Rosemount CT5100(Ex) Continuous Gas Analyzer Manuals & Guides

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Rosemount™ CT5100(Ex)

Continuous Gas Analyzer

Reference Manual

00809-0100-4512, Rev AA

October 2019

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: 00809-0100-4512 Rev AA, October 2019

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

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

Rosemount CT5100(Ex) preliminary information

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

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

This article must not be changed amended or removed.

Important

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

All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain, and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The following document are available and/or referenced within this manual:

• Quick Start Guide

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

Authorized personnel

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

• Train staff

• Observe safety regulations

• Follow the safety instructions and procedures in the product manual

Operators must:

• Have been trained

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

• Know the safety mechanisms and regulations

WARNING

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

Important instructions

Important

All users must read this page before proceeding!

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

• 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.

Regulations and standards

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

Regulations / Standards Description

2014/35/EU The Low Voltage Directive

94/9/EC (until 19 April 2016)

2014/34/EU (from 20 April 2016)

(1)

(2)

The ATEX 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

NFPA 496 Standard for purged and pressurized enclosures for electrical

equipment

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

Standards Institute and NFPA 70: National Fire Protection Association)

47CFR: 2011 Part 15, Sub Part B Unintentional radiators; conducted and radiated emissions

limits.

IEC 60079-10: 2002-06 Electrical apparatus for explosive gas atmospheres. Part 10:

Classification of hazardous areas

IEC 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (Ingress

protection code)

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

requirements.

BS EN 61010-1 2010 IEC 61010-1 2010

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

IEC 61241-10: 2004-06 Electrical apparatus for use in the presence of combustible

dust. Part 10: Classification of areas where combustible dusts are or may be present.

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

laboratory use. EMC requirements. General requirements

IEC 60079-0 Explosive atmospheres: General requirements

IEC 60079-2 Explosive atmospheres: Equipment protection by pressurized

enclosure

IEC 60664-1 Pollution degree

FM3600 (2011) Electrical equipment for use in hazardous (classified) locations

– General requirements

FM3620 (2014) Approval standard for purged andpressurized electrical

equipment for hazardous (classified) locations

CAN/CSA-C22.2 No. 61010-1-12 Safety requirements for electrical equipment for

measurement, control, and laboratory use, part 1: General requirements

UL Std.No. 61010-1 (3rd edition) Safety requirements for electrical equipment for

measurement, control, and laboratory use - part 1: General requirements

(1) May affect equipment tested prior to 20 April 2016 but shipped at a later date. (2) All equipment tested from 20 April 2016 will be subject to this directive.

Associated publications

Quick Start Guide

Compliance approvals

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.

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

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

Explosive / hazardous area protection Emerson has satisfied the requirements of and complies with IEC, ATEX, and North

In accordance with IEC 60079-0: 2011 Clause 30.This statement must not be amended or changed.

Waste disposal

Do not dispose of measuring tools into household waste. Only for EC countries: In accordance with European Directive 2012/19/EU for Waste Electrical and Electronic Equipment and its implementation

into national right, measuring tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.

American regulators for operation of electrical/electronic equipment in hazardous locations .

Safety and information notices

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

DANGER

WILL CAUSE DEATH

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

WARNING

DANGER TO PERSONNEL

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

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

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

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

DANGER

ELECTRIC SHOCK

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

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

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

DANGER

EXPLOSION HAZARD

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

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

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

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

DANGER

FLAMMABLE SUBSTANCES

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

WARNING

TRANSPORTATION HAZARD

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

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

WARNING

FIRE AND EXPLOSION

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

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

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

WARNING

FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD

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

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

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

WARNING

COMBUSTIBLE GASES

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

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

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

WARNING

EXPLOSION HAZARD

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

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

WARNING

BURNS

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

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

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

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

WARNING

LASER

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

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

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

WARNING

HAZARDOUS SUBSTANCES

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

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

— Handle used gas handling components with extreme caution.

— Avoid direct skin contact with used gas handling components.

— Do not smoke, drink, or eat in the work area.

— Wear goggles or eye shields.

— Wear a suitable face mask to protect against inhalation of particulate matter.

— Do not wet fingers, eyes, or any exposed skin.

— Pack used gas handling components for disposal in sealed packaging and label them Contaminated.

— Dispose of contaminated items as hazardous material in accordance with applicable local, national, or international health

and safety regulations and pollution regulations.

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

WARNING

OPTICAL RADIATION EXPOSURE HAZARD

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

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

Parameter QCL ICL Diode Comment

Operation mode Pulsed Pulsed Pulsed N/A

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

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

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

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

per system

QCL at first accessible aperture: < 9.62 mW

WARNING

HAZARDOUS GAS

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

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

WARNING

HIGH PRESSURE GAS AND AIR

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

WARNING

HEAVY ITEM

In accordance with IEC 60079-0: 2011 Clause 30. Failure to propery handle the analyzer may cause injury to personnel.

