Installation, Operations, and Maintenance Manual
D-7010-0045, Rev C
January 2018
Rosemount™ CT5400 Continuous Gas Analyzer
Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no liability
for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further
enhancements while in service may mean that the manual does not reflect your particular system.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
Document Number: D-7010-0045
Rev C, January 2018
©
Emerson 2017. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic,
mechanical, photocopying, recording, or otherwise without the express prior written permission of the copyright holder.
If you require additional technical assistance, request help from Cascade Technical Support (qcl.csc@emerson.com) or Emerson
distribution partners.
General inquiries about this or other Cascade Technologies products should be sent to qcl.csc@emerson.com.
All trademarks used within this document are the property of their respective owners.
Important information
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section 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 instruction manuals shipped with the analyzer. The
following instruction manual(s) are available and / or referenced within this manual:
Rosemount CT5400 Quick Start Guide: D-7010-0061
All instructions must be saved for future use. Contact your local service center or sales office if you are missing documents.
User information
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section must not be changed, amended, or removed.
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 CT5400 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 instrument
- 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 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.
• To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except
when maintenance is being performed by qualified personnel.
• The information contained in this document is subject to change without notice.
General safety notice/residual risk
Installation, operation, and maintenance of the analyzer must be in accordance with these instructions.
When operated as intended and all applicable safety instructions are observed, an element of risk will remain, including, but not
limited to, the following:
• Explosion protection measures may become ineffective on the occurrence of one failure (for Category 3 instruments).
• 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.
Authorized personnel
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section must not be changed, amended, or removed.
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 for hazardous areas with the
operating company and the manufacturer. It is the operating company's responsibility to:
• Train staff.
• Observe safety regulations.
• Follow the safety instructions and procedures in the product manual.
Operators must:
• Be trained.
• Read and understand all relevant sections of the product manual before commencing work.
• Know the safety mechanisms and regulations.
WARNING!
To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate,
maintain, or service this instrument before reading and understanding this instruction manual and receiving appropriate training.
Regulations and standards
Regulations / Standards Description
2014/35/EU The Low Voltage Directive
2014/30/EU The Electromagnetic Compatibility Directive
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive
USA 21 CFR 1040.1 Laser products
NEC 505 National Electrical Code (issued by ANSI: American National Stand-
ards Institute and NFPA 70: National Fire Protection Association)
EN 6223: 2008 EMC Safety Standard
BS EN 60825-1:2007 Safety of laser products. Equipment classification and requirements
(identical to IEC 608250-1 2007).
BS EN 61010-1 2010 IEC 61010-1 2010 Safety requirements for electrical equipment for measurements,
control, and laboratory use. General requirements.
BS EN 61326-1: 2013 Electrical equipment for measurement, control, and laboratory use.
EMC requirements. General requirements.
Associated publications
Quick Start Guide: D-7010-0061
Compliance approvals
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.
This product complies with USA 21 CFR 1040.10. It is also designed and manufactured under an approved quality management system to ISO 9001:2008.
Emerson and the Rosemount CT5400 Gas Analyzer have satisfied the requirements for applying the CE marking to the Rosemount CT5400 Gas Analyzer.
This equipment meets all requirements of the EMC and Low Voltage directives.
Safety and information notices
DANGER!
WILL CAUSE DEATH
Failure to follow this warning will result in death or serious injury to personnel.
WARNING!
DANGER TO PERSONNEL
Failure to follow this warning may result in serious injury to personnel.
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 Information
All authorized users, including installation, operation, and maintenance personnel, must observe the following safety precautions
and warnings.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power ON/OFF switch at the rear of the panel
is set to OFF and tagged off before removing the top cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
DANGER!
FAILURE TO LOCK-OUT GAS HANDLING SYSTEM MAY CAUSE DEATH.
Always lock out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling system
when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being
released, causing fire or explosion.
DANGER!
FAILURE TO VENT SAMPLE GAS MAY CAUSE DEATH.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during startup.
The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance. Purging
the sample gas must be done in accordance with the safe working procedures for the site.
Allow the analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING!
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure.
Do not open while energized.
Installation requires access to live parts which can cause death or serious injury.
For safety and proper performance, this instrument must be connected to a properly grounded three-wire source of power.
WARNING!
LASER OPTICAL RADIATION EXPOSURE HAZARD
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.
The use of control or adjustments or performance of procedures other than those specified herein may result in hazardous radiation
exposure.
WARNING!
HAZARDOUS SUBSTANCES
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.
Gas handling components within the analyzer will 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 according to the applicable local, national, or international health and safety
regulations and pollution regulations.
WARNING!
EXPLOSION HAZARD
Always lock-out tag-out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling
system when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being
released, causing fire or explosion.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
The analyzer weighs 31 kg (68 lb). Always use suitable lifting/moving equipment when moving the analyzer. Wear suitable
protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
HAZARDOUS GAS
The product stream that the analyzer is examining may be hazardous even at low concentrations. Therefore, take special care to
ensure that the sample gas return port either returns the sample gas to the product stream or discharges the sample gas to a
location that will not cause a hazard.
WARNING!
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g., damage to eyes and skin
punctures from debris blown by the high pressure gas or compressed air.
Always lock out or tag off the calibration gas supply and compressed air supply when shutting down the analyzer.
WARNING!
EXPLOSION HAZARD
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during startup.
The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance. Purging
the sample gas must be done in accordance with the safe working procedures for the site.
Allow the analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING!
EXPLOSION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type.
CAUTION!
EQUIPMENT DAMAGE
Always follow the startup procedure. Damage to the analyzer may result from a failure to follow this procedure.
Failure to perform pre-system startup checks may cause damage to equipment.
CAUTION!
EQUIPMENT DAMAGE
Always follow the shutdown procedure. Damage to the analyzer may result from a failure to follow this procedure.
CAUTION!
UNSERVICEABLE EQUIPMENT
If the pressure and temperature measurements are out of tolerance, refer to Chapter 7 for guidance.
CAUTION!
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case you may be required to
take adequate measures.
CAUTION!
EQUIPMENT DAMAGE
Ensure that the local power voltage where the unit is to be installed corresponds to the unit’s nominal voltage as given on the name
plate label.
CAUTION!
EQUIPMENT DAMAGE
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the
analyzer are in place.
Before commencing the start-up process, it is important to ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the analyzer.
Safety and system labels and annotation
The labels and annotation applied to the analyzer are specified in the table below.
Label type Example Location
Identification label (including serial number, model number, and USA FDA compliance label
CAUTION - Hot label 1. Cell insulation
Laser radiation CAUTION label Baseplate
Made in the UK
Manufactured Sept. 2015
Rosemount CT5400 Continuous Gas
Analyzer
Serial number: CT5400-10008
Model number: CT5400
Glendevon House
Castle Business Park
Stirling, FK9 4TZ
United Kingdom
Tel. +44 (0)1786 447 721
Emerson.com/RosemountGasAnalysis
Rear panel
2. Both heated lines
3. Rack lid, near ventilation holes
Laser module identification label On each laser module housing
Earth identification label Back plate
WARNING statement Rear panel
Label type Example Location
CAUTION Laser Radiation safety statement Rear panel
AC power supply voltage label On analysis cell insulation
AC power supply Danger label 1. Rear panel, above mains power input
socket
2. On reverse of front panel, next to On/
Off switch
AC power supply label Rear panel, below power socket
Abbreviations
The following abbreviations are used in this manual.
