Quick Start Guide
00825-0100-3511, Rev AA
August 2020
Rosemount ™ CT5100 QSG Continuous
Gas Analyzer
Quick Start Guide August 2020
Safety precautions
Important
The precautions in this manual MUST NOT be changed amended or removed. All authorized users,
installation, operation and maintenance personnel, must observe the following safety precautions and
warnings.
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or serious injury to personnel.
Death, personal injury, and/or damage to persons and/or property may result if this is not observed.
Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the
top cover or opening the front cover. The analyzer must be earthed.
Only trained, qualified personnel may install and connect power and signal cables. The installation/
connection must be in accordance with all legislative requirements and applicable standards.
Only qualified personnel, familiar with potential risks, should install the analyzer.
WARNING
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition
source. The interior of a analyzer is always hot unless it has been switched off and allowed to cool
down. A fire may result if this precaution is not observed.
Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.
WARNING
TRANSPORTATION HAZARD
The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/
moving equipment.
Handle the analyzer with caution during unpacking, installation, maintenance, and transport to
prevent crushing of hands, feet, or other body parts.
Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by
air, road, or rail, safeguard the analyzer against movement or break-away during transport by securely
strapping it in place.
Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings
for the weight of the equipment, and is in good operational condition.
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WARNING
FIRE AND EXPLOSION
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not
avoided, may cause death, personal injury, and/or damage to persons and/or property.
Always lock out the gas handling system when shutting down the analyzer.
DO NOT operate the analyzer with doors or covers open.
Refer to local regulations as this may require a competent hot work supervisor to issue a hot work
permit.
When the analyzer is out of order all inputs and outputs connected to external equipment MUST be
shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not
pressurized.
Only properly trained personnel who understand the contents of all applicable manuals and related
instructions should start up the analyzer.
Use only replacement parts and components authorized by Emerson.
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
a customer serviceable item.
only be conducted by Rosemount Customer Care personnel. It is
MUST
NOT
WARNING
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause
an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury,
and/or damage to persons and/or property.
Operators and service personnel do not have access to the laser/electrics or upper cell compartments
for general maintenance or service.
WARNING
BURNS
Some parts of the analyzer may be heated to 374 °F (190°C). To prevent burns, do not touch any of the
hot parts.
Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been
switched off and allowed to cool for at least two hours. Before performing any maintenance on, or in
the vicinity of, the analysis cell, allow the analyzer to cool for at least 12 hours as the analysis cell is
insulated against heat loss.
When handling the analyzer, always wear suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
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WARNING
HAZARDOUS SUBSTANCES
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and
components with extreme caution. Wear personal protective equipment (PPE) when handling the
equipment.
Gas handling components within the analyzer contain particulate matter residue from the sample
gases. Over the life of the the analyzer, the concentration of particulate matter will become enriched
within the gas handling components. When performing repairs and maintenance on the the analyzer:
Handle used gas handling components with extreme caution.
Avoid direct skin contact with used gas handling components.
Do not smoke, drink, or eat in the work area.
Wear goggles or eye shields.
Wear a suitable face mask to protect against inhalation of particulate matter.
Do not wet fingers, eyes, or any exposed skin.
Pack used gas handling components for disposal in sealed packaging and label them
Contaminated.
Dispose of contaminated items as hazardous material in accordance with applicable local,
national, or international health and safety regulations and pollution regulations.
Take special care to ensure that the sample gas return port either returns the sample gas to the
product stream or discharges the sample gas to a location that will not cause a hazard.
WARNING
OPTICAL RADIATION EXPOSURE HAZARD
There are three types of laser that may be included in the Rosemount CT5100: Quantum Cascade
Lasers (QCLs), Interband Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are
Class 1. The characteristics of the lasers contained within the analyzer are given in the table below.
The emitted laser light is invisible (mid-infrared), and the combined laser powers are sufficiently low at
the first accessible aperture that the unprotected eye will not be damaged. This class is eye safe under
all operating conditions.
It is, however, possible to cause damage to the eye through not following correct procedures. Do not
look at the laser with any kind of magnifier or optical measuring device.
Parameter QCL ICL Diode Comment
Operation mode Pulsed Pulsed Pulsed N/A
Lasers per system 1 - 6 1- 6 1- 6 Maximum of 6 lasers per system
Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A
Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first
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.
< 100 kHz < 100 kHz < 100 kHz N/A
accessible aperture: < 9.62 mW
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The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10.
The use of controls or adjustments or performance of procedures other than those specified herein
may result in hazardous radiation exposure.
WARNING
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g.,
damage to eyes and skin punctures from debris blown by the high pressure gas or compressed air.
Always lock off or tag out the calibration gas supply and compressed air supply when shutting down
the analyzer.
The maximum gas pressure valve must not exceed 100 psig (690 kPa).
