Rosemount™ CT5100
Continuous Gas Analyzer
Reference Manual
00809-0100-4511, Rev AA
May 2020
Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no
liability for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further
enhancements while in service may mean that the manual does not reflect your particular system.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
Document number: 00809-0100-4511
Rev AA, May 2020
©
Emerson 2020. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic,
mechanical, photocopying, recording, or otherwise without the express prior written permission of the copyright holder.
If you require additional technical assistance, request help from cascade.support@emerson.com or Emerson distribution partners.
Send general inquiries to cascade.support@emerson.com.
All trademarks used within this document are the property of their respective owners.
Preliminary information
This section details important user information for the Rosemount CT5100 Continuous Gas Analyzer.
Important
Users must read, understand, and comply with the following information before proceeding.
All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain,
and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The
following information is also available and/or referenced in the Rosemount CT5100 Quick Start Guide: 00825-0100-4511.
Save all instructions for future use. Contact your local service center or sales office when missing documents.
Authorized personnel
In-depth specialist knowledge is an absolute requirement for working with and on the analyzer. Personnel installing, operating,
servicing, and maintaining the analyzer must be instructed, trained, qualified, and authorized personnel of the operating company
for hazardous areas and the manufacturer. It is the responsibility of the operating company to:
• Train staff
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Have been trained
• Have read and understand all relevant sections of the product manual before commencing work
• Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate,
maintain, or service this analyzer before reading and understanding this document and receiving appropriate training.
2
Important instructions
Important
All users must read this page before proceeding!
Emerson designs, manufactures and tests its products to meet many national and international standards. The Rosemount
CT5100 is a sophisticated technical product, and to ensure it continues to operate as designed and within normal specifications it
MUST be installed, used, and maintained correctly. The following instructions MUST be adhered to and integrated into your safety
program when installing, using, and maintaining Emerson products.
• Failure to follow the proper instructions may cause:
— Loss of life
— Personal injury
— Damage to property
— Damage to this analyzer
— Warranty invalidation
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the installation instructions of the appropriate Reference Manual and in accordance with
applicable local and national codes.
• Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
• Unauthorized parts and procedures can affect the product’s performance; place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
3
Regulations and standards
Regulations/standards Description
2014/35/EU The Low Voltage Directive
2014/30/EU The Electromagnetic Compatibility Directive
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive
USA 21 CFR 1040.1 Laser products
NEC 505 National Electrical Code (issued by ANSI: American National Standards
BS EN 60825-1:2007 Safety of laser products. Equipment classification and requirements
BS EN 61010-1 2010
IEC 61010-1 2010
BS EN 61326-1: 2013 Electrical equipment for measurement, control, and laboratory use.
Associated publications
Rosemount CT5100 Quick Start Guide
Compliance approvals
Important
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
This product complies with USA 21 CFR 1040.10.
This product is designed and manufactured under an approved quality management
system to ISO 9001: 2015.
Institute and NFPA 70: National Fire Protection Association)
(identical to IEC 608250-1 2007)
Safety requirements for electrical equipment for measurements,
control, and laboratory use. General requirements
EMC requirements. General requirements
Waste disposal
Emerson and the Rosemount CT5100 have satisfied the requirements for applying
the CE marking to the Rosemount CT5100 Gas Analyzer.
This equipment meets all requirements of the EMC and Low Voltage directives.
Do not dispose of measuring tools into household waste.
Only for EC countries:
In accordance with European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment and its implementation into national right, measuring tools
that are no longer usable must be collected separately and disposed of in an
environmentally correct manner.
4
Safety and information notices
DANGER
WILL CAUSE DEATH
Failure to follow this warning will result in death or serious injury to personnel.
WARNING
DANGER TO PERSONNEL
Failure to follow this warning may result in death or serious injury to personnel.
CAUTION
MAY CAUSE DAMAGE TO EQUIPMENT
Failure to follow this warning may result in damage to the equipment.
NOTICE
Important or tip messages will appear in this format.
Safety precautions
Important
The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and
maintenance personnel, must observe the following safety precautions and warnings.