Abbreviation Description
©
% Percent
< Less than
° Degree
AC Alternating current
Barg Pressure, in units of bars, above or below atmospheric pressure
BS British Standard
C Celsius
CE European Conformity
CFR Code of Federal Regulations
CH
4
CO Carbon monoxide
CO
2
DC Direct current
Deg Degree (temperature)
e.g. For example
EC European Community
EMC Electromagnetic compatibility
EU European Union
Hrs Hours
Hz Hertz
H2O Water
ICL Interband Cascade Laser
IEC International Electro-technical Commission
in. Inches
IP Ingress protection
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
Copyright
Methane
Carbon dioxide
Abbreviation Description
LCD Liquid crystal display
LED Light emitting diode
L/min Liters per minute
m Meter
3
m
Cubic meter
mA Milliamp
Max Maximum
mBar milli-Bar
mbps Megabits per second
mg Milligram
3
mg/m
Microgram/cubic meter
Mid IR Mid Infrared
min Minute
mm Millimeter
N
2
Nitrogen
NEC National Electrical Code
NFPA National Fire Protection Association
nm Nanometer
NO Nitric oxide
NO
2
Nitrogen dioxide
N2O Nitrous oxide
NH
3
Ammonia
No. Number
O
2
Oxygen
PC Personal computer
PM Preventative maintenance
ppm Parts per million
psi Pounds per square inch
QCL Quantum Cascade Laser
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
Abbreviation Description
WEEE Waste electrical and electronic equipment
μm Micro-meter
Contents
Contents
Chapter 1 Plan ............................................................................................................................... 1
1.1 Description .................................................................................................................................. 1
1.2 Equipment purpose and role ........................................................................................................1
1.3 System overview ..........................................................................................................................2
1.4 Customer information ................................................................................................................. 4
1.5 Safety precautions and conditions for safe use .............................................................................5
1.6 Qualified personnel ......................................................................................................................6
1.7 Software version .......................................................................................................................... 6
1.8 Gas detection .............................................................................................................................. 6
1.9 Detailed system specifications .....................................................................................................6
1.9.1 Optical description ...................................................................................................... 10
1.10 Unpacking the analyzer ............................................................................................................. 10
Chapter 2 Install ...........................................................................................................................13
2.1 Site selection ............................................................................................................................. 13
2.2 Rack mounting the analyzer .......................................................................................................14
2.3 Gas inputs and outputs .............................................................................................................. 16
2.4 Connecting the electrical/electronic inputs and outputs ............................................................17
2.5 Commissioning the analyzer ......................................................................................................19
Chapter 3 Startup procedure ........................................................................................................21
3.1 Introduction .............................................................................................................................. 21
3.2 Preparation for use .................................................................................................................... 21
3.3 Startup procedure ..................................................................................................................... 22
Chapter 4 Operating the analyzer .................................................................................................25
4.1 Introduction .............................................................................................................................. 25
4.2 Normal operation ...................................................................................................................... 25
4.3 Front panel controls and indicators ............................................................................................26
4.4 Rear panel controls .................................................................................................................... 28
4.5 Display controller .......................................................................................................................28
4.6 Gas Sensor Main screen ............................................................................................................. 30
4.7 Pressure and Temperature screen ..............................................................................................31
4.8 Help system ...............................................................................................................................31
4.9 Main menu ................................................................................................................................ 32
4.10 BACK button .............................................................................................................................. 33
Chapter 5 Verifying Gas Concentrations ....................................................................................... 35
5.1 Verification ................................................................................................................................ 35
5.1.1 Zero verification .......................................................................................................... 35
5.1.2 Span verification ......................................................................................................... 39
Chapter 6 Gas Calibration Procedures ...........................................................................................45
6.1 Required tools ........................................................................................................................... 45
6.2 Main menu ................................................................................................................................ 45
6.3 Calibration .................................................................................................................................46
6.3.1 Zero calibration ........................................................................................................... 46
6.3.2 Span calibration .......................................................................................................... 51
6.4 Reference gas - suggested concentration ranges ....................................................................... 56
Installation, Operations, and Maintenance Manual i
Contents
Chapter 7 Troubleshooting and diagnostics ................................................................................. 57
7.1 Troubleshooting, repairs, and failure diagnostics .......................................................................57
7.2 Using the Built-in-Test (BIT) fault diagnostics .............................................................................59
7.3 Visual examination .................................................................................................................... 64
7.4 Failure diagnostics ..................................................................................................................... 65
7.5 Repairable items ........................................................................................................................68
7.6 Tools and test equipment required for troubleshooting .............................................................68
7.7 Removing the top cover .............................................................................................................69
7.8 Removing the bottom cover ...................................................................................................... 72
7.9 Replacing the LCD display ..........................................................................................................73
7.10 Replacing the USB circuit board ................................................................................................. 76
7.11 Replacing the power socket fuses .............................................................................................. 80
7.12 Replacing the internal fuses ....................................................................................................... 82
7.13 Replacing the fans ..................................................................................................................... 87
7.14 Replacing the terminal electric cooler (TEC) board .....................................................................89
7.15 Replacing the peripheral PCA board ...........................................................................................92
7.16 Replacing the motherboard ....................................................................................................... 95
7.17 Replacing the DIN Rail ................................................................................................................98
7.17.1 Replacing the analog input unit ...................................................................................98
7.17.2 Replacing the DC power supply .................................................................................101
7.17.3 Replacing the temperature controller ....................................................................... 102
7.17.4 Replacing the Ethernet switch ...................................................................................104
7.17.5 Replacing the laser modules ......................................................................................107
7.18 Replacing the gas temperature sensor ..................................................................................... 110
7.19 Replacing the pressure sensor ..................................................................................................112
7.20 Replacing the thermal cut-out ................................................................................................. 114
7.21 Replacing the gas input line ..................................................................................................... 117
7.22 Replacing the gas output line ...................................................................................................119
7.23 Replacing the analysis cell ........................................................................................................121
7.24 Cleaning the analysis cell mirrors ............................................................................................. 124
7.25 Installing the Top Cover ........................................................................................................... 127
7.26 Installing the bottom cover ......................................................................................................127
7.27 Downloading data for diagnostics and service ......................................................................... 128
7.27.1 Downloading data to a USB flash drive ...................................................................... 128
7.27.2 Downloading data using TFTP .................................................................................. 133
Chapter 8 Shutdown procedure ................................................................................................. 139
8.1 Shutdown procedure safety precautions .................................................................................139
8.2 Shutdown procedure ............................................................................................................... 140
Chapter 9 Preventative maintenance ......................................................................................... 145
9.1 Maintaining the analyzer ..........................................................................................................145
9.2 Scheduled maintenance .......................................................................................................... 145
Appendices and reference
Appendix A Theory of Operation ................................................................................................... 147
A.1 Overview ................................................................................................................................. 147
A.2 Quantum Cascade Laser measurement principle ..................................................................... 147
A.3 Process analyzer - gas concentration measurements ............................................................... 148
Appendix B Spare parts list ........................................................................................................... 149
ii Rosemount CT5400
Contents
Appendix C Engineering Drawings ................................................................................................151
C.1 Engineering drawings .............................................................................................................. 151
Installation, Operations, and Maintenance Manual iii
Contents
iv Rosemount CT5400
1 Plan
1.1 Description
The Rosemount™ CT5400 Continuous Gas Analyzer, hereafter referred to as the
Rosemount CT5400 or the analyzer, 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 twelve different types of gas at
concentrations ranging from parts per million (ppm) to percentage levels in the process
gas stream. The analyzer is designed to be mounted in a standard 482.6 mm (19 in.) rack.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
Plan
1.2
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
This manual is intended for the personnel who install, operate, and maintain the
equipment.
Equipment purpose and role
The analyzer is a gas sensor system that can be configured to measure the concentrations
of multiple small molecules in a gas sample that is provided to the analyzer via a sample
line.
The types of molecules that are measured depend on the system configuration.
Installation, Operations, and Maintenance Manual 1
Plan
Rosemount CT5400Figure 1-1:
The analyzer can be configured to detect and measure up to twelve different gases,
depending on the combination of laser modules fitted.
1.3 System overview
A complete Rosemount CT5400 system consists of a gas handling system, the analyzer,
and the associated interconnecting wiring and gas piping.
Measurement data from the analyzer can be displayed in the process control center. You
must provide the gas handling system and interconnecting wiring and gas piping; Emerson
supplies the CT5400.
In Figure 1-2, the items supplied by Emerson are colored orange; the items supplied by you
are colored blue. Table 1-1 lists the main items of the system.
2 Rosemount CT5400
Plan
Complete Rosemount CT5400 Gas Analysis SystemFigure 1-2:
A. Gas handling system
B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT5400 Gas Analyzer
E. Electrical power
F. Measurement data
G. Control center
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 a 240 Vac 50 Hz supply.
Gas concentrations are measured using mid-infrared optical absorption spectroscopy. The
light sources are quantum cascade lasers (QCLs), which are operated to produce
wavelength sweeps that cover the absorption lines of the gases. The light from each laser
is routed through an optical path to the analysis cell, which provides measurement of low
concentrations of the subject gases. An external sample handling system conditions the
sample gas and draws it through the analysis cell. The light exits the multi-pass analysis cell
and is directed to a receiver in the analyzer. The variation in the intensity of light in the
vicinity of the absorption lines is measured, and the concentration is determined using a
comprehensive spectral fitting routine.
There is no sample conditioning provided within the analyzer; the sampled gas must be
brought within the parameters shown in Section 1.9 before entering the analyzer. Detailed
characteristics of the analyzer are also given in Section 1.9.
Main Items of the Rosemount CT5400 SystemTable 1-1:
Item Name or description Supplied by Part number Quantity Notes
1 Rosemount CT5400 Emerson CT5400 1
2 Rosemount CT5400 software
package, version 5.x.x
3 Gas handling system Customer Customer choice 1
Emerson N/A 1 Software is
embedded in
PC board.
Version described in
manual
Installation, Operations, and Maintenance Manual 3
Plan
Main Items of the Rosemount CT5400 System (continued)Table 1-1:
Item Name or description Supplied by Part number Quantity Notes
4 Heated gas sample line hose Customer Customer choice 1
5 Exhaust line hose (for sample
gas)
6 Reference gas cylinders (in-
strument gas) for calibration
purposes
7 Pressure regulator Customer Customer choice 1 per gas cylin-
8 Pneumatic T-piece Customer Customer choice 2 Required for
9 Excess flow line Customer Customer choice 1 Required for
10 240 Vac power cable Customer Customer 1
11 Cable from analyzer to con-
trol center
12 482.6 mm (19 in.) rack sys-
tem
Customer Customer choice 1
Customer Customer choice Dependent
upon number of
gases being
measured
Required for
der
Customer Customer choice 1 1
Customer Customer choice 1 Holds the
calibration
calibration
calibration
CT5400
1.4 Customer information
This manual contains all the important information that must be followed to ensure the
correct operation and safety of personnel when operating the analyzer.
All personnel must read this manual carefully before commencing any work on the
analyzer.
For information regarding installation, consult Chapter 2 and the Quick Start Guide
(D-7010-0052).
Emerson is committed to continuously improving its products and documentation. Every
effort will be made to include in the documentation any modifications by the
manufacturer. However, it should be noted that this document reflects the supplied
sensor at the revision date on the front cover.
Should you require further information, or should particular problems arise that are not
covered in this manual, you can request additional help from Cascade Technical Support
(qcl.csc@emerson.com) or Emerson distribution partners. Further contact details for
Emerson can be found on the back page of this manual.