WARNING
HAZARD BY WRONG INPUT VOLTAGE
Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an
explosion, injury, or damage to the installation. Failure to observe this warning could cause an
explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury,
and/or damage to persons and/or property.
This type of analyzer is always setup for a specific rated input voltage; see nameplate label.
Ensure the voltage at site of installation meets the rated analyzer input voltage.
WARNING
MAINTENANCE/MODIFICATIONS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided,
could result in death or serious injury.
On completion of any maintenance and or modifications verify:
All tools and equipment are removed.
No contamination (water/dust) is in the compartments.
Analyzer is wiped clean.
Vents are clear and not obstructed.
Verify that system is in a safe state for operation.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end
users’ equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true for
all systems used within the facility.
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CAUTION
EQUIPMENT DAMAGE
Failure to perform pre-system start-up checks may cause damage to equipment.
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and
pneumatic connections to the analyzer are in place.
Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the analyzer.
Always follow the Start-up procedure.
Always follow the Shutdown procedure.
CAUTION
UNSERVICEABLE EQUIPMENT
If the pressure and temperature screen does not display measurements similar to those shown in
Figure 7-1 and Figure 7-2 .
CAUTION
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in
which case the user may be required to take adequate measures.
As a general principle, if any optical component other than the cell assembly, the laser modules, and
the detectors is unserviceable, the analyzer must be repaired by Emerson. This is because the repair,
replacement, and alignment of the optical components requires the use of special optical test/
calibration equipment and procedures.
Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement
procedure is given in this manual, then the fault must be repaired by Emerson.
Contents
Introduction.................................................................................................................................7
Description................................................................................................................................ 10
Specifications.............................................................................................................................12
Install......................................................................................................................................... 18
Controls and display controller...................................................................................................32
Start-up procedure.....................................................................................................................39
Operating the analyzer...............................................................................................................45
Shutdown procedure................................................................................................................. 47
Engineering drawings.................................................................................................................52
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1 Introduction
1.1 Description
The Rosemount™ CT5100 Continuous Gas Analyzer, referred to hereafter as
the Rosemount CT5100, or analyzer, is an electronic sensor that uses laser
spectroscopy to perform analysis of process gas streams.
Important
The Rosemount CT5100 is designed for use in Non Hazardous areas ONLY.
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 .
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
SAFE USE PRECAUTIONS
Before installing or performing any maintenance on the analyzer, read and
understand the safety information given in the preliminary information of
this manual.
The analyzer described in this document 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 (mid-infrared) and the pulse duration so short that the unprotected
eye will not be damaged.
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The nature of the laser beam path and beam width further ensures that it
should be impossible to cause any eye damage. The analyzer has warning
labels at appropriate positions in accordance with USA 21 CFR 1040.10.
General safety notice/residual risk
Installation, operation, and maintenance of the analyzer must be in
accordance with these instructions.
When operated as intended and all applicable safety instructions are
observed, an element of risk will remain, including, but not limited to, the
following:
• The emission of gases hazardous to health may be possible when all gas
connections have been correctly made.
• To avoid exposure to the dangers of residual risks, take particular care
when installing, operating, maintaining, and servicing the analyzer.
1.4 Qualified personnel
In-depth specialist knowledge is an absolute requirement for working with
and on the analyzer. Personnel installing, operating, servicing, and
maintaining the analyzer must be instructed, trained, qualified, and
authorized personnel of the operating company for hazardous areas and the
manufacturer.
It is the operating company's responsibility to:
• Train staff
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Be trained
• Read and understand all relevant sections of the product manual before
commencing work
• Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this
equipment and on-site property, do not install, operate, maintain, or service
this analyzer before reading and understanding this reference manual and
receiving appropriate training.
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1.5 Software version
The analyzer includes software that is used to control the operation of the
analyzer. This document describes the software version as: 5.7.13.
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2 Description
2.1 System overview
A complete Rosemount™ CT5100 system consists of the analyzer, and the
associated interconnecting wiring and gas piping.
The customer MUST provide the gas handling system and interconnecting
wiring and gas piping.
The circuit breaker used to control the application of electrical power to the
analyzer, the interconnecting wires, and gas piping are provided by the
customer.
In Figure 2-1, the items supplied by Emerson are colored blue; the items
supplied by the customer are colored purple. The green gas handling system
may be provided by Emerson or the customer.
Figure 2-1: Rosemount CT5100 Installation
A. Gas handling system
B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT5100
E. Electrical power
F. Two pole main isolator complete with RCD
G. Control center
H. Measurement data
The analyzer contains an optical system with multiple lasers and a series of
optical components that provide an optical path, a heated multi-pass
analysis cell, and sample inlet and outlet ports that can be connected to a
gas handling system and control and analysis electronics. The number of
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lasers installed depends upon customer requirements. The complete system
operates at either 110 or 240 Vac 50/60 Hz supply.