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Death, personal injury, and/or
damage to persons and/or property may result if this is not observed.
Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the top cover or opening the front
cover. The analyzer must be earthed.
Only trained, qualified personnel may install and connect power and signal cables. The installation/connection must be in
accordance with all legislative requirements and applicable standards.
Only qualified personnel, familiar with potential risks, should install the analyzer.
DANGER
EXPLOSION HAZARD
Failure to observe this precaution will cause death, personal injury, and/or damage to persons.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during prolonged shutdowns.
The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes and 30 seconds at a minimum
flow rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance.
Purge the sample gas in accordance with the safe working procedures for this site.
5
WARNING
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition source. The interior of a
analyzer is always hot unless it has been switched off and allowed to cool down. A fire may result if this precaution is not observed.
Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.
WARNING
TRANSPORTATION HAZARD
The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/moving equipment.
Handle the analyzer with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet, or
other body parts.
Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard
the analyzer against movement or break-away during transport by securely strapping it in place.
Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings for the weight of the
equipment, and is in good operational condition.
WARNING
FIRE AND EXPLOSION
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized .
The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials or unless all equipment within the protected enclosure is de-energized.
Always lock out the gas handling system when shutting down the analyzer.
After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes and 30
seconds at a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar.
DO NOT operate the analyzer with doors or covers open.
Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit.
When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to
external equipment MUST be shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.
Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up
the analyzer.
Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test.
Use only replacement parts and components authorized by Emerson.
All replacement parts and components must be certified and approved for use in hazardous areas.
The analyzer contains a battery for data backup purposes.
Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement
MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.
6
WARNING
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially
hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.
Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or
service.
WARNING
BURNS
Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly
important when working at heights.
Some parts of the analyzer may be heated to 374 °F (190°C). To prevent burns, do not touch any of the hot parts. All parts of a
analyzer are always hot unless it has been switched off and allowed to cool down.
Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been switched off and allowed to cool
for at least two hours. Before performing any maintenance on, or in the vicinity of, the analysis cell, allow the analyzer to cool for
at least 12 hours as the analysis cell is insulated against heat loss.
When handling the analyzer, always wear suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
WARNING
HAZARDOUS SUBSTANCES
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may cause death, personal
injury, and/or damage to persons and/or property.
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.
Wear personal protective equipment (PPE) when handling the equipment.
Gas handling components within the analyzer contain particulate matter residue from the sample gases. Over the life of the the
analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the the analyzer:
— Handle used gas handling components with extreme caution.
— Avoid direct skin contact with used gas handling components.
— Do not smoke, drink, or eat in the work area.
— Wear goggles or eye shields.
— Wear a suitable face mask to protect against inhalation of particulate matter.
— Do not wet fingers, eyes, or any exposed skin.
— Pack used gas handling components for disposal in sealed packaging and label them Contaminated.
— Dispose of contaminated items as hazardous material in accordance with applicable local, national, or international health
and safety regulations and pollution regulations.
Take special care to ensure that the sample gas return port either returns the sample gas to the product stream or discharges the
sample gas to a location that will not cause a hazard.
7
WARNING
OPTICAL RADIATION EXPOSURE HAZARD
There are three types of laser that may be included in the Rosemount CT5100: Quantum Cascade Lasers (QCLs), Interband
Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are Class 1. The characteristics of the lasers contained within
the analyzer are given in the table below.
The emitted laser light is invisible (mid-infrared), and the combined laser powers are sufficiently low at the first accessible aperture
that the unprotected eye will not be damaged. This class is eye safe under all operating conditions.
It is, however, possible to cause damage to the eye through not following correct procedures. Do not look at the laser with any
kind of magnifier or optical measuring device.
Parameter QCL ICL Diode Comment
Operation mode Pulsed Pulsed Pulsed N/A
Lasers per system 1 - 6 1- 6 1- 6 Maximum of 6 lasers per system
Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A
Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first accessible
Pulse duration < 1 µs < 1 µs < 5 µs N/A
Pulse repetition
frequency
Duty cycle < 5 % < 5 % < 25 % N/A
The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW.