4 Rosemount CT5400
1.5 Safety precautions and conditions for safe use
WARNING!
Before installing or performing any maintenance on the analyzer, read and understand the
safety information given in the preliminary information of this manual.
The analyzer described in this manual has been quality control tested and left the
manufacturer in pristine condition. To achieve the correct and safe operation of this
product, it must be transported, installed, operated, and maintained as described by the
manufacturer.
All lasers used within the instrument are Class 1. The emitted laser light is invisible (midinfrared) and the pulse duration so short that the unprotected eye will not be damaged.
The nature of the laser beam path and beam width further ensures that it should be
impossible to cause any eye damage. The instrument has warning labels at appropriate
positions in accordance with USA 21 CFR 1040.10.
Conditions for safe use
• This equipment has flamepaths which differ from those in IEC60079-1/EN 60079-1.
Cascade Technologies, Ltd (qcl.csc@emerson.com) must be contacted for guidance
when maintaining the flamepaths.
• The fasteners which secure the cover are non-standard and shall therefore only be
replaced by fasteners supplied by the manufacturer for this purpose. The fasteners
must always be fitted with the washer supplied by the manufacturer.
• The equipment has non-conductive surfaces which are a potential electrostatic
charging hazard - see instructions for guidance.
• The process gas flow rate is limited to a maximum of 6 liters per minute.
• The equipment shall only be used with process gases which are in gas groups B, C or
D (Divisions) or IIB + H 2 (Zones) and must not contain oxygen or any other oxidizer
in concentrations greater than that found in normal air.
Plan
CSA Certificate North American conditions
• The equipment has flameproof joints with dimensions which are other than those
specified in Table 2 of ANSI/UL 60079-1: 6th edition and Table 3 of CSA C22.2
60079-1:16. These flameproof joints are not intended to be repaired, but where
necessary the original manufacturer shall be contacted for guidance and
information on the dimensions of the flameproof joints.
• The fasteners which secure the cover are non-standard and shall therefore only be
replaced by fasteners supplied by the manufacturer for this purpose. The fasteners
must always be fitted with the washer supplied by the manufacturer.
• The equipment has non-conductive surfaces which are a potential electrostatic
charging hazard – see the instructions for guidance.
• The user shall ensure that the flow of process gas is limited to a mazimum flow rate
of 6 liters per minute.
Installation, Operations, and Maintenance Manual 5
Plan
• The equipment shall only be used with process gases which are in gas groups B, C or
D (Divisions) or IIB + H2 (Zones) and must not contain oxygen or any other oxidizer in
concentrations greater than that found in normal air.
• 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 1mm2 (18 AWG).
• The 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, local requirements always take
precedence.
• The equipment is not to be used with flammable liquids.
1.6 Qualified personnel
This manual provides installation, operation, and maintenance personnel with the level of
knowledge required to safely start, operate, and switch off the analyzer.
1.7
1.8
Only technically qualified personnel in the field of instrumentation and control who are
familiar with this manual and have been specially trained on the analyzer should install,
operate, switch off, and service the analyzer. Only qualified and trained persons have the
required specific knowledge to correctly interpret the general safety information,
warnings, and procedures given in this manual and apply them to this particular
application. Emerson or its distribution partners can provide this training on request.
Knowledge of the safety information within this manual and its technically correct
implementation are prerequisites for danger-free installation, operation, and maintenance
of the analyzer.
Software version
The analyzer includes software that is used to control the operation of the instrument. This
manual describes software version 5.x.x.
Gas detection
The analyzer is highly configurable in the gases that can be detected and their range of
concentrations.
1.9
6 Rosemount CT5400
Detailed system specifications
Table 1-2 gives the physical characteristics of the analyzer. Schematic diagrams of the
sensor and mounting points are shown in Figure 1-3, Figure 1-4, and Figure 1-5. Table 1-3
gives the general characteristics of the instrument.
Physical CharacteristicsTable 1-2:
Rosemount CT5400 Value Units Comment
External dimensions 482.6 x 673 x 221.5
19 x 26.5 x 8.7
Weight 31
68.34
mm
in.
kg
lb
Length x Width x Height
Nominal dimensions
Approximate weight
General CharacteristicsTable 1-3:
Rosemount CT5400 Value Units Comment
Supply voltage 240 Vac 50 Hz
Peak power consumption
Continuous steadystate power consumption
Frame and structure
material
Housing material - - Powder coated steel
Wetted materials PFA coated aluminum, 315 stainless steel,
Measurement technique
Mid IR source - - Quantum Cascade Laser
Laser classification Class 1 BS EN 60825-1: 2007 safety of laser products.
Inlet gas port connector
Outlet (exhaust) gas
port connector
Measurement result
signals
Warm-up time 90 minutes
600 W Max consumption
300 W Once the gas analyzer has stabilized and the
analysis cell has reached the temperature set
point
- -
- - Mid IR absorption spectroscopy
6
1/4
6
1/4
4 to 20 mA 4 or 8 channel outputs, specify on order
mm
in.
mm
in.
Anodized and powder coated aluminum
FKM and FFKM seals, CaF2 and BaF2 windows,
protected gold coated aluminum mirrors
Equipment classification and requirements
(identical to IEC 60825-1 2007)
Swagelok type, factory-configured, specify on
order
Swagelok type, factory-configured, specify on
order
Plan
Installation, Operations, and Maintenance Manual 7
Plan
Dimensions - Front ViewFigure 1-3:
A. User interface
B. Data extraction port
C. 4 off Ø system locking holes
D. Ventilation. Do not obstruct.
Dimensions - Side ViewFigure 1-4:
A. Handle swings out 63 mm (2.5 in.)
B. 2 off telescopic slide, 610 mm (24 in.) long, 55 kg (121.3 lb.) max load. 50.8 mm (2 in.) over travel.
9.6 mm (.4 in.) slide thickness. Lock-out. Front disconnect.
8 Rosemount CT5400
Plan
Dimensions - Top ViewFigure 1-5:
A. Ventilation. Do not obstruct.
Environmental CharacteristicsTable 1-4:
Environmental characteristic Value Units Comment
Operating temperature range 0 to 45
32 to 113
Sample gas temperature range 50 to 195
122 to 383
Sample gas particulate density 5 mg/m
Sample gas particulate size 10 μm Maximum
Sensor humidity range 10 to 95 % Relative humidity (non-condens-
Note
The CT5400 Continuous Gas Analyzer is suitable for indoor use only
°C
°F
°C
°F
Ambient temperature
Factory set, specify on order
3
Maximum
ing) at 45 °C (113 °F)
Installation, Operations, and Maintenance Manual 9
Plan
1.9.1 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 2 m and 5 m through multiple reflections along the length of the cell. The laser
beams exit the cell at the opposite end from where they entered and are directed using a
second optical block to a receiver.
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.
1.10 Unpacking the analyzer
This procedure may require a minimum of two people to safely remove the equipment
from the shipping container.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
TRANSPORTATION HAZARD
Use safety-approved lifting equipment. You must ensure safe lifting procedures for the weight
and mass of the equipment are followed.
Failure to use proper lifting procedures may cause injury to personnel or damage the analyzer.
Procedure
1. Visually inspect the exterior of the analyzer for signs of damage, corrosion, gas
leaks, or signs of previously overheating.
2. Report anything found to the maintenance organization.
3. One person carefully guides and assists the other person lifting the equipment from
the container.
4. If necessary, use safety approved and tested lifting equipment to remove the
analyzer from the shipping container.
10 Rosemount CT5400
Front View Showing Lifting HandlesFigure 1-6:
A. Front panel left-side handle
B. Front panel right-side handle
Rear View Showing Lifting HandleFigure 1-7:
Plan
A. Rear panel handle
5. Place the analyzer on a solid, level surface and prepare to rack mount the analyzer.
Installation, Operations, and Maintenance Manual 11
Plan
12 Rosemount CT5400
2 Install
2.1 Site selection
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
Procedure
1. Install the analyzer in a standard 482.6 mm (19 in.) rack.
Install
NOTICE
Fitting the analyzer into the rack and securing it are your responsibilities.
2. Install the analyzer in a suitable shelter to protect it from environmental elements
and water. The Ingress Protection rating (IP) for the analyzer is IP-44 per the IEC
60529 standard.
DANGER!
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 190 °C (374 °F) and may present
an ignition source. Exercise care when using oil, paint, cleaning rags, and other
flammable substances near the analyzer. A fire may result if this precaution is not
observed. Always assume that the interior of a analyzer is hot unless it has been
switched off and allowed to cool down.
Installation, Operations, and Maintenance Manual 13
Install
2.2 Rack mounting the analyzer
This procedure may require two people to safely move and rack mount the Rosemount
CT5400.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
Note
You must supply the rack.
Procedure
1. One person aligns the analyzer's telescoping slide rails on the unit as the other
person carefully guides the analyzer into the rack using the front panel and rear
handles (see Figure 2-1).
Left Side View - Lifting Handles and Telescopic Slide RailsFigure 2-1:
A. Rear panel handle
B. Telescopic slide for rack mount units
C. Front panel handles
2. Make sure the chassis ventilation holes in the front, top, rear, and bottom are not
obstructed.
14 Rosemount CT5400
Top and Bottom View - VentilationFigure 2-2:
A. Top ventilation holes
B. Bottom ventilation holes
Install
Rear View - Ventilation and HandleFigure 2-3:
A. Rear ventilation holes
B. Rear panel handle
3. Inspect the analyzer and ensure the unit is correctly mounted in the rack and glides
easily on the telescoping slide rails.
