main Screen

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Figure 10-3: Pressure and Temperature Screen

Figure 10-4: Main Menu

Use the Main menu (Figure 10-4) to access the software routines and screens
necessary for this process.

2. Use the middle buttons (

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3. Press SEL.

Figure 10-5: Gas Service (PER GAS)

4. Use the middle buttons ( and ) to scroll up or down to select PER GAS.

5. Press SEL.

Figure 10-6: Select Gas (NO)

6. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g.,
NO).

7. Press SEL.

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8. To check or change the current offset value, select ZERO OFFSET and press CAL to
view.

Figure 10-7: Action

Figure 10-8: Zero Offset Screen

9. Use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to enter the
desired offset (-0.587313 in Figure 10-8).

10. Press OK to confirm.

The factory default offset is zero, and under normal circumstances, the offset
should never be a positive number.

If it is shown as positive, press LEFT until the space to the left of the number is
highlighted, then select INCR to change it to a minus (–) sign.

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11. To check or change the current span value, select SPAN FACTOR and press CAL to
view.

Figure 10-9: Input Type

Figure 10-10: Span Factor Screen

12. Use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to enter the
desired offset (1.06 ppm in Figure 10-10).

13. Press OK to confirm.

The factory default span factor is 1, and under normal circumstances, the offset
should be between 0.8 and 1.2.

10.2.1

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Zero calibrate an individual gas

Procedure

1. To get to the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or
the Pressure and Temperature screen (Figure 10-3).

Note

To cancel the procedure, press BACK to return to the previous screen.

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2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press
SEL.

Figure 10-11: Main Menu (GAS SERVICE)

3. Use the middle buttons ( and ) to scroll up or down to select PER GAS. Press SEL.

Figure 10-12: Gas Service Menu (PER GAS)

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4. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g.,
NO). Press SEL.

Figure 10-13: Select Gas (NO)

5. Use the middle buttons ( and ) to scroll up or down to select RUN ZERO.

Figure 10-14: Action Screen for NO (RUN ZERO)

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6. Press CAL to calibrate, or VER to verify.

Figure 10-15 displays as the calibration progresses.

Figure 10-15: Calibration

Once complete, the program will automatically open the Result screen .

Figure 10-16: Result Screen

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7. Press OK.

The Verify next screen displays.

Figure 10-17: Verify Next Screen

8. Press DONE to finish.

• To calibrate additional gases, select GAS and repeat Step 1 through Step 7.

10.2.2

• To change types, select TYPE.

This completes the process, and the display will return to the Main menu.

Span calibrate an individual gas

Procedure

1. Gas Sensor MainTo get to the Main menu, press the MENU button on the screen
(Figure 10-2) or the Pressure and Temperature screen (Figure 10-3).

Note

To cancel the procedure and return to the previous screen, press BACK.

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2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press
SEL.

Figure 10-18: Main Menu (GAS SERVICE)

3. Use the middle buttons ( and ) to scroll up or down to select PER GAS. Press the
SEL button.

Figure 10-19: Gas Service (PER GAS)

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4. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g.
NO). Press SEL.

Figure 10-20: Select Gas (NO)

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5. Use the middle buttons ( and ) to scroll up or down. Select RUN SPAN. Press CAL
to calibrate, or VER to verify.

Figure 10-21: Action (RUN SPAN)

The Calibration screen show as the calibration progresses.

Figure 10-22: Calibration

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6. Using the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons, enter the
cylinder concentration (e.g., 25 ppm).

Figure 10-23: Span Input

7. Press OK to confirm.

Once complete, the program will automatically open Span input For NO
(Figure 10-23).

NOTICE

If an excessively high or low span factor is calculated (<0.7 or > 1.3 for example,) and
if the calibration gas is a different concentration from that set above, it will be
rejected and the previous span factor will be displayed and will continue to be used.

8. Press OK.
The Result screen displays.

Figure 10-24: Result

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9. Press DONE to finish.

Refer to Figure 10-25.

Figure 10-25: Calibration Complete

This completes the process, and the display will return to the Main menu.