The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of laser safety labels on
the analyzer is specified in Safety and system labels and annotation.
The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous
radiation exposure.
< 100 kHz < 100 kHz < 100 kHz N/A
aperture: < 9.62 mW
WARNING
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g., damage to eyes and skin
punctures from debris blown by the high pressure gas or compressed air.
Always lock off or tag out the calibration gas supply and compressed air supply when shutting down the analyzer.
The maximum gas pressure valve must not exceed 100 psig (690 kPa).
WARNING
EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE
In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Failure to
observe this warning and or follow safety instructions could cause an explosion or potentially hazardous situation, which if not
avoided, could result in death or serious injury.
Take suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area.
Clean the device surface by gently wiping it with a damp or antistatic cloth only.
8
WARNING
HAZARD BY WRONG INPUT VOLTAGE
Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the
installation. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.
This type of analyzer is always setup for a specific rated input voltage; see nameplate label.
Ensure the voltage at site of installation meets the rated analyzer input voltage.
WARNING
LOOSE ITEMS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
Do not place any loose items on top of the system or inside the compartments when doors / covers are open.
Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers.
WARNING
MAINTENANCE/MODIFICATIONS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
On completion of any maintenance and or modifications verify:
— All tools and equipment are removed.
— No contamination (water/dust) is in the compartments.
— Analyzer is wiped clean.
— Vents are clear and not obstructed.
— Verify that system is in a safe state for operation.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
CAUTION
EQUIPMENT DAMAGE
Failure to perform pre-system start-up checks may cause damage to equipment.
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the
analyzer are in place.
Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any calibration gases that are
required are available to the analyzer.
Always follow the Start-up procedure.
Always follow the Shutdown procedure.
9
CAUTION
UNSERVICEABLE EQUIPMENT
If the pressure and temperature screen does not display measurements similar to those shown in Figure 8-1 and Figure 8-2, refer
to Troubleshooting and diagnostics.
CAUTION
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is
unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical
components requires the use of special optical test/calibration equipment and procedures.
Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this
manual, then the fault must be repaired by Emerson.
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Contents
Chapter 1 Introduction.............................................................................................................15
1.1 Description................................................................................................................................ 15
1.2 Customer information............................................................................................................... 15
1.3 Safety precautions and conditions for safe use...........................................................................15
1.4 Qualified personnel....................................................................................................................16
1.5 Software version........................................................................................................................16
1.6 Glossary and abbreviations........................................................................................................ 17
Chapter 2 Theory of operation................................................................................................. 21
2.1 Overview................................................................................................................................... 21
2.2 Laser measurement principle.....................................................................................................21
2.3 Gas concentration measurements............................................................................................. 21
Chapter 3 Description.............................................................................................................. 23
3.1 Equipment purpose and role......................................................................................................23
3.2 System overview........................................................................................................................23
3.3 Gas inputs and outputs.............................................................................................................. 25
3.4 Connecting the electrical/electronic inputs and outputs............................................................27
3.5 Optical description.................................................................................................................... 31
Chapter 4 Specifications...........................................................................................................33
4.1 Gas detection............................................................................................................................ 33
4.2 Detailed system specifications...................................................................................................33
4.3 Safety and system labels and annotation................................................................................... 39
Chapter 5 Install.......................................................................................................................41
5.1 Site selection............................................................................................................................. 41
5.2 Unpacking................................................................................................................................. 43
5.3 Mounting the analyzer...............................................................................................................44
5.4 Connecting the electrical/electronic inputs and outputs............................................................49
Chapter 6 Controls and display controller.................................................................................57
6.1 Front panel controls and indicators............................................................................................57
6.2 Display controller.......................................................................................................................58
6.3 Gas Sensor Main screen............................................................................................................. 58
6.4 Pressure and Temperature screen..............................................................................................60
6.5 Help system...............................................................................................................................61
6.6 Main menu................................................................................................................................ 62
6.7 BACK button..............................................................................................................................62
Chapter 7 Start-up procedure...................................................................................................63
7.1 Introduction.............................................................................................................................. 63
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7.2 Preparation for use.................................................................................................................... 63