The analyzer must slide in and out of the rack to make the power, analog, digital,
Ethernet, and gas connections.
Installation, Operations, and Maintenance Manual 15
Install
2.3 Gas inputs and outputs
The analyzer has one gas input and one gas output, both of which are located on the rear
panel of the instrument (Figure 2-4).
Procedure
1. The gas sample that is to be measured for impurities enters the instrument through
the sample gas input port (A) .
2. Once the gas sample has been examined for impurities, it is expelled from the
instrument through the sample gas return port (B).
Gas Inlet and Outlet ConnectorsFigure 2-4:
A. Sample gas input port
B. Sample gas return port
3. 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!
HAZARDOUS GAS
The product stream that the analyzer is examining may be hazardous even at low
concentrations. Therefore, take special care to ensure that the sample gas return port
either returns the sample gas to the product stream or discharges the sample gas to a
location that will not cause a hazard.
16 Rosemount CT5400
Install
2.4 Connecting the electrical/electronic inputs and outputs
Electrical / Electronic ConnectorsFigure 2-5:
A. Ethernet connector
B. Ventilation holes
C. Sample supply (stainless steel tubing)
D. Sample return (stainless steel tubing)
E. Main power supply
F. Analog outputs (4-20 mA)
G. Digital outputs
H. Status output (10 way connector)
Electrical/electronic signal connections to the analyzer are made through electrical
connectors located on the rear panel of the instrument, as shown in Figure 2-5. Use the
wiring diagram to make the electrical connections as shown in Appendix C.
Status outputs, 10 way socket (H)Table 2-1:
Pins Function
1-6 Status output 1 (check function), optional
2-7 Status output 2 (maintenance required), optional
3-8 Status output 3 (out of specification), optional
Installation, Operations, and Maintenance Manual 17
Install
Status outputs, 10 way socket (H) (continued)Table 2-1:
Pins Function
4-9 Status output 4 (failed), optional
Digital outputs, 16 way socket (G)Table 2-2:
Pins Function
1-9 Reading valid channel 0, set in config file
2-10 Reading valid channel 1, set in config file
3-11 Reading valid channel 2, set in config file
4-12 Reading valid channel 3, set in config file
5-13 Reading valid channel 4, set in config file
6-14 Reading valid channel 5, set in config file
7-15 Reading valid channel 6, set in config file
8-16 Reading valid channel 7, set in config file
Analog outputs, 16 way socket (F)Table 2-3:
Pins Function
1-9 Analog channel 0, set in config file
2-10 Analog channel 1, set in config file
3-11 Analog channel 2, set in config file
4-12 Analog channel 3, set in config file
5-13 Analog channel 4, set in config file
6-14 Analog channel 5, set in config file
7-15 Analog channel 6, set in config file
8-16 Analog channel 7, set in config file
CAUTION!
EQUIPMENT DAMAGE
Make sure that the mains supply cable used is of a suitable rating for the unit power
requirements. Failure to do so may result in damage to property.
The Ethernet connector (Figure 2-5, A) provides an Ethernet output from the instrument
that may be used for downloading data for failure diagnosis purposes.
The results of the gas analysis are output from the instrument through the 4-20 mA analog
outputs (Figure 2-5, F) and sent to your process control center.
18 Rosemount CT5400
Install
The status outputs (H) provide fault indications to your process control center. Each digital
output is connected to a normally closed relay, located inside the analyzer, which will open
in response to the detection of a specific fault. The possible causes of a fault indication are:
1. The sample gas concentration is outside of specification, i.e., the sample gas
concentration has exceeded the measurement range of the instrument.
2. The analyzer is out of specification or has developed a fault.
WARNING!
HIGH VOLTAGE
Voltages up to 250 Vac, 50 Hz may be present on the digital output terminals.
External circuits should be installed in accordance with national wiring regulations.
Failure to obey the wiring regulations may result in serious injury to personnel.
WARNING!
ELECTRIC SHOCK
The analyzer passed electromagnetic compatibility (EMC) tests based on all electrical cables
and harnesses attached to the instrument having a length of 3 m (9.8 ft.) Attaching cables and
wiring harnesses longer than 3 m (9.8 ft.) may cause injury to personnel.
2.5 Commissioning the analyzer
Once the analyzer is fully installed as described, it should be commissioned according to
local government regulations and the commissioning plan agreed upon between you and
Emerson.
Installation, Operations, and Maintenance Manual 19
Install
20 Rosemount CT5400
3 Startup procedure
3.1 Introduction
CAUTION!
EQUIPMENT DAMAGE
Always follow the startup procedure. Damage to the Rosemount™ CT5400 may result from a
failure to follow this procedure.
The Rosemount CT5400 normally operates continuously. It should only be necessary to
start up the instrument under the following circumstances.
• When the Rosemount CT5400 is first switched on following installation.
• Following repair or maintenance.
• When it has been switched off as part of a plant shutdown or maintenance.
Startup procedure
3.2 Preparation for use
The analyzer must be installed and fully commissioned prior to startup.
CAUTION!
EQUIPMENT DAMAGE
Do not power up or try to operate the analyzer unless it is physically secure and all electrical
and pneumatic connections to the analyzer are in place.
Before commencing the start-up process, it is important to ensure that electrical power,
sample gas handling facilities, and any calibration gases that are required are available to the
analyzer.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
Installation, Operations, and Maintenance Manual 21
Startup procedure
3.3 Startup procedure
NOTICE
The gases shown in the screenshots and the measurements thereof may be different from
those shown in your particular analyzer. They indicate the functionality of the software, which
is the same regardless of the gases being measured.
NOTICE
To stop the startup procedure at any time, set the main circuit breaker to OFF.
To start up the analyzer, perform the following steps:
Procedure
1. Visually inspect the exterior of the analyzer for signs of damage, corrosion, gas
leaks, or overheating. Report anything found to the maintenance organization.
2. Make sure that the analyzer has been correctly installed (see Chapter 2).
3. Make sure that the rack lid is fitted to the analyzer. If it is not, report it to the
maintenance organization and do not proceed further until the rack lid has been
fitted.
4. Make sure that the On/Off switch at the rear of the analyzer is set to I (ON).
5. On the front panel (Figure 3-1) of the analyzer, set the On/Off switch (B) to I (ON).
Check that the switch illuminates.
Front panelFigure 3-1:
A. Display controller
B. Illuminated On/Off switch
The startup sequence commences automatically under software control.
22 Rosemount CT5400
Startup procedure
After a few seconds, the Gas Sensor Main screen (Figure 3-2) appears on the display
controller. If it does not, report the fault to the maintenance organization.
Gas Sensor Main screenFigure 3-2:
6. Start up the system for returning the sample gas.
7. Start up the gas handling system that conditions the sample gas before it is fed into
the analyzer. Allow the analyzer to warm up in accordance with Table 1-3 before the
sample gas supply is turned on.
Installation, Operations, and Maintenance Manual 23
Startup procedure
24 Rosemount CT5400
4 Operating the analyzer
4.1 Introduction
This section describes the normal operation of the analyzer and how to use the display
controller located on the front panel 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.
4.2 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. The shutdown procedure used to switch off the analyzer is
described in Chapter 8 of this manual.
Operating the analyzer
Provided that the start-up procedure described in Chapter 3 has been followed, the
analyzer does not require any human intervention during normal operation other than
occasional calibration checks.
During normal operation, either the Gas Sensor Main screen (Figure 4-1) or the Pressure and
Temperature screen (Figure 4-2) is shown on the display controller. To toggle between
these two screens, press
Gas Sensor Main screenFigure 4-1:
.
Installation, Operations, and Maintenance Manual 25
Operating the analyzer
Pressure and Temperature screenFigure 4-2:
CAUTION!
UNSERVICEABLE EQUIPMENT
4.3
If the pressure and temperature measurements are out of tolerance, refer to Chapter 7 for
guidance.
On both the Gas Sensor Main screen and the Pressure and Temperature screen, has no
function when the analyzer is operating correctly. If, however, the software detects a fault
and an error message is displayed, press to get further information on the error.
On both the Gas Sensor Main screen and the Pressure and Temperature screen, if the
analyzer makes more measurements than can fit on the display, use
down the list.
and to scroll
Front panel controls and indicators
There are two controls located on the front panel (
the illuminated On/Off switch (B).
Figure 4-3): the display controller (A) and
26 Rosemount CT5400
Operating the analyzer
Front panelFigure 4-3:
A. Display controller
B. Illuminated On/Off switch
The front panel On/Off switch (Figure 4-3, B) controls the application of electrical power to
the electronic circuits inside the instrument. On the switch, I identifies the On position and
O identifies the Off position. The switch includes an indicator that illuminates red when the
switch is set to On.
Note that setting the front panel On/Off switch to Off does not remove all electrical power
from the instrument. Part of the power distribution circuit will remain live. To remove all
electrical power from the instrument, set the On/Off switch on the rear panel (refer to
Section 4.4) to Off.
Operation of the analyzer is controlled primarily through the display controller (Figure 4-4).
Display controllerFigure 4-4:
Installation, Operations, and Maintenance Manual 27
Operating the analyzer
4.4 Rear panel controls
There is only one control on the rear panel (Figure 4-5), a fused socket (A) that incorporates
an On/Off switch. The function of the rear panel On/Off switch is to control the application
of electrical power to the complete instrument.
Rear PanelFigure 4-5:
4.5
A. On/Off switch - fused socket
Display controller
Front Panel Display ControllerFigure 4-6:
A. LCD display
B. Navigation buttons
28 Rosemount CT5400
Operating the analyzer
You can control the analyzer through six navigation buttons (Figure 4-6, B) on the display
controller.