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3 Specifications
3.1 Detailed system specifications
Table 3-1 gives the physical characteristics of the analyzer. Schematic
diagrams of the sensor and mounting points are shown in Figure 3-1 and
Figure 3-2. Table 3-2 gives the general characteristics of the analyzer.
Table 3-1: Physical Characteristics
Rosemount CT5100 Value Comment
External dimensions 22.64 x 11.73 x 28.11 in.
Weight 117 lb.
575 x 298 x 714 mm
53 kg
Table 3-2: General Characteristics
Rosemount CT5100 Value Units Comment
Instrument supply voltage 110 to 240 Vac 50/60 HZ ±10%
Peak power consumption 500 W Max consumption per
Continuous steady-state
power consumption
Electrical compartment
enclosure
Optical compartment
enclosure
Wetted materials N/A N/A AISI 316 (EN 1.4401
300 W Once the gas analyzer
N/A N/A 304 stainless steel
N/A N/A Polyester TGIC free
Length x width x height
Nominal dimensions
Approximate weight
gas analyzer
has stabilized and the
analysis cell has reached
the temperature set
point
powder coated 304
stainless steel
grade) stainless steel
tubing and fittings
including thermowell
and pressure diaphragm,
PFA coated aluminum
cell body, PTFE seals,
protected gold coated
mirrors, CaF2 windows,
and FKM (typically
Viton™) or FFKM
(typically Kalrez™) Orings
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Table 3-2: General Characteristics (continued)
Rosemount CT5100 Value Units Comment
Measurement technique N/A N/A Mid infrared (IR)
Mid IR source N/A N/A Quantum Cascade Laser
Near IR source Interband Cascade Laser
Laser classification Class 1 BS EN 60825-1: 2007
Inlet gas port connector ¼
Outlet (exhaust) gas port
connector
Measurement result signals 4 to 20 mA 4 or 8 channel outputs,
Communication 10/100 Mbps Ethernet
Warm-up time 90 minutes N/A
6
¼
6
in.
mm
in.
mm
absorption spectroscopy
Diode Laser
safety of laser products.
Equipment classification
and requirements
(identical to IEC 60825-1
2007)
Swagelok® type, factoryconfigured, specify on
order
Swagelok type, factoryconfigured, specify on
order
specify on order
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Figure 3-1: Rosemount CT5100 Dimensions - Front View
Dimensions are in inches (mm).
A. Lifting eyelet
B. Ventilation
C. User interface
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Figure 3-2: Rosemount CT5100 Dimensions - Top View
Dimensions are in inches (mm).
A. Lifting eyelet
B. Sample return
C. Sample inlet
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Figure 3-3: Rosemount CT5100 Dimensions - Bottom View
Dimensions are in inches (mm).
A. Cable glands
B. Earth point
Table 3-3: Environmental Characteristics
Environmental
characteristic
Operating temperature
range
Sample gas temperature
range
Sample gas particulate
density
Sample gas particulate size 10 µm Maximum
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Value Units Comment
-4 to 131
-20 to 55
131 to 374
50 to 190
5 mg/m
°F
°C
°F
°C
3
Ambient temperature
Factory set, specify on
order
Maximum
August 2020 Quick Start Guide
Table 3-3: Environmental Characteristics (continued)
Environmental
characteristic
IP code IP66 (electrical
Sensor humidity range 10 to 95 % Relative humidity (non-
Value Units Comment
N/A IP to IEC 60529
compartment
enclosure)
IP20 (optical
compartment
enclosure)
condensing) at 113 °F (45
°C)
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4 Install
4.1 Site selection
The Rosemount CT5100 has a T3 temperature classification which specifies
the maximum surface temperature of the analyzer.
WARNING
FIRE AND EXPLOSION
Death, personal injury, and/or damage to persons and/or property may
result if this is not observed.
The analyzer's electrical compartment must not be opened unless the
atmosphere in the area is known to be below the ignitable concentration of
combustible gases or materials, or unless all equipment within the protected
enclosure is de-energized.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or
serious injury to personnel. Failure to observe this precaution will cause
death, personal injury, and/or damage to persons and/or property.
Ensure that the circuit breakers are set to Off and locked out and tagged out
off before removing the top cover or opening the front cover.
The analyzer is intended to be installed in a suitable Division 2 shelter to
protect it from the elements.
Provide sufficient space around the analyzer to allow the maintenance and
servicing of the unit.
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4.2 Unpacking
This procedure requires a minimum of two people to safely remove the
equipment from the shipping container.
WARNING
HEAVY INSTRUMENT - LIFTING HAZARD
Handle the analyzer with caution during unpacking, installation,
maintenance, and transport to prevent crushing of hands, feet, or other
body parts.