Ensure the wall the analyzer is mounted on is solid, stable, and of suitable material to hold the weight of the analyzer. Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands,

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

WARNING

EXPLOSION HAZARD / ELECTRIC SHOCK HAZARD

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

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

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

WARNING

HIGH PRESSURE HAZARD

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

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

injury.

WARNING

EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE

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

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

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

WARNING

EXPLOSION HAZARD

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

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

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

WARNING

POSSIBLE EXPLOSION HAZARD

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

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

WARNING

HAZARD BY WRONG INPUT VOLTAGE

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

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

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

WARNING

EXPLOSION HAZARD

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

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

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

WARNING

EXPLOSION HAZARD

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

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

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

WARNING

EXPLOSION HAZARD

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

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

WARNING

EXPLOSION HAZARD

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

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

WARNING

EXPLOSION HAZARD

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

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

WARNING

EXPLOSION HAZARD

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

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

WARNING

EXPLOSION HAZARD BY BATTERY

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

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

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

WARNING

LOOSE ITEMS

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

injury.

WARNING

MAINTENANCE/MODIFICATIONS

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

— All tools and equipment are removed.

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

— Analyzer is wiped clean.

— Vents are clear and not obstructed.

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

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

WARNING

TRANSPORTATION HAZARD

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

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

WARNING

PHYSICAL ACCESS

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

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

CAUTION

EQUIPMENT DAMAGE

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

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

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

CAUTION

EQUIPMENT DAMAGE

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

CAUTION

EQUIPMENT DAMAGE

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

CAUTION

UNSERVICEABLE EQUIPMENT

If the pressure and temperature screen does not display measurements similar to those shown in Figure 6-6 and Figure 6-8, 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.

CAUTION

EMC

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

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

Reference Manual Contents

00809-0100-4512 October 2019

Chapter 1 Introduction.................................................................................................................21

1.1 Description.....................................................................................................................................21

1.2 Customer information....................................................................................................................21

1.3 Safety precautions and conditions for safe use............................................................................... 21

1.4 Qualified personnel........................................................................................................................ 23

1.5 Software version.............................................................................................................................24

1.6 Glossary and abbreviations.............................................................................................................24

Chapter 2 Theory of operation..................................................................................................... 27

2.1 Overview........................................................................................................................................ 27

2.2 Laser measurement principle..........................................................................................................27

2.3 Gas concentration measurements..................................................................................................27

Chapter 3 Description.................................................................................................................. 29

3.1 Equipment purpose and role.......................................................................................................... 29

3.2 System overview............................................................................................................................ 29

3.3 Gas flow through analyzer.............................................................................................................. 32

3.4 Connecting the electrical/electronic inputs and outputs.................................................................34

3.5 Optical description......................................................................................................................... 37

Chapter 4 Specifications...............................................................................................................39

4.1 Gas detection................................................................................................................................. 39

4.2 Detailed system specifications........................................................................................................39

4.3 Safety and system labels and annotation........................................................................................ 42

Chapter 5 Install...........................................................................................................................47

5.1 Site selection.................................................................................................................................. 47

5.2 Unpacking...................................................................................................................................... 48

5.3 Mounting the analyzer....................................................................................................................50

5.4 Connecting the electrical/electronic inputs and outputs.................................................................56

Chapter 6 Controls and display controller.....................................................................................67

6.1 Front panel controls and indicators.................................................................................................67

6.2 Display controller........................................................................................................................... 69

6.3 Gas Sensor Main screen.................................................................................................................. 70

6.4 Pressure and Temperature screen.................................................................................................. 72

6.5 Help system....................................................................................................................................73

6.6 Main menu..................................................................................................................................... 74

6.7 BACK button...................................................................................................................................74

Chapter 7 Start-up procedure.......................................................................................................75

7.1 Introduction................................................................................................................................... 75

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7.2 Preparation for use......................................................................................................................... 75

7.3 Start-up..........................................................................................................................................76

7.4 Front panel controls and indicators.................................................................................................80

Chapter 8 Operating the analyzer.................................................................................................85

8.1 Introduction................................................................................................................................... 85

8.2 Normal operation........................................................................................................................... 85

Chapter 9 Shutdown procedure................................................................................................... 87

9.1 Shutdown procedure safety precautions ........................................................................................87

9.2 Shutdown procedure......................................................................................................................88

Chapter 10 Gas calibration............................................................................................................. 93

10.1 Required tools.............................................................................................................................. 93

10.2 Main menu calibration routines.................................................................................................... 94

Chapter 11 Troubleshooting and diagnostics............................................................................... 113

11.1 Using the Built-in-Self-Test (BIST) fault diagnostics.....................................................................113

11.2 Faults menu................................................................................................................................116

11.3 Failure diagnosis principles.........................................................................................................118

11.4 Repairable faults.........................................................................................................................118

11.5 Tools and test equipment...........................................................................................................119

11.6 General troubleshooting and diagnostics information................................................................119

11.7 Diagnostics menu.......................................................................................................................119

11.8 Visual examination..................................................................................................................... 122

11.9 Functional failure diagnostics..................................................................................................... 122

Chapter 12 Repair and replacement............................................................................................. 127