10.2.3

Calibrate all gases (zero and span)

On systems with valve control, it is possible to run a calibration on all gases. The valves will
sequentially switch through each of the span and zero gases.

This option is not practical to use on systems which require manual valve switching.

In order to set the cylinder concentration when using a new span gas cylinder, it is
necessary to perform a single gas calibration as described in Span calibrate an individual

gas. This concentration will then be stored for future calibrations.

Procedure

1. To get to the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or
the Pressure and Temperature screen (Figure 10-3).

NOTICE

To cancel the procedure and return to the previous screen, press BACK.

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2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press
SEL.

Figure 10-26: Main Menu (GAS SERVICE)

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3. Use the middle buttons ( and ) to scroll up or down to select CALIBR ALL. Press
SEL.

Figure 10-27: Gas Service (CALIBR ALL)

The system will work through the zero and span calibration process for all readings.
The Please wait screen will be displayed. This takes approximately one minute per
gas depending on the purge time.

Figure 10-28: Calibration

The Finished screen displays when the zero and span calibration processes
complete.

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Figure 10-29: Calibration (Finished)

4. Press BACK.

This completes the process, and the display returns to the Main menu.

10.2.4

Change the automatic calibration settings

Procedure

1. To get to the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or
the Pressure and Temperature screen (Figure 10-3).

NOTICE

To cancel the procedure and return to the previous screen, press BACK.

2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press
SEL.

Figure 10-30: Main Menu (GAS SERVICE)

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3. Use the middle buttons ( and ) to scroll up or down to select CALIBR PARAMS or
VERIFY PARAMS for validation settings). Press SEL.

Figure 10-31: Gas Service (CALIBR PARAMS)

This section applies to systems configured to perform automatic calibration at
timed intervals only.

4. To adjust the frequency of automatic calibration, use the middle buttons ( and )
to scroll up or down

5. Select AUTO PERIOD.

6. Press SEL.

Figure 10-32: Calibr param (AUTO PERIOD)

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7. To change the time and the units (days, hours, minutes and seconds) between
calibrations, use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to
set the number and time interval.

Figure 10-33: (Calibration) Period

8. Press OK.

9. To adjust the length of time for the span gas to flush the cell, use the middle
buttons ( and ) to scroll up or down and select PURGE TIME.

Figure 10-34: Calibr param (PURGE TIME)

10. Press SEL.

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11. To change the time between opening the valve and performing the calibration, use
the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to set the number
and time interval.

Figure 10-35: Purge Time

12. Press OK.

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11 Troubleshooting and diagnostics

11.1 Use the Built-in-Self-Test (BIST) fault diagnostics

The analyzer has a Built-In-Self-Test (BIST) function that can be used to perform failure
diagnosis of some functions in situations where there is a fault other than a complete
failure of the equipment. To access and control the BIST, use the display controller
mounted on the door of the electrical compartment.

The BIST runs in the background when the analyzer is operating and continuously
monitors the analyzer for faults.

If the BIST detects a fault, the STATUS display in the bottom left-hand corner of the Gas
Sensor Main screen (Figure 11-1) will change from OK to flashing the word FAILURE.

Figure 11-1: Gas Sensor Main Screen

A. FAILURE message

B. FAILURE button

Similarly, if the BIST detects a fault and the Pressure and Temperature screen (Figure 11-2) is
being displayed, the STATUS display in the bottom left-hand corner of the screen will
change from OK to flashing the word FAILURE.

Rosemount CT5100 99

Troubleshooting and diagnostics Reference Manual

May 2020 00809-0100-4511

Figure 11-2: Pressure and Temperature Screen

A. FAILURE message

B. FAILURE button

Procedure

1. On either the Gas Sensor Main screen (Figure 11-1) or the Pressure and Temperature
screen (Figure 11-2), press FAILURE button to go to the Faults Menu screen (Figure

11-5).
Controls and display controller provides details of how to use the controls on the

display controller and functions of the BACK and HELP buttons.

2. You can also access the FAULTS menu through the Main Menu (Figure 11-3) as
follows:

100 Emerson.com/Rosemount