The analyzer weighs and should always be lifted and moved using suitable
lifting/moving equipment. Emerson recommends that a minimum of two
people using suitable tools for transportation and lifting are employed.
Wear suitable protective gloves and protective footwear.
CAUTION
EQUIPMENT DAMAGE
Failure to observe this caution may cause damage to the equipment.
When preparing the analyzer for transport by air, road, or rail, safeguard the
analyzer against movement or break-away during transport by securely
strapping it in place.
WARNING
EXPLOSION HAZARD
Installing and wiring the analyzer must comply with all relevant national
legislative requirements and regulations.
Consider all safety instructions within this manual and all associated analyzer
instruction manuals.
WARNING
EXPLOSION HAZARD
Installing the analyzer requires opening the enclosure and working at the
open unit. This is permitted only when both the analyzer and connected
external circuitry are de-energized.
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
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WARNING
HEAVY ITEM
Failure to propery handle the analyzer may cause injury to personnel.
Ensure the wall the analyzer is mounted on is solid, stable, and of suitable
material to hold the weight of the analyzer.
Handle the analyzer with caution during unpacking, installing,
maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
Emerson recommends that a minimum of two people move and lift the
analyzer.
Wear suitable protective gloves and protective footwear.
CAUTION
SHOCK AND VIBRATION
Damage to the analyzer may result from a failure to follow this caution.
The analyzer contains sensitive electronic equipment. It MUST NOT be
subjected to any shock and or vibration.
Procedure
1. On receipt of goods, look for any visible damage to the analyzer and
verify that all items 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.
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4.3 Mounting the analyzer
This procedure requires two people to safely move and mount the
Rosemount CT5100.
Procedure
1. Ensure that there is free space around the analyzer to allow
ventilation of the upper part of the analyzer.
WARNING
HEAVY ITEM
Failure to propery handle the analyzer may cause injury to personnel.
Ensure the wall the analyzer is mounted on is solid, stable, and of
suitable material to hold the weight of the analyzer.
Handle the analyzer with caution during unpacking, installing,
maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
The analyzer weighs 117 lb. (53 kg).
Emerson recommends that a minimum of two people move and lift
the analyzer.
Wear suitable protective gloves and protective footwear.
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2. Attach suitably rated and testing lifting slings to the safety
engineered lifting eye bolts mounted on top of the analyzer.
Figure 4-1: Front View Dimensions
Dimensions are in inches (mm).
A. Lifting eye bolt
B. Sample gas input port
C. Sample gas return port
D. Lifting eye bolt
E. 0.413-in. (10.5 mm) diameter mounting bolts
3. One person should carefully guide the equipment while the other
person operates the lifting equipment.
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4. Use safety approved and tested lifting equipment to lift the analyzer
from the stable platform.
5. Ensure that the wall fixing points are capable of supporting a load of
242 lb (110 kg) each; this includes a x 2 factor of safety. Figure 4-2
shows the locations of the mounting points on the analyzer.
6. Mount the analyzer using four M8 (⅜-in.) fasteners to attach to the
wall. Do not overtighten the fasteners..
The bolts must be positioned in such a way to allow maximum use of
all the thread length.
7. Remove the lifting eyes and retain them for future use.
Threads must be protected with a suitable grease and plastic
grommets.
Figure 4-2: Mounting Details
Dimensions are in inches (mm).
A. Mounting points
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Figure 4-3: Clearance with Door Open
Dimensions are in inches (mm).
A. Door open
B. Door closed
C. Door opening arc
Postrequisites
After mounting, do not place any additional load on the analyzer. or leave
any loose items on flat surfaces.
4.4
Connecting the electrical/electronic inputs and outputs
4.4.1 AC power
Power is connected to the analyzer instrumentation through the power
entry point fitted to the base of the analyzer. Refer to Figure 4-4.
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Figure 4-4: Power Gland
A. Power and signal/exit points
B. M6 earth stud
The customer supplied circuit breaker, complete with RCD, MUST be in
accordance with local and national standards.
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Figure 4-5: Power Entry Point Connections
A. To mains input fuses
B. Mains input filter
C. To enclosure earth stud
Table 4-1: Mains Input Terminals User Connections
Terminal Function
1 Sensor system supply (L)
2 Sensor system supply (N)
3 Earth (E)
Electrical protection for the instrumentation circuitry of the analyzer is
provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 4-6.
The customer supplied power cable for the analyzer instrumentation will be
connected to terminals 1 - 3.
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Table 4-2: Electrical Power Requirements
Electrical supply Power
Instrumentation
supply voltage
For the electrical power wiring use 16 AWG stranded, three conductor
copper or tin-plated copper power wire, rated for at least 250 Vac, of the
required length. Cables must be terminated in the power entry points in
accordance with local and national electrical codes. The full electrical wiring
diagram is provided in Engineering drawings.