12.1 Repair policy...............................................................................................................................127

12.2 Opening the electrical compartment door................................................................................. 127

12.3 Closing the electrical compartment door................................................................................... 128

12.4 Replacing the fuses.....................................................................................................................129

12.5 Replacing the TEC board.............................................................................................................133

12.6 Replacing the peripheral board...................................................................................................135

12.7 Replacing the motherboard........................................................................................................137

12.8 Replacing the Ethernet in/out relay modules.............................................................................. 139

12.9 Lower (main) DIN rail electronic components.............................................................................140

12.10 Replacing a DC power supply....................................................................................................141

12.11 Replace the 10 Amp solid state relay........................................................................................ 143

12.12 Replacing the Ethernet connector............................................................................................ 143

12.13 Replacing the laser module...................................................................................................... 144

12.14 Replacing the detector module................................................................................................ 146

12.15 Replacing the O2 detector........................................................................................................ 147

12.16 Replacing the main terminal board...........................................................................................149

12.17 Replacing the mains power filter.............................................................................................. 151

xviii Rosemount CT5100(Ex)

Reference Manual Contents

00809-0100-4512 October 2019

12.18 Removing the top cover........................................................................................................... 151

12.19 Replacing the PT100 gas temperature sensor...........................................................................152

12.20 Replacing the pressure sensor.................................................................................................. 155

12.21 Cleaning the cell mirrors...........................................................................................................156

12.22 Spare parts list..........................................................................................................................162

Chapter 13 Preventative maintenance......................................................................................... 163

13.1 Maintaining the analyzer............................................................................................................ 163

13.2 Scheduled maintenance............................................................................................................. 163

Chapter 14 ATEX/IECEX assessment report summary....................................................................165

14.1 Certification overview................................................................................................................ 165

14.2 Applicant's name and address.................................................................................................... 165

14.3 Manufacturer's name and address.............................................................................................. 165

14.4 Trademark..................................................................................................................................165

14.5 Product name/model number.................................................................................................... 165

14.6 Rating.........................................................................................................................................165

14.7 Assessment standards................................................................................................................ 166

14.8 Markings.................................................................................................................................... 166

14.9 Conditions of certification/special conditions for safe use...........................................................169

14.10 Conditions of certification for the replacement of simple devices.............................................170

Appendix A Engineering drawings................................................................................................ 173

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xx Rosemount CT5100(Ex)

Reference Manual

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Introduction

1 Introduction

1.1 Description

The Rosemount™ CT5100(Ex) Continuous Gas Analyzer, referred to hereafter as the Rosemount CT5100(Ex) Continuous Gas Analyzer or Rosemount CT5100(Ex), 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.

The analyzer meets all current requirements for operation in potentially explosive environments.

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 (cascade.support@emerson.com) 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

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

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

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

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Introduction

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Reference Manual

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

Conditions for safe use (Europe)

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

(160 °C).

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

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

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

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

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

defined in IEC 60664-1.

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

of mechanical damage and must be suitably protected.

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

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

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

at least 25 L/min for leakage compensation.

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

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

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

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

Conditions for safe use (North America)

• The maximum sample gas temperature that the analyzer can operate with is 176 °F (80

°C).

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

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

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

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

of mechanical damage and must be suitably protected.

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

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

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

at least 25 L/min for leakage compensation.

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

the equipment not related to safety.

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

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

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

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

• Equipment is not to be used with flammable liquids.

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

operational state.

Introduction

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

jurisdiction.

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

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

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

detailed in NFPA496 Clause 4.12.5.

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

suitably certified conduit.

General safety notice/residual risk

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

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

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

failure (for Category 3 analyzers).

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

have been correctly made.

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

operating, maintaining, and servicing the analyzer.

1.4

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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

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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

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 .

1.6 Glossary and abbreviations

Table 1-1: 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

CFR Code of Federal Regulations

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Table 1-1: Abbreviations (continued)

Abbreviation Description

CGA Continuous Gas Analyzer

Methane

Carbon dioxide

DC Direct current

Deg Degree (temperature)

e.g. For example

EC European Community

EMC Electromagnetic compatibility

EU European Union

Hrs Hours

Hz Hertz

H2O Water

ICL Interband Cascade Laser

IEC International Electro-technical Commission

in. Inches

IP Ingress protection

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

IS Intrinsically safe

ISO International Organization for Standardization

k Thousand

kg Kilogram

kHz Kilo hertz

L Liter

lb. Pound

LCD Liquid crystal display

LED Light emitting diode

L/min Liters per minute

m Meter

Cubic meter

mA Milliamp

Max Maximum

mBar milli-Bar

mbps Megabits per second

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Table 1-1: Abbreviations (continued)

Abbreviation Description

mg Milligram

mg/m

Mid IR Mid Infrared

min Minute

mm Millimeter

Milligram/cubic meter

NEC

Nitrogen

National Electrical Code

NFPA National Fire Protection Association

nm Nanometer

Ammonia

NO Nitric oxide

Nitrogen dioxide

No. Number

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

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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2 Theory of operation

2.1 Overview

The Rosemount™ CT5100(Ex) 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 Rosemount CT5100(Ex) 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 lasers a higher output power than traditional semi-conductor lasers.