The LCD display (A) can be used to display:
1. Gas concentration measurements obtained
2. Operating temperature and pressure
3. Help screens
4. Step-by-step calibration
5. Diagnostics
The navigation buttons (B) are configured to perform different functions according to
which software screen is shown on the LCD display.
Display Controller Navigation Button FunctionsTable 4-1:
Button Description
Normally used to scroll up. Referred to as UP.
Normally used to scroll down. Referred to as DOWN.
Normally used to select. Also accesses the Main Menu from the Home screen.
Referred to as RIGHT.
Used to go back to the previous screen. No function from the Home screen. Referred to as LEFT.
Used to access the context sensitive Help pages. Referred to as HOME.
Generally used to select an alternative function. Also allows you to toggle between gas and physical measurements from the Home screen. Referred to as
ENTER.
The analyzer employs Intelligent Device Management which enables self-monitoring and
diagnostics. This ensures that operators are made aware of malfunctions so they can take
appropriate action. Table 4-2 defines the symbols that may be displayed.
Diagnostic symbolsTable 4-2:
System running
Maintenance required: still valid output signal
Out of specification: signal out of the specified range
Indicates the analyzer is performing a calibration or validation or that the software has been deliberately stopped.
Failure: non-valid output signal
Installation, Operations, and Maintenance Manual 29
Operating the analyzer
4.6 Gas Sensor Main screen
When the analyzer is switched on, at the end of the startup procedure, the Gas Sensor Main
screen (Figure 4-7) 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.
Gas Sensor Main screenFigure 4-7:
The Gas Sensor Main screen displays the gas concentration measurements obtained by the
analyzer. In the example shown in Figure 4-7, the gases ammonia (NH3), water (H2O),
carbon monoxide (CO), and formaldehyde (H2CO) are being measured, and for each gas,
the concentration detected is in parts per million (ppm).
At the end of the startup procedure, the gas measurements initially appear as 0.00 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 4-7, the instrument is Running and OK (i.e., no faults have been identified).
If a fault is identified, ? is displayed; if maintenance is required,
is a link between the Gas Sensor Main screen (Figure 4-7) and the Pressure and
Temperature screen (Figure 4-8). Press
is a link to the Help system. Press to go to a Help screen (described in Section 4.8).
to toggle between the two screens.
is displayed.
30 Rosemount CT5400
On the Gas Sensor Main screen, has no function when the analyzer is operating
correctly. If, however, the software detects a fault, an error message is displayed. Press
to get further information on the error.
4.7 Pressure and Temperature screen
The Pressure and Temperature screen (Figure 4-8) shows pressure and temperature
measurements taken inside the analyzer.
Pressure and Temperature ScreenFigure 4-8:
Operating the analyzer
4.8
The
Cell reading is the temperature, in °C, of the analysis cell.
The Press 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.
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 4-9 shows an example of a help screen.
Installation, Operations, and Maintenance Manual 31
Operating the analyzer
Example of a Help ScreenFigure 4-9:
4.9 Main menu
To access the Main menu (Figure 4-10), press on either the Gas Sensor Main screen
(Figure 4-7) or the Pressure and Temperature screen (Figure 4-8). The Main menu options are:
• DIAGNOSTICS: Displays various parameters used in the internal calculations and
compares desired and actual parameters, for example, the analysis cell pressure and
temperature. The diagnostics routines and screens are used to perform fault
diagnosis.
• FAULTS: Takes you to a screen that lists any faults affecting the analyzer. This option
is used as part of the failure diagnosis procedures.
• GAS SERVICE: Allows you to check the sensor readings against a known gas source
(verification) or, if necessary, to calibrate the analyzer against that known gas source
(calibration).
• DATA SERVICE: Takes you to a screen that allows data to be downloaded from the
instrument. The downloaded data is used to diagnose faults.
• SYSTEM: Takes you to a screen that allows you to shut down the analyzer or access
system information, such as software versions or IP addresses. The main
motherboard IP address can also be changed from this menu. Some of these options
are not available on older analyzers.
32 Rosemount CT5400
Main menuFigure 4-10:
4.10 BACK button
Operating the analyzer
On most of the software screens, is configured as a BACK button. Press to return to
the previous screen.
Installation, Operations, and Maintenance Manual 33
Operating the analyzer
34 Rosemount CT5400
Verifying Gas Concentrations
5 Verifying Gas Concentrations
5.1 Verification
Verification flows the known gas concentration through the analyzer and gives you a
display of the measurement, the cylinder value, and the difference between the two. You
can use verification to confirm that the analyzer is within tolerance. If it is out of tolerance,
perform a calibration (see Section 6.3).
5.1.1 Zero verification
Zero verification confirms that when no sample gas is flowing through the analyzer, the
gas concentrations measured by the instrument are zero. Zero verification is done by
comparing the analyzer measurements to a known sample gas using the following
procedure:
Prerequisites
Run the analyzer at a stable temperature for at least thirty minutes prior to commencing
this procedure.
Use nitrogen gas of instrument gas purity as the zero verification gas.
Procedure
1. Make sure that a pressure regulator is connected to the nitrogen gas bottle.
2. Connect a hose from the nitrogen gas bottle through a T-piece to the sample supply
port on the rear of the analyzer. Connect an excess flow line to the unused port on
the T-piece and route the excess flow line to a suitable extractor.
3. On the display controller of the analyzer, browse to the Main menu as described in
Section 4.9.
4.
Refer to Figure 4-10. Using
5.
Press .
The Select gas screen (Figure 5-1) opens.
and , select GAS SERVICE.
Installation, Operations, and Maintenance Manual 35
Verifying Gas Concentrations
6.
Select gas ScreenFigure 5-1:
Use and to move the cursor until the gas that you wish to zero verify is
selected. Press .
The Select Type screen (Figure 5-2) opens.
Select Type ScreenFigure 5-2:
7.
Use and to move the cursor until the ZERO verification option is selected, as
shown in Figure 5-2.
8.
To perform a verification, press
.
The Manual/Automatic screen (Figure 5-3) opens.
36 Rosemount CT5400
Manual/Automatic ScreenFigure 5-3:
9.
Press for manual verification. Press for automatic verification.
NOTICE
Verifying Gas Concentrations
Pressing will automatically allow configuration verification in a future release of
GasSensor-3 software.
The Verify Zero screen (Figure 5-4) opens.
Verify Zero ScreenFigure 5-4:
10. Allow the concentrations to stabilize and wait for two minutes after stabilization.
Installation, Operations, and Maintenance Manual 37
Verifying Gas Concentrations
11.
This screen gives a reading of the concentration of the selected gas that is present as
an impurity in the nitrogen calibration gas, as measured by the instrument. In the
example (Figure 5-4), the gas being measured is NH3 (ammonia), and the instrument
has detected a concentration of 0.40 ppm.
If the reading is within tolerance, no further action is required. Press to end the
zero verification process.
The display controller proceeds to the Result screen (Figure 5-5).
Result ScreenFigure 5-5:
12. If the reading is outside tolerance, the instrument should be zero calibrated.
Refer to Section 6.3.1.
13.
In either case, press to return to the Calibration / Verification Complete screen
(Figure 5-6).
Calibration / Verification Complete ScreenFigure 5-6:
38 Rosemount CT5400
14.
To perform a zero verification for another gas, press .
The software returns to the Select gas screen (Figure 5-1).
15. Repeat the actions in steps 6-13 for the next gas.
16.
To perform a span verification, press . Then follow the span verification
procedure in Section 5.1.2.
17.
If you are finished verifying the analyzer, press .
The software returns to the Gas Sensor Main screen (Figure 4-7).
5.1.2 Span verification
To verify the span gas concentrations measured by the analyzer when reference gas is
flowing, use the following procedure.
Prerequisites
Run the analyzer at a stable temperature for at least thirty minutes prior to commencing
this procedure.
Verifying Gas Concentrations
Procedure
1. Use a certified reference gas cylinder as the source of the span verification gas.
2. Make sure that a pressure regulator is connected to the reference gas bottle.
3. Connect a hose from the reference gas bottle, through a T-piece, to the sample
supply port on the rear panel of the analyzer.
4. Connect an excess flow line to the unused port on the T-piece and route the excess
flow line to a suitable extractor.
5. On the display controller, browse to the Main menu as described in Section 4.9.
6.
Using and , select GAS SERVICE (Figure 5-7).
Installation, Operations, and Maintenance Manual 39
Verifying Gas Concentrations
7.
Main menuFigure 5-7:
Press .
The Select gas screen (Figure 5-8) opens.
Select gas ScreenFigure 5-8:
8.
Use and to move the cursor until the gas that you wish to span verify is
selected. Press .
The Select Type screen (Figure 5-9) opens.
40 Rosemount CT5400
9.
Use
Verifying Gas Concentrations
Select Type screenFigure 5-9:
and until the SPAN verification option is selected, as shown in Figure 5-9.
To perform a verification, press .
The Mode selection screen opens (Figure 5-10) for manual or automatic verification.
Mode selection ScreenFigure 5-10:
10.
Press for manual verification.
The Span input screen (Figure 5-11) opens.
Installation, Operations, and Maintenance Manual 41
Verifying Gas Concentrations
11.
Span input ScreenFigure 5-11:
Use and to highlight each digit in turn; then use and to increase or
decrease the value until the concentration displayed matches the cylinder you are
using.
NOTICE
The cylinder concentration must be entered in ppm.