7.3 Start-up procedure.................................................................................................................... 64
7.4 Front panel controls and indicators............................................................................................67
Chapter 8 Operating the analyzer.............................................................................................69
8.1 Introduction.............................................................................................................................. 69
8.2 Normal operation...................................................................................................................... 69
Chapter 9 Shutdown procedure............................................................................................... 71
9.1 Safety precautions .................................................................................................................... 71
9.2 Shutdown procedure................................................................................................................. 72
Chapter 10 Gas calibration......................................................................................................... 77
10.1 Required tools......................................................................................................................... 77
10.2 Main menu calibration routines............................................................................................... 78
Chapter 11 Troubleshooting and diagnostics............................................................................. 99
11.1 Use the Built-in-Self-Test (BIST) fault diagnostics..................................................................... 99
11.2 Use the Faults menu.............................................................................................................. 103
11.3 Failure diagnosis principles.................................................................................................... 104
11.4 Repairable faults.................................................................................................................... 105
11.5 Tools and test equipment...................................................................................................... 106
11.6 General troubleshooting and diagnostics information........................................................... 106
11.7 Navigate the Diagnostics menu............................................................................................. 106
11.8 Visually examine the analyzer................................................................................................ 109
11.9 Functional failure diagnostics................................................................................................ 109
Chapter 12 Repair and replacement......................................................................................... 115
12.1 Repair policy.......................................................................................................................... 115
12.2 Open the electrical compartment door..................................................................................115
12.3 Close the electrical compartment door..................................................................................117
12.4 Replace the fuses...................................................................................................................117
12.5 Replace the TEC board........................................................................................................... 121
12.6 Replace the peripheral board................................................................................................. 123
12.7 Replace the motherboard......................................................................................................125
12.8 Replace the Ethernet in/out relay modules............................................................................ 127
12.9 Lower (main) DIN rail electronic components........................................................................ 128
12.10 Replace a DC power supply..................................................................................................129
12.11 Replace the 10 Amp solid state relay....................................................................................131
12.12 Replace the Ethernet connector...........................................................................................131
12.13 Replace the laser module.....................................................................................................132
12.14 Replace the detector module...............................................................................................134
12.15 Replacing the O2 detector................................................................................................... 135
12.16 Replace the main terminal board......................................................................................... 138
12.17 Replace the mains power filter.............................................................................................139
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12.18 Remove the top cover..........................................................................................................140
12.19 Replace the pressure sensor.................................................................................................141
12.20 Replace the PT100 cell temperature sensor......................................................................... 142
12.21 Cleaning the cell mirrors...................................................................................................... 145
12.22 Spare parts list..................................................................................................................... 150
Chapter 13 Preventative maintenance..................................................................................... 153
13.1 Cleaning the analyzer............................................................................................................ 153
13.2 Maintaining the analyzer........................................................................................................154
13.3 Scheduled maintenance........................................................................................................ 154
Appendix A Engineering drawings............................................................................................ 155
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Introduction
1 Introduction
1.1 Description
The Rosemount CT5100 Continuous Gas Analyzer, referred to hereafter as the Rosemount
CT5100, is an electronic sensor that uses laser spectroscopy to perform analysis of process
gas streams.
The function of the analyzer is to detect and measure up to 10 different types of gas at
concentrations ranging from parts per million (ppm) to percentage levels in the process
gas stream.
Important
The Rosemount CT5100 is designed for use in Non Hazardous areas ONLY.
Note
This manual is intended for the personnel who install, operate, and maintain the
equipment.
1.2 Customer information
This manual contains all the important information that must be followed to ensure the
correct operation and safety of personnel when operating the analyzer.
For information regarding installation, consult Install and the Quick Start Guide.
Emerson is committed to continuously improving its products and documentation. Every
effort will be made to include in the documentation any modifications by the
manufacturer. However, this document reflects the supplied analyzer at the revision date
on the front cover.
Should you require further information, or should particular problems arise that are not
covered in this manual, you can request additional help from Cascade Technical Support
(cascade.support@emerson.com) or Emerson distribution partners. Further contact
details for Emerson can be found on the back page of this manual.