The lasing wavelength of the 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, have excellent spectral quality in chirped mode, and have good tuneability.

2.3 Gas concentration measurements

In the Rosemount CT5100(Ex), gas concentrations are measured using 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 laser 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(Ex) 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(Ex) system consists of a gas handling system, the analyzer, and the associated interconnecting wiring and gas piping.

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

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

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

Figure 3-2: Complete Rosemount CT5100(Ex) Installation

A. Gas handling system

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

E. Rosemount CT5100(Ex)

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

I. Control center J. Measurement data

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 from 110 to 230 Vac 5050/60 Hz supply.

The analyzer uses mid-infrared optical absorption spectroscopy to measure gas concentrations. The light sources are lasers, which are operated to produce wavelength

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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 Table 4-1.

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

Item Name or

description

1 Rosemount

CT5100(Ex)

2 Rosemount

CT5100(Ex) software package, version 5.7.13

3 Gas handling

system

4 Heated gas sample

line hose

5 Exhaust line hose

(for sample gas)

6 Reference gas

cylinders (instrument gas) for calibration purposes

7 Pressure regulator Customer Customer choice 1 per gas cylinder Required for

8 Pneumatic T-piece Customer Customer choice 1 Required for

Supplied by Part number Quantity Notes

Emerson Rosemount

CT5100(Ex)

Emerson N/A.Software is

embedded in the system.

Customer (optionally by Emerson)

Customer Customer choice 1

Customer Customer choice Dependent upon

Customer Choice or Emerson

1 Version described

in manual

number of gases being measured

calibration

9 Excess flow line Customer Customer choice 1 Required for

calibration

10 Power cables to

Rosemount CT5100(Ex)

11 Cables from

Rosemount CT5100(Ex) to control center

12 Main circuit

breaker

Reference Manual 31

Customer Customer choice 1

Customer Customer choice

Description

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Table 3-1: Main Items of the Rosemount CT5100(Ex) Installation (continued)

Reference Manual

Item Name or

description

13 Secondary circuit

breaker

Supplied by Part number Quantity Notes

Customer Customer choice

3.2.1 Explosive safety

To prevent explosive vapors from entering the analyzer, the electrical compartment is held at a positive pressure above the surrounding air pressure.

3.3 Gas flow through analyzer

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

Figure 3-3: Gas Inlet and Outlet Connectors

A. Sample gas return port

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

E. Laser/electrical compartment

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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, Items A and B).

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

analyzer through the sample gas return port (A).

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

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

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

WARNING

AIR SUPPLY

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

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Description

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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.

Figure 3-4: Electrical / Electronic Connectors

A. Purge power and alarm entry point

B. Power entry point

C. Analog/digital entry point

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

Figure 3-5.

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Description

Figure 3-5: Signal Cable Outputs

A. To digital modules

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

E. To status relays

F. Status output terminals

Note

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

Note

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

Two sources of electrical power are applied to the analyzer through power entry points (see Figure 3-4 Items A and B).

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

electrical compartment of the analyzer entry point (A).

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

analyzer entry point (C).

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

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Description

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The wiring diagram (Figure 3-6) for the purge electrical supply is in accordance the with the latest Pepperl+Fuchs 5500 Series Installation Manual Purge and Pressurization System documentation (www.Pepperl-fuchs.com). It is recommended that these instructions are verified from the Pepperl+Fuchs website to ensure the latest wiring instructions for the purge controller have been followed during installation. The complete wiring diagram used during the manufacture of the Rosemount CT5100(Ex) is included for reference in

Engineering drawings.

Figure 3-6: Pepperl +Fuchs Wiring Diagram (External Mount)

Figure 3-7: Pepperl +Fuchs Wiring Diagram (Internal Mount)

Figure 3-8: Pepperl +Fuchs Wiring Diagram (Terminal Block Connections)

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

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

system. Also see IEC60079-14.

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

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

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

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

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

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

(0.1 mm) or greater.

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

• Terminal torque is 0.5 Nm to 0.6 Nm.

• There shall be only one wire per terminal.

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

termination.

Description

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 0.7 ft. (0.2 m) and 49.2 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.

3.5.1

Explosion protection

The process gas stream being analyzed is highly flammable and explosive, as are other gases that could, in the event of a gas escape, be present around the analyzer. To prevent fires or explosion in the event of a gas escape, the analyzer has been designed to meet industry standard requirements for explosion protection.

A zonal approach to explosion protection has been adopted. A sample of the process gas stream passes through the analysis cell, and therefore the analysis cell is a sealed unit. The optical compartment is not airtight, and, in the event of a gas escape, flammable and explosive gases could enter the optical compartment. To prevent electrical ignition of a gas escape, all electrical components in the optical compartment (the pressure sensor, temperature sensor, and block heater) have been certified as safe for use in explosive

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Description Reference Manual

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atmospheres. The components in the optical compartment are mounted on a metal baseplate that is sealed to prevent gases from entering the electrical compartment.