12.
Press
The Verify span screen (Figure 5-12) opens.
to proceed to the next step.
Verify span ScreenFigure 5-12:
42 Rosemount CT5400
Verifying Gas Concentrations
13.
Press to cancel the manual verification.
14.
Press to finish.
15. Repeat steps 5-9.
16.
Press for automatic verification.
This opens the valve (where applicable) and flows the span gas.
17. Allow the concentrations to stabilize and wait for two minutes after stabilization.
This screen gives a reading of the concentration of the selected gas that is present,
as measured by the instrument. In the example shown in Figure 5-12, the gas being
measured is NH3 (ammonia), and the instrument has detected a concentration of
2000.29 ppm.
18.
If the reading is within tolerance, no further action is required. Press to end the
span verification process.
The display controller proceeds to the Result screen (Figure 5-13).
Result ScreenFigure 5-13:
19. If the reading is outside tolerance, the instrument should be span calibrated.
Refer to Section 6.3.2.
20.
Press to return to the screen shown in Figure 5-14.
Installation, Operations, and Maintenance Manual 43
Verifying Gas Concentrations
21.
Calibration / Verification ScreenFigure 5-14:
If you wish to perform a span for another gas, press .
The software returns to the Select gas screen (Figure 5-1) Repeat steps 8 - 16 for the
next gas.
22.
If you wish to perform a zero verification, press . Then follow the zero verification
procedure in Section 5.1.1.
23.
If you are finished verifying the analyzer, press
.
The software returns to the Gas Sensor Main screen (Figure 4-7).
The span verification procedure is now complete.
44 Rosemount CT5400
6 Gas Calibration Procedures
6.1 Required tools
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, where 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.
Gas Calibration Procedures
6.2
If calibration must be carried out (e.g., for legal requirements), it can be calibrated by using a
water vapor generator to supply a known concentration of water vapor.
Main menu
The calibration functions are accessed through the Main menu (Figure 6-1). To get to the
Main menu, press MENU on either the Gas Sensor Main screen or the Pressure and
Temperature screen, as described in Section 4.9.
Main menuFigure 6-1:
Installation, Operations, and Maintenance Manual 45
Gas Calibration Procedures
The Main menu is used to access the software routines and screens that are used for
calibration and maintenance. Five options are presented (Figure 6-1). For more information
about the options on the Main menu, see Section 4.9.
On the Main menu,
the option you want is highlighted (GAS SERVICE is the example shown in Figure 6-1), press
to go to the first screen of that software routine.
and can be used to scroll between the menu options (A). When
6.3 Calibration
Calibration flows the known cylinder gas through the analyzer and then adjusts the
readout until the measurement matches the cylinder. This adjustment is then applied to all
measurements until the next calibration. There are two circumstances in which you may
want to calibrate.
1. After you verify (see Chapter 5) and find that the analyzer readings are outside of
tolerance
2. At regular intervals, such as once a day or once a shift
6.3.1 Zero calibration
Zero calibration is calibrating the analyzer so that when no sample gas is flowing through
it, the gas concentrations measured by the instrument are zero. Zero calibration is done by
calibrating the analyzer measurements against a known sample gas using the following
procedure:
Prerequisites
Run the analyzer at a stable temperature for at least thirty minutes prior to commencing
this procedure.
Use nitrogen gas of instrument gas purity as the zero calibration gas.
Procedure
1. Make sure that a pressure regulator is connected to the nitrogen gas bottle.
2. Connect a hose from the nitrogen gas bottle through a T-piece to the sample supply
port on the rear of the analyzer. Connect an excess flow line to the unused port on
the T-piece and route the excess flow line to a suitable extractor.
3. On the display controller of the analyzer, browse to the Main menu as described in
Section 4.9.
46 Rosemount CT5400
Main menuFigure 6-2:
4.
Using and ,select GAS SERVICE.
5.
Press .
Gas Calibration Procedures
The Select gas screen (Figure 6-3) opens.
Select gas ScreenFigure 6-3:
6.
Use and to move the cursor until the gas that you wish to zero calibrate is
selected. Press .
The Select Type screen (Figure 6-4) opens.
Installation, Operations, and Maintenance Manual 47
Gas Calibration Procedures
7.
8.
Select Type ScreenFigure 6-4:
Use and to move the cursor until the ZERO calibration option is selected (see
Figure 6-4).
To perform a calibration, press
.
The Mode selection screen (Figure 6-5) opens.
Mode selection ScreenFigure 6-5:
9.
Press for manual calibration. Press for automatic calibration.
The Calibrate zero screen (Figure 6-6) displays.
48 Rosemount CT5400
10.
Press to confirm.
Gas Calibration Procedures
Calibrate zero ScreenFigure 6-6:
The Result screen (Figure 6-7) displays.
Result ScreenFigure 6-7:
11.
Press to finish the process.
12. Allow the concentrations to stabilize and wait for two minutes after stabilization.
This screen gives a reading of the concentration of the selected gas that is present as
an impurity in the nitrogen calibration gas, as measured by the instrument. In the
example shown (Figure 6-7), the gas being measured is NH3 (ammonia), and the
instrument has detected a concentration of 0.530 ppm (vol).
Installation, Operations, and Maintenance Manual 49
Gas Calibration Procedures
13.
14.
15.
16.
If the reading is within tolerance, no further action is required. Press to end the
zero calibration process.
If the reading is outside tolerance, press .
The analyzer returns to its factory set calibration. Allow a minute to ensure the
readings are stable.
If the reading is now within tolerance, no further action is required. Press or
to abort the Zero Calibration process.
If the calibration of the analyzer remains outside of tolerance, press to display
the Calibrate screen (Figure 6-8) to re-calibrate with a new zero offset value.
Calibrate screen (Confirmation)Figure 6-8:
17.
To proceed with the automatic re-calibration, press .
The automatic re-calibration of the instrument's zero point starts, and the offset
shown on the screen (-0.852 ppm (vol) in Figure 6-8) is applied to the instrument.
Press the UP
or DOWN button to abort the calibration process.
When the calibration is complete, Figure 6-9 is displayed.
50 Rosemount CT5400
Calibration Complete ScreenFigure 6-9:
18.
Press to display the Calibrate gas screen (Figure 6-4) and perform a span
calibration on the same gas (see Section 6.3.2).
Gas Calibration Procedures
6.3.2
19.
Press to perform a zero calibration for another gas.
The software Select gas screen (Figure 5-1) displays.
20. Repeat steps 7 - 17 for the next gas.
21.
If you are finished calibrating the analyzer, press .
The Main menu (Figure 6-2) displays.
Span calibration
The span gas concentrations measured by the analyzer when reference gas is flowing can
be verified and, if necessary, calibrated against the known reference gas by using the
following procedure.
Prerequisites
Run the analyzer at a stable temperature for at least thirty minutes prior to commencing
this procedure.
Procedure
1. Use a certified reference gas cylinder as the source of the span calibration gas.
2. Make sure that a pressure regulator is connected to the reference gas bottle.
3. Connect a hose from the reference gas bottle, through a T-piece, to the sample
supply port on the rear panel of the analyzer. Connect an excess flow line to the
unused port on the T-piece and route the excess flow line to a suitable extractor.
4. On the display controller of the analyzer, browse to the Main menu as described in
Section 4.9.
Installation, Operations, and Maintenance Manual 51
Gas Calibration Procedures
5.
6.
Refer to Figure 6-2. Using and DOWN , select GAS SERVICE.
Press .
The Select gas screen (Figure 6-10) opens.
Select gas ScreenFigure 6-10:
7.
Use and to move the cursor until the gas that you wish to span calibrate is
highlighted by the cursor. Press .
The Select type screen (Figure 6-11) opens.
Select Type ScreenFigure 6-11:
8.
Use
calibration, press
and to move the cursor until SPAN is selected (Figure 6-11). To perform a
.
The Mode selection screen (Figure 6-12) opens.
52 Rosemount CT5400
Mode selection screenFigure 6-12:
9.
Press to perform a manual calibration.
The Span input screen (Figure 6-13) opens.
Gas Calibration Procedures
Span input ScreenFigure 6-13:
10.
Use
and to highlight each digit in turn; then use and to increase or
decrease the value until the concentration displayed matches the cylinder you are
using. Press
to proceed to the next step.
NOTICE
The cylinder concentration must be entered in ppm.
The begin Calibrate span screen (Figure 6-14) opens.
Installation, Operations, and Maintenance Manual 53
Gas Calibration Procedures
11.
Begin Calibrate span ScreenFigure 6-14:
Press to confirm. The Calibrate span screen Figure 6-15 opens.
Calibrate span Result ScreenFigure 6-15:
12. Allow the concentrations to stabilize and wait for two minutes after stabilization.
This screen gives a reading of the concentration of the selected gas that is present,
as measured by the instrument. In Figure 6-15, the gas being measured is NH
3
(ammonia), and the instrument has detected a concentration of 119.41 ppm (vol).
13.
If the reading is within tolerance, no further action is required. Press
or to
abort the span calibration process.
14.
If the reading is outside tolerance, press ENTER .
The analyzer returns to its factory-set calibration.
15. Allow a minute to ensure the readings are stable.
16.
If the reading is now within tolerance, no further action is required. Press or
to abort the span calibration process.
54 Rosemount CT5400
Gas Calibration Procedures
17. If the calibration of the analyzer remains outside of tolerance, you can adjust the
calibration by pressing .
This brings up a Calibrate screen (Figure 6-16).
Calibrate - re-calibrate with New ZERO offset screenFigure 6-16:
18.