4.4.2 Fuses
Figure 4-6 shows the location of the fuses.
Figure 4-6: Fuses
consumption
Voltage Fuse
500 W 100 to 230 Vac, 50/60 Hz
±10%
3.15 A
internal
fuses
F1 and F2
A. Fuse F4 (24 Vdc supply)
B. Fuse F3 (12 Vdc supply)
C. Fuse F1 (mains supply – live)
D. Fuse F2 (mains supply – neutral)
E. Industrial power supply
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Table 4-3: Fuse Requirements
Fuse Function Rating Schurter part
1 Live line 110/240
Vac (following
mains filter)
2 Neutral line
110/240 Vac
(following mains
filter)
3 Analyzer 12 Vdc
supply rail
4 Analyzer 24 Vdc
supply rail
3.15 A, 240 V, fast
acting ceramic
3.15 A, 240 V, fast
acting ceramic
3.15 A, 240 V, fast
acting ceramic
3.15 A, 240 V, fast
acting ceramic
4.4.3 Connecting the sample supply and return line
Sample gas supply and sample return connections are ¼-in. (6
mm) ”Hamlet” compression tube fittings. To avoid the risk of gas leaks,
confirm that these connections are made correctly and tightly. Both the
sample gas supply pipe and the sample return pipe should be thermal
insulated.
The maximum sample gas supply pressure is 2 BarG.
4.4.4 Connecting the signal cables
The signal cables are connected to the system through conduit outlets (B
and C as shown in Figure 1). All signal cables are to be minimum 20 AWG trirated switchgear cable. Customer supplied conduit and cables are to be
terminated in the conduit outlets in accordance with local and national
electrical codes.
number
0001.1009
0001.1009
0001.1009
0001.1009
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Figure 4-7: Signal Cable Outputs
A. To mains input fuses
B. Mains input filter
C. To enclosure earth stud
D. To digital modules
E. To digital modules
F. To analog modules
G. To status relays
H. Digital output terminals
I. Analog or digital output terminals
J. Analog output terminals
K. Status output terminals
L. Mains input terminals
Table 4-4: System Wiring
Terminal Function
1 Sensor system supply (L)
2 Sensor system supply (N)
3 Earth
11 Digital output 1
12 Digital output 2
13 Digital output 3
14 Digital output 4
15 Digital output 5
16 Digital output 6
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Table 4-4: System Wiring (continued)
Terminal Function
17 Digital output 7
18 Digital output 8
19 Digital output 9
20 Digital output 10
21 Digital output 11
22 Digital output 12
23 Analog output 1
24 Analog output 2
25 Analog output 3
26 Analog output 4
27 Analog output 5
28 Analog output 6
29 Analog output 7
30 Analog output 8
31 Status output 1 (Check function)
32 Status output 2 (Maintenance required)
33 Status output 3 (Out of specification)
34 Status output 4 (Failed)
01 Analog or digital input/output
02 Analog or digital input/output
03 Analog or digital input/output
04 Analog or digital input/output
05 Analog or digital input/output
06 Analog or digital input/output
4.4.5 Power input cables and circuit breaker
The power input cable circuit breaker can be tested as follows:
• Set the main power circuit breaker to ON.
• Check that the display controller lights up. The analyzer will then begin
to power-up.
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4.4.6 Temperature sensor and cell heater
The sample cell is controlled to operate at a pre-set temperature when it
leaves the factory.
With the analyzer on, the cell will reach the pre-set operating temperature in
approximately 90 minutes.
4.4.7 Pressure sensor
The pressure sensor monitors the pressure in the analysis cell.
To test that it is functioning, check that a pressure reading is displayed under
pressure on the Display Controller as described in Pressure and Temperature
screen.
The reading will be approximately 760 Torr at atmospheric pressure. If
desired, cap off the gas inlet and use an external pump to evacuate the cell.
Verify that the pressure drops as expected.
NOTICE
A Torr is a non-SI unit of pressure, defined as 1/760 of standard atmospheric
pressure, and is equal to the fluid pressure of 1 mm of mercury.
4.4.8 Analog output cable
In order to generate a 4-20 mA output, the analyzer must be left for 90
minutes to warm up, and the analysis cell must be at the correct pressure.
The 4-20 mA outputs will operate when the analysis cell temperature and
pressure are within the required test range. It is not essential to flow sample
gas through the system; nitrogen or atmospheric air will be adequate for this
test.
With the analyzer at operating temperature and pressure, ensure that a
current between 4 mA and 20 mA is generated on each 4-20 mA output.
This can either be measured as a current with a multimeter, or as a gas
concentration through the control station.