The electrical compartment contains a PC and numerous electrical/electronic components that are not certified for use in hazardous atmospheres. To prevent explosive gases from entering the electrical compartment, it is sealed and held at a positive air pressure - above the surrounding air pressure - when the analyzer is switched on.

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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 for the analyzer while Table 4-2 gives the

general characteristics. Schematic diagrams of the analyzer are shown in Figure 4-1, Figure

4-2, and Figure 4-3.

Table 4-1: Physical Characteristics

Rosemount CT5100(Ex) Value Comment

External dimensions 22.68 x 11.7 x 30.94 in.

575 x 298 x 786 mm

Weight 121 lb.

55 kg

Length x width x height Nominal dimensions

Approximate weight

Table 4-2: General Characteristics

Rosemount™ CT5100(Ex) Value Units Comment

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

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

Peak power consumption 500 W Max consumption per gas analyzer

Continuous steady-state power consumption

Electrical compartment enclosure N/A N/A Stainless steel

Optical compartment enclosure N/A N/A Stainless steel

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

Operating conditions

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

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

300 W Once the gas analyzer has stabilized and

the analysis cell has reached the temperature set point

Diode Laser

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

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

2007)

Inlet gas port connector ¼

Reference Manual 39

in. mm

Swagelok® type, factory-configured, specify on order

Specifications Reference Manual

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Table 4-2: General Characteristics (continued)

Rosemount™ CT5100(Ex) Value Units Comment

Outlet (exhaust) gas port connector ¼

Purge connector ⅜

Purge air pressure 2 Barg

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

Communication 10/100 Mbps Ethernet

Warm-up time 90 minutes

in. mm

Swagelok type, factory-configured, specify on order

Purge inlet (certified system only)

Figure 4-1: Rosemount CT5100(Ex) Dimensions - Front View

A. Ventilation

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

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Figure 4-2: Rosemount CT5100(Ex) Dimensions - Top View

A. Ventilation

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

Figure 4-3: Rosemount CT5100(Ex) Dimensions - Bottom View

A. Atmospheric pressure refer plug

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

E. Cable glands

F. Purge vent

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Table 4-3: Environmental Characteristics

Environmental characteristic Value Units Comment

Operating temperature range -4 to 131

-20 to 55

Sample gas temperature range (Condition for safe use Europe)

Sample gas temperature range (Condition for safe use North

America)

Sample gas moisture content 20 % Maximum

Sample gas particulate density 5 mg/m

Sample gas particulate size 10 µm Maximum

IP code 66 N/A IP to IEC 60529

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

122 to 329 50 to 160

122 to 176 50 to 80

°F °C

Ambient temperature

Factory set, specify on order

Maximum

condensing) at 113 °F (45 °C)

4.3 Safety and system labels and annotation

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

Label type

Identification label (including serial number and model number

Example Location

Front panel

Fuse identification label 1. Back plate

2. Top right inside of door

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Label type Example Location

IECEx and ATEX ratings label Enclosure side panel

North America / Canada ratings label Enclosure side panel

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Label type Example Location

Universal Ratings Label Enclosure side panel

Laser radiation CAUTION label Baseplate

Laser module identification label On each laser module housing

Intrinsically safe label 1. HMI

2. Intrinsically safe sensor barrier

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Label type Example Location

Terminal label (typical layout) Top left inside of door

Earth identification label Back plate

Manufacturer's label On analysis cell heater block

Electrical safety label On inside of electrical compartment

door

AC Power Supply Danger label 1. On outside of electrical

compartment door

2. On manifold block of air overpressure system

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5 Install

5.1 Site selection

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

DANGER

FIRE AND EXPLOSION

The analyzer's electrical compartment must not be opened unless the atmosphere in the area is known to be below the ignitable concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in accordance with NFPA496.

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

DANGER

ELECTRIC SHOCK

The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Ensure that the circuit breakers are set to Off and locked out and tagged out off before removing the top cover or opening the front cover.

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

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

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

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Figure 5-1: Clearance with Door Open

A. Door open

B. Door closed

C. Door opening arc

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 121 lb. (55 kg) and should always be lifted and moved using suitable lifting/moving equipment. Emerson recommends that a minimum of two people using suitable tools for transportation and lifting are employed.

Wear suitable protective gloves and protective footwear.

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CAUTION

EQUIPMENT DAMAGE

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

Failure to observe may cause damage to the equipment.

WARNING

EXPLOSION HAZARD

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

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

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

WARNING

EXPLOSION HAZARD

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

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

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

WARNING

HEAVY ITEM

In accordance with IEC 60079-0: 2011 Clause 30. Failure to propery handle the analyzer may cause injury to personnel.

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

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

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

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CAUTION

SHOCK AND VIBRATION

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

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

Procedure

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

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

3. Report anything found to the maintenance organization.

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

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

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(Ex).

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

In accordance with IEC 60079-0: 2011 Clause 30. Failure to propery handle the analyzer may cause injury to personnel.