To proceed with the automatic re-calibration, press .
The automatic re-calibration of the instrument's span calibration starts, and the
offset shown on the screen (in Figure 6-17 it is 0.997) is applied to the instrument.
Press
or to abort the calibration process.
When the calibration or verification is complete, the screen shown in Figure 6-17 is
displayed.
Calibrate Complete ScreenFigure 6-17:
19.
If you wish to perform a span calibration for another gas, press .
The software returns to the Select gas screen (Figure 6-10). Repeat steps 7-18 for the
next gas.
Installation, Operations, and Maintenance Manual 55
Gas Calibration Procedures
20.
If you are finished calibrating the analyzer, press . The software returns to the
Main menu shown in Figure 6-2.
6.4 Reference gas - suggested concentration ranges
Calibration gas ranges are recommended to be between 80% and 100% of the full range of
the analyzer. Please contact Emerson if you require assistance.
56 Rosemount CT5400
Troubleshooting and diagnostics
7 Troubleshooting and diagnostics
7.1 Troubleshooting, repairs, and failure diagnostics
Failure diagnosis of the analyzer comprises interpretation of system fault messages shown
on the LCD display, visual examination, performing failure diagnostic tests, and
downloading performance data and sending that data to Emerson for analysis.
In the failure diagnosis procedures, all controls and indicators are on the analyzer unless
otherwise indicated.
The analyzer is specifically designed to run unattended for long periods, to automatically
resolve system issues, and to recover from power failures and return to a normal working
state. This troubleshooting guide is intended to assist maintenance personnel when the
analyzer has not appeared to be working normally for a period of more than five minutes. If
the procedures given in this chapter fail to return the analyzer to normal operations or do
not identify a repairable fault, notify your Customer Care Representative for further
assistance.
Observe and obey all safety precautions when performing preventative maintenance on
the analyzer.
Important
The troubleshooting and failure diagnosis procedures described in this chapter assume that any host
equipment provided by you is fully functional. Always make sure that the host equipment is fully
serviceable before performing failure diagnosis on the analyzer.
Failure diagnosis, repair, and maintenance must only be performed by:
• Maintenance engineers who have the necessary skills and training , and who have
been authorized to perform maintenance on the analyzer.
• Emerson™ customer care engineers
In all the cases described in this chapter, maintenance personnel must perform the repairs
by directly replacing the faulty item with a known serviceable spare part supplied by
Emerson. All other items must be repaired or replaced by the manufacturer.
You can gain access to repairable and replaceable parts by removing the top and or
bottom covers of the analyzer. There is no need to remove any other parts.
Installation, Operations, and Maintenance Manual 57
Troubleshooting and diagnostics
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and
lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable
protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
FIRE AND EXPLOSION
Do not open the Ex d enclosure of the analyzer unless the atmosphere in the area is known to
be below the ignitable concentration of combustible gases or materials.
Failure to observe this precaution will cause death, personal injury, and/or damage to persons.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
58 Rosemount CT5400
Troubleshooting and diagnostics
WARNING!
HAZARDOUS SUBSTANCES
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and
components with extreme caution.
Gas handling components within the analyzer will 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 according to the applicable local,
national, or international health and safety regulations and pollution regulations.
7.2 Using the Built-in-Test (BIT) fault diagnostics
The analyzer has a limited BIT diagnostics function.
Prerequisites
The BIT function can be used to perform failure diagnosis of some functions in situations
where there is a fault other than a complete failure of the equipment. The BIT is accessed
and controlled through the display controller mounted on the front panel.
Procedure
1. The STATUS information can be displayed from either the Gas Sensor Main screen
(see Figure 7-1) or the Pressure and Temperature screen (see Figure 7-2)
Installation, Operations, and Maintenance Manual 59
Troubleshooting and diagnostics
Gas Sensor Main ScreenFigure 7-1:
Pressure and Temperature ScreenFigure 7-2:
2. When the analyzer is running correctly, the STATUS displays Running and OK (see
Figure 7-1).
3. If a fault is detected the STATUS display in the bottom left-hand corner of the screen
changes from OK to a flashing .
60 Rosemount CT5400
Troubleshooting and diagnostics
Fault Status - Analyzer Running ScreenFigure 7-3:
If the analyzer stops the STATUS changes to Stopped, and OK changes to a ?.
Fault Status - Analyzer StoppedFigure 7-4:
4. From either the Gas sensor main screen (see Figure 7-1) or the Pressure and
Temperature screen (see Figure 7-2), press to go to the Main menu.
5.
Press
and to scroll to the Faults screen.
Installation, Operations, and Maintenance Manual 61
Troubleshooting and diagnostics
Main menu - FAULTS ScreenFigure 7-5:
If the no faults have been identified by the BIT the central area of the Faults screen is
blank.
Faults Screen - No Faults DetectedFigure 7-6:
If the faults are identified by the BIT, the display controller indicates the fault. The
precise data displayed varies depending upon where the fault has occurred in the
analyzer.
Faults Detected ScreenFigure 7-7:
62 Rosemount CT5400
Troubleshooting and diagnostics
6.
Press and to list the fault listed.
7.
Press to display the Fault diagnostic information screen.
Cell heater Temperature Out of RangeFigure 7-8:
8. Examine the data shown on the Fault screen to determine if the suspect component
has failed or is operating outside of its correct parameters. If you do not have the
necessary information to determine if the suspect component is faulty, contact your
local Customer Care representative.
9.
From the Main menu, press and to scroll to DIAGNOSTICS.
Main MenuFigure 7-9:
The Diagnostics screen lists those main components of the analyzer where problems
can be diagnosed using the BIT system. The Diagnostics screen also enables you to
check on the status and, where appropriate, the values of any of the listed
components.
Installation, Operations, and Maintenance Manual 63
Troubleshooting and diagnostics
10.
11.
Diagnostics MenuFigure 7-10:
Press
Press to display the component's diagnostic information. See Figure 7-11 for a
diagnostics example for Laser 1.
and to scroll to the component for further troubleshooting.
Laser 1 Component Diagnostics ScreenFigure 7-11:
The parameters data displayed varies depending upon which component was
selected for diagnosis.
12. Examine the data shown on the Component Diagnostic screen to determine if the
suspect component has failed or is operating outside of its correct parameters. If
you do not have the necessary information to determine if the suspect component
is faulty, contact your local Customer Care representative.
7.3
64 Rosemount CT5400
Visual examination
A visual examination of the analyzer is recommended as the next step in failure diagnosis if
the BIT fails to identify the problem.
Troubleshooting and diagnostics
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
7.4
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
Procedure
1. Power down the analyzer and allow it to cool.
2. Visually examine the exterior of the analyzer for signs of damage.
3. Perform a visual inspection of the optical and electrical components inside the
analyzer.
4. If any loose connections are found in the electrical compartment, refer to the wiring
diagrams (see Appendix C) to identify and repair the connection.
Failure diagnostics
If the BIT and the visual examination fail to identify the fault, perform the failure
diagnostics and recommended actions.
General troubleshooting and diagnostics information
To assist with failure diagnosis, use the wiring diagrams (see Appendix C) to locate the
position of a wiring connector should it become disconnected.
Installation, Operations, and Maintenance Manual 65
Troubleshooting and diagnostics
Functional failure diagnostics tableTable 7-1:
Step Symptom Test Result
1 Gas reading ab-
normal.
2A Calibration/vali-
dation drift
2B Check calibra-
2C Check calibra-
3 Measurement
invalid flag
4 Single gas read-
ing invalid.
Check measurement validity flag.
Check measurement validity flag.
tion cylinder.
tion pipework.
Check display
controller to
assess which
measurements
are invalid.
Check which
gas.
Reading invalid.
Reading valid. Perform a new
Reading invalid.
Reading valid. Perform a new
Cylinder near
empty.
Pipework damaged.
All gas readouts invalid.
One gas readout invalid.
Any gas. Check fault
Recommended actions Result Cause
Refer to step 3.
zero and span
calibration to
ensure calibration factors are
correct.
Refer to step 3.
zero and span
calibration to
ensure calibration factors are
correct.
Replace cylinder.
Replace pipework.
Use the display
controller to
check pressure
and cell temperature.
Refer to step 4.
reading.
Readings return to normal.
Abnormal
readings persist.
Readings return to normal.
Drift persists. Refer to step
Readings return to normal.
Drift persists. Refer to step
Readings return to normal.
Drift persists. Unknown.
Pressure and
temperature
are both in
range.
Pressure or
temperature is
out of range.
Fault reading
active.
Sensor required calibration.
Unknown.
Contact Cascade Technologies, Ltd.
Sensor required calibration.
2B.
Cylinder was
empty.
2C.
Pipework was
damaged.
Contact Cascade Technologies, Ltd
Hardware failure. Contact
Cascade Technologies, Ltd.
Refer to steps
5 or 6 as appropriate.
Use Fault to access further diagnostic information; contact Cascade
Technologies,
Ltd.
66 Rosemount CT5400
Functional failure diagnostics table (continued)Table 7-1:
Step Symptom Test Result
5 Analysis cell
pressure out of
range.
6 Analysis cell
temperature
out of range
7 Sensor frozen
or unresponsive.
8 Other error not
covered above.
Adjust inlet
valve to
change pressure.
Read cell temperature from
display controller.
Attempt a reboot.
Unknown.
Contact Cascade Technologies Ltd.
Pressure returns to normal.
Pressure is unstable or impossible to adjust.
Temperature
too low.
Temperature
too high.
System reboots successfully.