4.4.9 Seal glands
Where poured seal glands are a local industry requirement for cable
termination, they should be made in accordance with the manufacturer’s
instructions once acceptance tests have been made on the system to ensure
that the analyzer does not need to be removed.
4.4.10 Commissioning
Once the sensor is fully installed as described above, it should be
commissioned in accordance with the commissioning plan agreed between
Emerson and the customer.
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5 Controls and display controller
5.1 Front panel controls and indicators
The Rosemount™ CT5100 is configured from the control display located on
the front panel.
A. Display controller
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NOTICE
ON/OFF circuit breaker
There is no ON/OFF switch on the analyzer. The external circuit breaker
controls the application of electrical power to the analyzer.
The external circuit breaker is a simple two-pole ON/OFF circuit breaker that
must to set to ON to permit the safe operation of the analyzer.
The display controller controls operation of the analyzer.
5.2 Display controller
The six buttons on the display controller control operation of the Rosemount
CT5100.
A. LCD display
B. Configurable button
C. Scroll up button
D. Scroll down button
The LCD display can be used to display:
• Gas concentration measurements obtained
• Operating temperature and pressure
• Help screens
• Step-by-step calibration
• Diagnostics
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Use the two scroll buttons to scroll through the information on the LCD
display. Use the right-hand scroll button to scroll up and the left-hand scroll
button to scroll down.
5.3 Gas Sensor Main Screen
When the analyzer is switched on at the end of the start-up procedure, the
Gas Sensor Main screen 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.
The Gas Sensor Main screen displays the gas concentration measurements
obtained by the analyzer. In the example shown in the gases are being
measured and, for each gas, the concentration detected is in parts per
million (ppm).
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 the analyzer is Running and OK (e.g. no faults have been
identified).
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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.
A. MENU button
B. MENU text
C. PAGE text
D. PAGE button
E. HELP button
F. HELP text
G. STATUS button
PAGE
HELP
MENU
On the Gas Sensor Main screen, the STATUS button has no function when the
analyzer is operating correctly. If, however, the software detects a fault, an
error message is displayed. Press STATUS to get further information on the
error.
5.4
Quick Start Guide 35
Pressure and Temperature screen
The Pressure and Temperature screen shows pressure and temperature
measurements taken inside the analyzer.
A link between the Gas Sensor Main screen and the Pressure and
Temperature screen (described in Pressure and Temperature
screen). Press PAGE to toggle between these two screens.
A link to the Help system. Press to go to the Help screen (described
in Help system).
A link to the Main menu of the software. Press MENU to go to the
Main menu screen (described in Main menu).
Quick Start Guide August 2020
The Cell reading is the temperature, in °C, for the analysis cell.
The Gas reading is the temperature, in °C, of the gas within the analysis cell.
The Pres reading is the pressure, in Torr, inside the analysis cell.
NOTICE
A Torr is a non-SI unit of pressure defined as 1/760 of standard atmospheric
pressure and is equal to the fluid pressure of 1 mm of mercury.
5.5
36 Emerson.com/Rosemount
Help system
The analyzer software includes a context-sensitive help system. Press HELP,
which is available on most of the software screens, to open the help system.
The help system contains a number of different Help screens, each
conveying a different message. As the help system is context-sensitive, the
Help screen that appears is the one that is most appropriate to the software
function engaged when HELP was pressed. Figure 5-1 shows an example of a
Help screen.
August 2020 Quick Start Guide
Figure 5-1: Example of a Help Screen
Quick Start Guide 37
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5.6 Main menu
To access the Main menu, press MENU on either side of the Gas Sensor Main
screen (#unique_38/
unique_38_Connect_42_CT5100ExGasSensorMainScreen) or the Pressure
and Temperature screen (#unique_31/
unique_31_Connect_42_CT5100PressureandTemperatureScreen). The
Main menu is used for calibration, diagnostics, fault finding, downloading
data, and shutting down the analyzer.
5.7 BACK button
On most of the software screens, the top left hand button is configured as a
BACK button. Press BACK to return to the previous screen.
A. BACK button
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6 Start-up procedure
6.1 Introduction
CAUTION
EQUIPMENT DAMAGE
Damage to the analyzer may result from a failure to follow this procedure.
Always follow the start-up procedure.
The analyzer normally operates continuously. It should only be necessary to
start up the analyzer under the following circumstances:
• When the analyzer is first switched on following installation
• Following repair or maintenance
• When the analyzer has been switched off as part of a plant shutdown or
maintenance
6.2 Preparation for use
Install and fully commission the Rosemount™ CT5100 before starting it up.
WARNING
BURN HAZARD
Personal injury and/or damage to property may result if these safety
precautions are not observed.
Some parts of the analyzer may be heated to 374 °F (190 °C). To prevent
burns, do not touch any of the hot parts.