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

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

The analyzer weighs 121 lb. (55 kg). Emerson recommends that a minimum of two people move and lift the

analyzer. Wear suitable protective gloves and protective footwear.

2. Attach suitably rated and tested lifting slings to the safety engineered lifting eye bolts (see Figure 5-2, items A and D) mounted on top of the analyzer.

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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 points

F. Purge compressed air supply port

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

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

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

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

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

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

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

kg) each; this includes a x 2 factor of safety. Figure 5-4 shows the locations of the mounting points on the analyzer. All mounting points are 0.413-in. (10.5 mm) diameter holes.

Confirm the bolts are secure. Do not over tighten the fasteners. The analyzer must be mounted using the four off factory fitted and pre-drilled 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. For transportation, the purge vent (D) located on the base of the analyzer is fitted

with a temporary protector cap (C). This protector cap MUST remain in place until the analyzer is commissioned. Refer to Figure 5-3.

The vent cap (A), O-ring (E) and grub screws (B) are shipped loose in the crate. Refer to Figure 5-3.

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Figure 5-3: Connecting the Purge Vent Cap

A. Vent cap

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

E. O-ring

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

Refer to Figure 5-2. An Allen key is provided for the grub screws. The protector cap (C) must be retained as it will need to be refitted whenever the

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

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Figure 5-4: Mounting Details

A. Mounting points

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Figure 5-5: Clearance with Door Open

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 (B) and the purge controller through the purge power and alarm entry point (A) fitted to the base of the analyzer. Refer to Figure 5-6.

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Figure 5-6: Power Gland

A. Purge power and alarm entry point

B. Power entry point

Two sources of electrical power are applied to the analyzer:

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

electrical compartment of the analyzer. Refer to Figure 5-6 (Item A).

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

analyzer. See Figure 5-6 (Item B).

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

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Figure 5-7: Power Entry Point Connections

A. To mains input fuses

B. Mains input filter

C. To enclosure earth stud

Table 5-1: Mains Input Terminal

Terminal Function

1 Sensor system supply (L)

2 Sensor system supply (N)

3 Earth

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Figure 5-8: Purge Power and Alarm Entry Point Connections

A. SV1

B. Power C. Bypass D. To purge solenoid

E. To be run separately from other cables looms

F. To PT100 sensor

Note

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

Terminal

L Purge control supply (live)

N Purge control supply (neutral)

K1 (normally open) Alarm contract

K2 (normally closed) Alarm contract

Function

Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 5-9.

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

Purge supply voltage 100 to 230 Vac, 2.3

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

VA (without digital valve)

Voltage Fuse

internal fuses F1 and F2

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

AC: 2.0A

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

Fuses

Figure 5-9 shows the location of the fuses.

Figure 5-9: Fuses

A. Fuse F4 (24 Vdc supply)

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

Table 5-3: Fuse Requirements

Fuse Function Rating Schurter part number

1 Live line 110/230 Vac

(following mains filter)

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3.15 A, 250 V, fast acting ceramic

0001.1009

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Table 5-3: Fuse Requirements (continued)

Fuse Function Rating Schurter part number

2 Neutral line 110/230

Vac (following mains filter)

3 Analyzer 12 Vdc supply

rail

4 Analyzer 24 Vdc supply

rail

3.15 A, 250 V, fast acting ceramic

5 A, 250 V, fast acting ceramic

3.15 A, 250 V, fast acting ceramic

0001.1009

0001.1011

0001.9011

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 an entry point outlet 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 entry point provided in accordance with local electrical codes.

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Figure 5-10: Signal Cable Outputs

A. To digital modules

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

E. To status relays

F. Status output terminals

Table 5-4: User Connections

Terminal Function

11 Digital output 1

12 Digital output 2

13 Digital output 3

14 Digital output 4

15 Digital output 5

16 Digital output 6

17 Digital output 7

18 Digital output 8

19 Digital output 9

20 Digital output 10

21 Digital output 11

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Table 5-4: User Connections (continued)

Terminal Function

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)

Install

34 Status output 4 (failed)

5.4.5 Power input cables and circuit breakers

WARNING

FLAMMABLE/EXPLOSIVE GASES

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

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

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

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

when the K1 LED on the purge control panel comes on indicating the purge process is complete can you proceed to the next step. Refer to Figure 6-4.

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

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

5.4.6

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Temperature sensor and cell heater

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

screen.

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

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 Beka Display Controller as described in Pressure and Temperature screen.

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

NOTICE

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

5.4.8

5.4.9

Analog output cables

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

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

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

Ethernet

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

DANGER

FIRE AND EXPLOSION

The electrical compartment of the analyzer must not be opened unless the atmosphere in the area is known to be below the ignitable concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in accordance with NFPA 496.

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

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5.4.10 Seal glands

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

5.4.11 Commissioning

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

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6 Controls and display controller

6.1 Front panel controls and indicators

The Rosemount™ CT5100(Ex) is configured from the two control displays located on the front panel. Refer to Figure 6-1.