1.3 Safety precautions and conditions for safe use
WARNING
SAFE USE PRECAUTIONS
Before installing or performing any maintenance on the analyzer, read and understand the
safety information given in the preliminary information of this manual.
The analyzer described in this guide has been quality control tested and left the
manufacturer in pristine condition. To achieve the correct and safe operation of this
product, it must be transported, installed, operated, and maintained as described by the
manufacturer.
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All lasers used within the analyzer are Class 1. The emitted laser light is invisible (midinfrared) and the pulse duration so short that the unprotected eye will not be damaged.
The nature of the laser beam path and beam width further ensures that it should be
impossible to cause any eye damage. The analyzer has warning labels at appropriate
positions in accordance with USA 21 CFR 1040.10.
General safety notice/residual risk
Installation, operation, and maintenance of the analyzer must be in accordance with these
instructions.
When operated as intended and all applicable safety instructions are observed, an element
of risk will remain, including, but not limited to, the following:
• The emission of gases hazardous to health may be possible when all gas connections
have been correctly made.
• To avoid exposure to the dangers of residual risks, take particular care when installing,
operating, maintaining, and servicing the analyzer.
Reference Manual
1.4 Qualified personnel
In-depth specialist knowledge is an absolute requirement for working with and on the
analyzer. Personnel installing, operating, servicing, and maintaining the analyzer must be
instructed, trained, qualified, and authorized personnel of the operating company for
hazardous areas and the manufacturer.
It is the operating company's responsibility to:
• Train staff
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Be trained
• Read and understand all relevant sections of the product manual before commencing
work
• Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site
property, do not install, operate, maintain, or service this analyzer before reading and
understanding this reference manual and receiving appropriate training.
1.5 Software version
The analyzer includes software that is used to control the operation of the analyzer. This
manual describes the software version as: 5.7.13.
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1.6 Glossary and abbreviations
Abbreviation Description
©
% Percent
< Less than
° Degree
AC Alternating current
ATEX Explosive atmospheres
Barg Pressure, in units of bars, above or below atmospheric pressure
BS British Standard
C Celsius
CDA Compressed dry air
CE European Conformity
Copyright
CFR Code of Federal Regulations
CGA Continuous Gas Analyzer
CH
4
CO
2
DC Direct current
Deg Degree (temperature)
e.g. For example
EC European Community
EMC Electromagnetic compatibility
EU European Union
Hrs Hours
Hz Hertz
H2O Water
ICL Interband Cascade Laser
IEC International Electro-technical Commission
in. Inches
IP Ingress protection
Methane
Carbon dioxide
IPxx Ingress protection (xx are numbers that define the protection level)
IS Intrinsically safe
ISO International Organization for Standardization
k Thousand
kg Kilogram
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Abbreviation Description
kHz Kilo hertz
L Liter
lb. Pound
LCD Liquid crystal display
LED Light emitting diode
L/min Liters per minute
m Meter
3
m
mA Milliamp
Max Maximum
mBar milli-Bar
mbps Megabits per second
Cubic meter
mg Milligram
3
mg/m
Milligram/cubic meter
Mid IR Mid Infrared
min Minute
mm Millimeter
N
2
NEC
®
Nitrogen
National Electrical Code
NFPA National Fire Protection Association
nm Nanometer
NH
3
Ammonia
NO Nitric oxide
NO
2
Nitrogen dioxide
N2O Nitrous oxide
No. Number
O
2
Oxygen
PC Personal computer
PM Preventative maintenance
ppm Parts per million
psi Pounds per square inch
QCL Quantum Cascade Laser
TDL Tunable Diode Laser
Torr Unit of pressure defined as exactly 1/760 of a standard atmosphere
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Abbreviation Description
UKAS United Kingdom Accreditation Service
USA United States of America
USB Universal serial bus
V Volt
VA Volt-ampere
Vac Volt alternating current
Vdc Volt direct current
W Watt
WEEE Waste electrical and electronic equipment
µm Micro-meter
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2 Theory of operation
2.1 Overview
The Rosemount CT5100 is a gas sensor system that can be configured to measure the
concentrations of multiple small molecules carried in the gas sample. The types of
molecules that are measured depend on the system configuration.