System does
not reboot.
Troubleshooting and diagnostics
Recommended actions Result Cause
No further action required.
Contact Cascade Technologies Ltd.
Allow system
time to heat
up.
Contact Cascade Technologies Ltd.
No further action required.
Fault reading
not displayed.
Pressure returns to normal.
System heats
up with time.
System does
not heat up.
System reboots successfully.
Unknown.
Contact Cascade Technologies, Ltd.
Pressure was
out of range.
System was recently started
from cold.
Heater failure.
Contact Cascade Technologies, Ltd.
Computer
freeze-up or
connection
failure. Contact
Cascade Technologies Ltd. if
this recurs.
PC or HMI failure. Contact
Cascade Technologies, Ltd.
Installation, Operations, and Maintenance Manual 67
Troubleshooting and diagnostics
7.5 Repairable items
The major items that are repairable without Emerson's assistance are listed in Spare parts
list. In all cases, the repair is by direct replacement of the faulty item with a known
serviceable item purchased from Emerson . If any items other than those listed require
service, Emerson must perform the repair.
Before commencing any repair on the analyzer, allow it to cool down as detailed in the
safety precautions below.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
7.6
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
Only standard hand tools are required to perform the tasks described in this section.
Tools and test equipment required for troubleshooting
The following tools are required to remove and replace components
Required ToolsTable 7-2:
3 mm Hex key needed to open the box
2.5 mm Hex Socket (Allan key)
4.0 mm Hex Socket (Allan key)
68 Rosemount CT5400
Troubleshooting and diagnostics
Required Tools (continued)Table 7-2:
5.0 mm Hex Socket (Allan key)
7.0 mm Spanner
8.0 mm Spanner
14 mm Spanner
16 mm Spanner
Small snap on ratchet
Small flat blade screwdriver (used for wiring terminals)
Multi-meter - used to perform continuity checks on electrical wiring during an inspection.
Control drawing
Wiring diagrams - Appendix C
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
7.7
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
Removing the top cover
Remove the top cover to access the interior of the analyzer.
Observe all safety precautions before starting this procedure.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
Installation, Operations, and Maintenance Manual 69
Troubleshooting and diagnostics
WARNING!
ELECTRIC SHOCK
Do not operate without covers secure.
Do not open while energized.
Installation requires access to live parts which can cause death or serious injury.
For safety and proper performance, this instrument must be connected to a properly grounded
three-wire source of power.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and
lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable
protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
To gain access to the electrical, pneumatic, and optical components, it may be necessary
to remove the top cover.
70 Rosemount CT5400
Troubleshooting and diagnostics
Removing the Top CoverFigure 7-12:
A. Top cover
B. M5 x 12 mm button head socket screws (4)
C. Chassis assembly
D. M5 flat washers (4)
Procedure
1. Set the ON/OFF switches on the front and back panel to OFF.
2. Allow the analyzer to cool for at least two hours. Allow it to cool for twelve hours if
replacing the analysis cell.
3. Disconnect all external cables.
Tag if necessary.
4. Remove the analyzer from the rack and place on a flat, stable surface that can
accommodate the weight. This step requires two people to lift and transport the
analyzer.
Installation, Operations, and Maintenance Manual 71
Troubleshooting and diagnostics
5. Remove and retain the four M5 button head socket screws and associated flat
washers.
6. Lift the cover vertically, clear of the chassis assembly. Set it aside, out of the working
area.
7. Examine the cover for signs of physical damage. If it is undamaged, retain and
reinstall it when all repairs are complete. Minor paintwork may be retouched.
7.8 Removing the bottom cover
To gain access to the electrical, pneumatic, and optical components, it may be necessary
to remove the bottom cover.
Observe all safety precautions before starting this procedure.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
72 Rosemount CT5400
Refer to Figure 7-13 and proceed as follows:
Removing the Bottom CoverFigure 7-13:
Troubleshooting and diagnostics
A. Bottom cover
B. M5 x 12 mm button head socket screws (4)
C. M5 flat washers (4)
Procedure
1. Set the ON/OFF switches on the front and back panel to OFF.
2. Allow the analyzer to cool for at least two hours. Allow to cool for twelve hours if
replacing the analysis cell.
3. Disconnect all external cables.
Tag if necessary
4. Remove the analyzer from the rack and place it upside down on a flat, stable surface
that can accommodate the weight. This step requires two people to lift and
transport the analyzer.
5. Remove and retain the four button head socket screws and associated flat washers.
6. Lift the cover vertically, clear of the chassis assembly. Set it aside, out of the working
area.
7. Examine the cover for signs of physical damage. If it is undamaged, retain and
reinstall when all repairs are complete. Minor paintwork may be re-touched.
7.9
Installation, Operations, and Maintenance Manual 73
Replacing the LCD display
To replace the display, complete the following instructions.
Troubleshooting and diagnostics
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
Procedure
1. Power down the analyzer by switching the ON/OFF switches on the front and rear
panel to the OFF position and allow the core to cool for twelve hours.
2. Remove the analyzer from the rack using two people to lift the analyzer and place it
on a clean workbench.
3. Remove the four screws and associated washers attaching the top cover to the
chassis. Vertically lift the cover from the chassis and set aside.
74 Rosemount CT5400
Troubleshooting and diagnostics
Replacing the LCD DisplayFigure 7-14:
A. Display controller PCB
B. LCD display
C. Front panel
D. Ribbon cable connection
E. 3 M hex nuts and plain washers
F. Display back cover
4. Disconnect the ribbon cables and wiring harness from the display.
5. Using a small spanner, remove and retain the two M3 hex nuts and plain washers (E),
holding the display back cover (F) in place.
6. Remove the back cover (F) from the rear of the display. If necessary, pry it off with a
small, flat-bladed screwdriver.
7. Remove the display (B) and the display controller PCB (A) by pulling them out to the
rear from the front panel.
8. Make sure the display bezel seal is present and free from cuts.
9. Unpack and visually inspect the replacement LCD display for damage. If damage has
occurred, contact your local Emerson Customer Care Representative.
10. Insert the display into the front panel.
11. Replace the eight M3 plain washers and M3 hex nuts retained when removing the
display.
12. Plug in the ribbon cables.
Installation, Operations, and Maintenance Manual 75
Troubleshooting and diagnostics
13. Apply power to restart the analyzer.
7.10 Replacing the USB circuit board
The USB printed circuit board (PCB), located on the rear of the front panel, is a replaceable
part. Replace the USB PCB as follows:
Observe all safety precautions before starting this procedure.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
ELECTRIC SHOCK
Do not operate without covers secure.
Do not open while energized.
Installation requires access to live parts which can cause death or serious injury.
For safety and proper performance, this instrument must be connected to a properly grounded
three-wire source of power.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and
lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable
protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
76 Rosemount CT5400
Troubleshooting and diagnostics
WARNING!
BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.
• Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.
• The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.
Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.
Procedure
1. Power down the analyzer and allow it to cool.
2. Remove the analyzer from the rack and place it on a stable workbench. This step
requires two people to properly lift and transport it to the workbench.
3. Remove and retain the top cover as described in Section 7.7.
4. Refer to Figure 7-15. Disconnect the spade connector on the end of the Earth lead (A)
from the tag clip (C).
Installation, Operations, and Maintenance Manual 77
Troubleshooting and diagnostics
Earth Ground ConnectionFigure 7-15:
A. Earth lead
B. M4 nut
C. Tag connector
D. Threaded spacer (front panel part)
E. USB circuit board
F. M4 flat washer
G. M4 spring washer
5. Disconnect the USB cable (F) from the USB PCB (A).
78 Rosemount CT5400
Troubleshooting and diagnostics
Removing the USB PCBFigure 7-16:
A. USB PCB
B. Threaded spacer (part of front panel)
C. M4 flat washer
D. M4 spring washer
E. M4 nut
F. USB cable
6. Remove and retain the three nuts (E), spring washers (D), and flat washers (C).
7. Remove the USB PCB.
8. Use caution when unpackaging and handling the USB PCB. Examine the
replacement USB PCB for physical damage and delamination.
CAUTION!
EQUIPMENT DAMAGE
Wear an ESD wrist strap or ground yourself to prevent damage to the USB PCB
electronics.
9. Place the replacement USB PCB (A) on the four threaded spacers (B) that form part
of the front panel.
Installation, Operations, and Maintenance Manual 79
Troubleshooting and diagnostics
10. Secure the USB PCB by fitting the three flat washers (C), spring washers (D) and nuts
(E) retained in Step 4, in the locations shown in Figure 12-7.
Do not fit securing hardware to the top left-hand threaded spacer at this stage.
11. Attach the USB cable (F) to the USB connector on the USB PCB.
12. Refer to Figure 7-16. Fit the tag connector (C) to the top left-hand threaded spacer
(D). Secure the tag connector with the flat washer (F), spring washer (G), and nut (B)
retained in Step 6.
13. Attach the spade connector at the free end of the Earth wire (A) to the tag connector
(C).
7.11 Replacing the power socket fuses
The analyzer contains two external fuses that are located in the fused power socket on the
rear panel.
Observe all safety precautions and allow the equipment to cool down before performing
this procedure.
The same procedure is used to replace both external fuses; therefore, the replacement of
only one is described.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power
ON/OFF switch at the rear of the panel is set to OFF and tagged off before removing the top
cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting
to prevent crushing of hands, feet, or other body parts.
The analyzer weighs 31 kg (68 lb). Emerson™ recommends that the analyzer is only moved and
lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
80 Rosemount CT5400
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