Figure 6-1: Front Panel

A. Display controller

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

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Figure 6-2: Exploded View

A. Vent cap

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

E. O-ring

The protector cap (Figure 6-2, C) must be removed from the purge vent (D) and replaced with the vented cap (A) supplied with the unit.

NOTICE

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

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

Operation of the analyzer is controlled primarily through the display controller. Refer to Figure 6-3.

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Figure 6-3: Display Controller

The purge control panel (Figure 6-4) is used to program the operation of the overpressure air system that prevents flammable and explosive gases from entering the analyzer's electrical compartment. Adjustment of the overpressure air system must only be performed by maintenance personnel.

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

Figure 6-4: Purge Control Panel

6.2 Display controller

Operation of the Rosemount CT5100(Ex) is controlled through the six buttons on the display controller: Figure 6-5.

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

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• Gas concentration measurements obtained

• Operating temperature and pressure

• Help screens

• Step-by-step calibration

• Diagnostics

Figure 6-5: Display Controller Buttons

A. LCD display

B. Configurable button C. Scroll button D. Configurable button

E. Configurable button

F. Scroll button

G. Configurable button

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

The other four buttons (B, D, E, and G) are configured to perform different functions according to which software screen 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 6-6) appears appears.

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

NOTICE

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

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Figure 6-6: Gas Sensor Main Screen

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

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

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

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

Figure 6-7, the analyzer is Running and OK (i.e., no faults have been identified). This area of

the display shows any errors detected by the software. On the software screens, highlighted items are links to other screens in the software. To

access a screen, press the button next to the highlighted item.

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Figure 6-7: Gas Sensor Main Screen Buttons

A. MENU button

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

E. HELP button

F. HELP text

G. STATUS button

PAGE (C) is a link between the Gas Sensor Main screen and the Pressure and Temperature

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

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

system).

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

On the Gas Sensor Main screen, STATUS (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.

6.4 Pressure and Temperature screen

The Pressure and Temperature screen (Figure 6-8) shows pressure and temperature measurements taken inside the analyzer.

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Figure 6-8: Pressure and Temperature Screen

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

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

NOTICE

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

6.5 Help system

The analyzer software includes a context-sensitive help system. Press , 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 was pressed. Figure

6-9 shows an example of a Help screen.

Figure 6-9: Example of a Help Screen

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6.6 Main menu

To access the Main menu (Figure 6-10), press the MENU button on either side of the Gas Sensor Main screen (Figure 6-6). or the Pressure and Temperature screen (Figure 6-8). The Main menu is used for calibration, diagnostics, fault finding, downloading data, and

shutting down the analyzer.

Figure 6-10: Main Menu

6.7 BACK button

On most of the software screens, the top left-hand button (Figure 6-11) is configured as a BACK button. Press BACK (A) to return to the previous screen.

Figure 6-11: 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

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

CAUTION

EQUIPMENT DAMAGE

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

Before commencing the start-up process, ensure that electrical power, sample gas handling facilities, and any calibration gases that are required are available to the analyzer. Failure to perform pre-system start-up checks may cause damage to equipment.

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WARNING

BURN HAZARD

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

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

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

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

7.3 Start-up

Note

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

Note

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

To start up the analyzer,

Procedure

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

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

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

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

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

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

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

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

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

7. Visually examine the three gas ports.

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

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Figure 7-1: Rosemount CT5100(Ex) Gas Inlet and Outlet and Electrical Connections

A. Sample gas return port

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

E. Laser/electrical compartment

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

8. Visually check that the electrical connections have been made to the three power entry points, Figure 7-1, at the base of the analyzer.

9. Visually check that the vent cap is fitted to the purge vent (Figure 5-3).

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UNDER NO CIRCUMSTANCES must the analyzer be started with the protector cap fitted as this will prevent the analyzer from venting during the purge process.

WARNING

FLAMMABLE/EXPLOSIVE GASES

The purge/pressurization cycle expels any flammable or explosive gases from the analyzer's electrical compartment. The analyzer must be purged for a minimum of 2 minutes 30 seconds at a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during the startup process.

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

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

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

Figure 7-2: Purge Control Panel

A. K1 LED

B. P/SV LED

C. PT100 LED

12. Observe the PT100 LED on the purge control panel (Figure 7-2).

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If the PT100 LED (C) illuminates red, the air pressurization system is unserviceable, and the start-up procedure must be halted immediately. To halt the start-up procedure, set the external main circuit breaker to Off. Lock off or tag off the main circuit breaker, turn off the compressed air supply, and report the fault to the maintenance organization.

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

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

WARNING

FLAMMABLE/EXPLOSIVE GASES

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

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

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

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

After a few seconds, the Gas Sensor main screen (Figure 7-3) appears on the display controller. If it does not, report the fault to the maintenance organization.

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Figure 7-3: Gas Sensor Main Screen

16. Start up the system for returning sample gas.

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

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

The start-up procedure is now complete.

7.4 Front panel controls and indicators

The Rosemount CT5100(Ex) is configured from the control display located on the front panel (Figure 7-4).