Before fitting, removing, or performing any maintenance on the analyzer,
make sure that it has been switched off and allowed to cool for at least two
hours. Before performing any maintenance on or, in the vicinity of the
analysis cell, allow the analyzer to cool for at least twelve hours, as the
analysis cell is insulated against heat loss.
When handling the analyzer, always use suitable protective gloves.
These precautions are especially important when working at heights. If a
burn is received, seek medical treatment immediately.
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CAUTION
EQUIPMENT DAMAGE
Failure to perform pre-system start-up checks may cause damage to
equipment.
Do not power up or try to operate the analyzer unless it is physically secure
and all electrical and pneumatic connections to the analyzer are in place.
Before starting up, ensure that electrical power, sample gas handling
facilities, and any required calibration gases are available to the analyzer.
6.3 Start-up procedure
NOTICE
The gases shown in the screenshots and the measurements thereof may be
different from those shown in your Rosemount CT5100. They indicate the
functionality of the software, which is the same regardless of the gases being
measured.
NOTICE
To stop the start-up procedure at any time, set the main circuit breaker to
OFF.
Procedure
1. Visually inspect the analyzer's exterior for signs of damage, corrosion,
gas leaks, or overheating. Report anything found to the maintenance
organization.
2. Ensure that the analyzer has been installed correctly as described in
Install.
3. Ensure that the top cover is fitted to the analyzer. If it is not, report it
to the maintenance organzation and do not proceed further until the
top cover has been fitted.
4. Ensure that the door to the electrical compartment is closed and
locked. If you cannot close and lock the door, report it to the
maintenance organization and do not proceed further until the door
has been repaired.
5. Ensure that the gas handlying system is turned off.
6. Ensure that the external circuit breaker is set to OFF.
7. Visually examine the gas ports.
Ensure that the sample supply line and the sample return line are
connected to the correct port.
40 Emerson.com/Rosemount
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A. Sample gas input port
B. Sample gas return port
C. Top cover (cell compartment)
D. Laser/electrical compartment
E. Analog/digital power entry point
F. Power entry point
8. Ensure that the electrical connection has been made to the power
entry point at the base of the analyzer.
9. Start up the system that vents the sample gas exiting the analyzer.
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10. Switch the circuit breaker to ON, applying electrical power to the
analyzer.
The control PC that forms part of the analzyer is configured to
automatically load the necessary gas sensor software and
configuration files.
The software automatically starts the start-up sequence. After a few
seconds, the Gas Sensor Main Screen appears on the display
controller.
If the screen does not appear, report the fault to the maintenance
organization.
11. Start up the system for venting the sample gas exiting the analyzer.
12. Start up the gas handling system that conditions the sample gas
before it is fed into the analyzer.
At the end of the start-up procedure, that gas measurements initially appear
as 0.00 ppm until the first readings are taken. After a few seconds, the initial
gas concentrations are displayed.
The start-up procedure is now complete.
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6.4 Front panel controls and indicators
Configure the analyzer from the control display located on the front panel.
A. Display controller
NOTICE
ON/OFF circuit breaker
There are no ON/OFF switches on the analyzer. A customer-provided
external circuit breaker controls the application of electrical power to the
analyzer.
The circuit breaker is a simple two-pole ON/OFF circuit breaker that must be
set to ON to permit the safe operation of the analyzer.
The display controller primarily controls operation of the analyzer.
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WARNING
Failure to follow these instructions may cause warranty invalidation,
property damage, and/or personal injury or death.
DO NOT, under any circumstances, press the top two buttons on the display
controller simultaneously. This will override the system code supplied with
the analyzer and display the default program screen for the controller.
This will lock the software controlling the analyzer requiring the analyzer to
shut down externally and restarted risking a possible corruption of the
software and loss of the analyzer operation during the shutdown and restart
process.
It is essential that only trained, qualified personnel operate the controls on
the analyzer.
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7 Operating the analyzer
7.1 Introduction
This section describes the normal operation of the analyzer.
NOTICE
The gas concentrations shown in the following screenshots may be different
from those shown in your particular analyzer. The screenshots indicate the
functionality of the software, which is the same regardless of the gases or
gas concentrations being measured.
WARNING
BURN HAZARD
Some parts of the analyzer may be heated to 374 °F (190 °C). All
components of the analyzer are hot unless it has been switched off and
allowed to cool down. Personal injury and/or damage to property may result
if these safety precautions are not observed.
Before fitting, removing, or performing any maintenance on the analyzer,
ensure that it has been switched off and allowed to cool for at least two
hours. Before performing any maintenance on or in the vicinity of the
analysis cell, allow the analyzer to cool for at least twelve hours, as the
analysis cell is insulated against heat loss.