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Figure 7-4: Front Panel

A. Display controller

B. Purge control panel

NOTICE

On/Off circuit breakers

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

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

Operation of the analyzer is controlled primarily through the display controller (Figure

7-5).

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Figure 7-5: Display Controller

CAUTION

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

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

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

and/or personal injury or death.

Figure 7-6: Default Program Screen

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

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

Figure 7-7: Purge Control Panel (if Applicable)

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8 Operating the analyzer

8.1 Introduction

This section describes the normal operation of the analyzer.

NOTICE

WARNING

BURN HAZARD

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

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

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

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

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 Shutdown procedure 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

WARNING

BURN HAZARD

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

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

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

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

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9.2 Shutdown procedure

To shut down the analyzer:

DANGER

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 gas handling system may cause death.

Always lock 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.

DANGER

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.

3. Allow the analyzer to run for five minutes with the purge gas connected, so that any

sample gas in the analyzer is vented to the exhaust. On the display controller, check that the gas concentrations read 0 ppm before stopping the purge flow.

WARNING

HIGH PRESSURE 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).

4. Turn off the calibration gas supply to the analyzer. Lock out and tag out the

compressed air supply.

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5. 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

6. On the Display Controller, select System as shown in Figure 9-4 (B).

7. Press SEL (select) (B). 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

8. Use scroll up (C) and scroll down (E) to select SHUTDOWN as shown in Figure 9-4 (B). Then press SEL (select) (B). The Shutdown screen (Figure 9-5) opens.

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Figure 9-5: Shutdown Screen

9. Press YES. The analyzer shuts down.

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

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

12. Remove the vent cap and O-ring fitted to the purge vent (see Figure 5-3) and fit the protector cap that was supplied with the analyzer to prevent moisture ingress during a prolonged shutdown.

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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.

CAUTION

EQUIPMENT DAMAGE

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

or death.

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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 in to the software. The calibration functions are accessed through the Main menu (Figure 10-4).

Procedure

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

NOTICE

Pressing the BACK button cancels the procedure and returns you to the previous screen.

Figure 10-2: Gas Sensor Main Screen

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Figure 10-3: Pressure and Temperature Screen

2. The Main menu (Figure 10-4) is used to access the software routines and screens that are used throughout the process.

Figure 10-4: Main Menu

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

4. Press the SEL button.

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Figure 10-5: Gas Service (PER GAS)

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

6. Press the SEL button.

Figure 10-6: Select Gas (NO)

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

8. Press the SEL button.

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

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Figure 10-7: Action

Figure 10-8: Calibration

10. Use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to enter the desired offset (in the example above, -0.06ppm).

11. 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.

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

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Figure 10-9: Input Type

Figure 10-10: Calibration

13. Use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to enter the desired offset (in the example above, 1.06 ppm).

14. Press OK to confirm. The factory default span factor is one, and under normal circumstances, the offset

should be between 0.8 and 1.2.

10.2.1

Zero calibrate an individual gas

Procedure

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

NOTICE

Pressing the BACK button will cancel the procedure and return the user to the previous screen.

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

Figure 10-11: Main Menu (GAS SERVICE)

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

Figure 10-12: 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 the SEL button.

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)

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

Figure 10-15 displays as the calibration progresses.

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Rosemount CT5100(Ex) Continuous Gas Analyzer Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Introduction

1.1 Description

1.2 Customer information

1.3 Safety precautions and conditions for safe use

Qualified personnel

1.5 Software version

1.6 Glossary and abbreviations

2 Theory of operation

2.1 Overview

2.2 Laser measurement principle

2.3 Gas concentration measurements

3 Description

3.1 Equipment purpose and role

3.2 System overview

3.2.1 Explosive safety

3.3 Gas flow through analyzer

3.4 Connecting the electrical/electronic inputs and outputs

3.5 Optical description

Explosion protection

4 Specifications

4.1 Gas detection

4.2 Detailed system specifications

4.3 Safety and system labels and annotation

5 Install

5.1 Site selection

5.2 Unpacking

5.3 Mounting the analyzer

5.4 Connecting the electrical/electronic inputs and outputs

5.4.1 AC power

Fuses

5.4.3 Connecting the sample supply and return line

Connecting the signal cables

5.4.5 Power input cables and circuit breakers

Temperature sensor and cell heater

5.4.7 Pressure sensor

Analog output cables

Ethernet

5.4.10 Seal glands

5.4.11 Commissioning

6 Controls and display controller

6.1 Front panel controls and indicators

6.2 Display controller

6.3 Gas Sensor Main screen

6.4 Pressure and Temperature screen

6.5 Help system

6.6 Main menu

6.7 BACK button

7 Start-up procedure

7.1 Introduction

7.2 Preparation for use

7.3 Start-up

7.4 Front panel controls and indicators

8 Operating the analyzer

8.1 Introduction

8.2 Normal operation

9 Shutdown procedure

9.1 Shutdown procedure safety precautions

9.2 Shutdown procedure

10 Gas calibration

10.1 Required tools

10.2 Main menu calibration routines

Zero calibrate an individual gas