When handling the analyzer, always use suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
7.2 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 7-1) or
the Pressure and Temperature screen (Figure 7-2) is shown on the display
controller. To toggle between these two screens, press PAGE.
Quick Start Guide 45
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Figure 7-1: Gas Sensor Main Screen
Figure 7-2: Pressure and Temperature Screen
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8 Shutdown procedure
8.1 Safety precautions
CAUTION
EQUIPMENT DAMAGE
Damage to the analyzer may result from a failure to follow this procedure.
Always follow the shutdown procedure.
The analyzer normally operates continuously. It should only be necessary to
shut down the analyzer in the following circumstances:
• In order to perform repairs or maintenance on the analyzer
• When the analyzer has to be switched off as part of a plant shutdown or
plant maintenance
Use the display controller to perform the shutdown procedure. Refer to
Display controller for the display controller navigation instructions.
NOTICE
The gas concentrations shown in the following screenshots may be different
from those shown in your particular analyzer. The screenshots indicate the
functionality of the software, which is the same regardless of the gases or
gas concentrations being measured.
WARNING
BURN HAZARD
Some parts of the analyzer may be heated up to 374 °F (190 °C). All parts of
the analyzer are hot unless it has been switched off and allowed to cool
down. Personal injury and/or damage to property may result if these safety
precautions are not observed.
Before fitting, removing, or performing any maintenance on the analyzer,
ensure that it has been switched off and allowed to cool for at least two
hours. Before performing any maintenance on, or in the vicinity of, the
analysis cell, allow the analyzer to cool for at least twelve hours, as the
analysis cell is insulated against heat loss.
When handling the analyzer, always use suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
Quick Start Guide 47
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8.2 Shutdown procedure
To shut down the analyzer.
WARNING
EXPLOSION HAZARD
Unauthorized operation of the gas handling system when maintenance is
being performed on the analyzer or on its associated pipes/hoses may result
in gas being released, causing fire or explosion. Failure to lock out the gas
handling system may cause death.
Always lock out the gas handling system when shutting down the analyzer.
Procedure
1. Shut down the gas handling system that conditions the sample gas
and feeds it to the analyzer. Always lock-out the gas handling system
to prevent its unauthorized operation during maintenance, which
may cause an escape of gas.
WARNING
EXPLOSION HAZARD
Failure to vent sample gas may cause death.
Vent the sample gas in the system to prevent fire or explosion
during maintenance and to prevent damage to the analyzer
during shutdown.
Purge the sample gas in the pipes leading to the analyzer to
prevent hazards to personnel during maintenance.
Purge the sample gas in accordance with safe working
procedures for the site.
Allow the analyzer and system for returning the sample gas to run
for five minutes to allow any sample gas in the analyzer to be
returned to the exhaust.
2. Purge any sample gas in the pipe/hose from the gas handling system
to the analyzer using factory air or nitrogen supply.
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WARNING
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a
pressure that can cause injury (e.g. damage to eyes and skin
punctures from debris blown by the high pressure gas or compressed
air).
3. Turn off the gas used to purge the analyzer.
4. Press MENU on the display controller in either the Gas Sensor Main
screen or the Pressure and Temperature screen.
The Main menu opens.
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A. BACK button
B. SELECT button
C. Scroll up button
D. HELP button
E. Scroll down button
5. On the display controller, select System.
6. Press SEL (select).
The System screen opens.
A. BACK button
B. SELECT button
C. Scroll up button
D. HELP button
E. Scroll down button
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7. Use scroll up and scroll down to select SHUTDOWN . Then press SEL
(select).
The Shutdown screen opens.
8. Press
YES.
The analyzer shuts down.
9. Set the external secondary circuit breaker to Off. Lock-out and tagout the secondary circuit breaker.
10. Set the external main circuit breaker to Off. Lock-out and tag-out the
main circuit breaker.
Quick Start Guide 51
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A Engineering drawings
Use the wiring diagrams for the Rosemount™ CT5100 analyzer to assist with
troubleshooting faults. You can use these diagrams to locate the position of
a wiring connector should it become disconnected.
Table A-1: List of Engineering Drawings
Drawing number Description
W-2000-0035 (Sheets 1-5) Rosemount CT5100 heated
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A.1 Wiring diagram W-2000-0035 (page 1)
Quick Start Guide 53
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A.2 Wiring diagram W-2000-0035 (page 2)
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A.3 Wiring diagram W-2000-0035 (Page 3)
Quick Start Guide 55
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A.4 Wiring diagram W-2000-0035 (Page 4)
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A.5 Wiring diagram W-2000-0035 (Page 5)
Quick Start Guide 57
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58 Emerson.com/Rosemount
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Quick Start Guide 59
*00825-0100-3511*
00825-0100-3511, Rev. AA
Quick Start Guide
August 2020
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