The analyzer can be configured to detect and measure up to 10 gases, with ranges varying
from volume to percent (%) volume levels. A detailed description of the system is given in
Detailed system specifications .
2.2 Laser measurement principle
The analyzer can use up to six lasers to detect and measure gases. Each laser can measure
between one and three gases. Inside the laser, which is about the size of a pin head,
electrons cascade down a series of quantum wells, producing a photon at each step.
This cascade of electrons can produce between 20 and 100 photons per electron, giving
the layers a higher output power than traditional semi-conductor lasers.
The lasing wavelength of a laser is determined by adjusting the physical thickness of the
semiconductor layers, giving access to high power lasers covering the mid-infrared
spectral region. The lasers have no need for cryogenic cooling and have excellent spectral
quality in chirped mode and good tuneability.
2.3 Gas concentration measurements
In the analyzer, gas concentrations are measured using mid-infrared optical absorption
spectroscopy. The laser light sources are operated to produce wavelength sweeps that
cover the absorption lines of the gases to be measured.
Sample gas, which may contain impurity gases that are to be detected and measured, is
conditioned and drawn into the analyzer. Inside the analyzer, the sample gas is fed into an
analysis cell, where the beams from the Quantum Cascade Lasers (QCLs) are passed
through the gas. The analysis cell contains a set of mirrors that bounce the light back and
forth many times, which lengthens the path of the lasers through the gas.
On exiting the analysis cell, the light is detected by a receiver unit. The variation in the
intensity of light in the vicinity of absorption lines for the gases being detected is
measured, and the concentration is determined using a comprehensive spectral fitting
routine.
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22 Emerson.com/Rosemount
Reference Manual
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Description
3 Description
3.1 Equipment purpose and role
The types of molecules that are measured depend on the system configuration.
Figure 3-1: Rosemount CT5100 Continuous Gas Analyzer
The analyzer can be configured to detect and measure up to 10 different gases, depending
on the combination of laser modules fitted.
3.2 System overview
A complete Rosemount CT5100 system consists of a gas handling system, the analyzer,
and the associated interconnecting wiring and gas piping.
The customer MUST provide the gas handling system and interconnecting wiring and gas
piping.
The Rosemount CT5100 is supplied by Emerson. The gas handling system may be
provided by either the customer or Emerson, depending upon the specific installation. The
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Description
Reference Manual
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circuit breaker used to control the application of electrical power to the analyzer, the
interconnecting wires, and gas piping are provided by the customer.
In Figure 3-2, the items supplied by Emerson are colored blue; the items supplied by the
customer are colored purple. The green gas handling system may be provided by Emerson
or the customer.
Table 3-1 lists the main items of the system.
Figure 3-2: Rosemount CT5100 Installation
A. Gas handling system
B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT5100
E. Electrical power
F. Two pole main isolator complete with RCD
G. Control center
H. Measurement data
The analyzer contains an optical system with multiple lasers and a series of optical
components that provide an optical path, a heated multi-pass analysis cell, and sample
and outlet ports that can be connected to a gas handling system and control and analysis
electronics. The number of lasers installed depends upon customer requirements. The
complete system operates at either 110 or 240 Vac 50/60 Hz supply.
The analyzer uses mid-infrared optical absorption spectroscopy to measure gas
concentrations. The light sources are Quantum Cascade Lasers (QCLs), which are operated
to produce wavelength sweeps that cover the absorption lines of the gases. The light from
each laser is routed through an optical path to the analysis cell, which provides
measurement of low concentrations of the subject gases. An external sample handling
system conditions the sample gas and draws it through the analysis cell. The light exits the
multi-pass analysis cell and is directed to a receiver in the analyzer. The variation in the
intensity of light in the vicinity of the absorption lines is measured, and the concentration
is determined using a comprehensive spectral fitting routine.
There is no sample conditioning provided within the analyzer; the sampled gas must be
brought within the parameters shown in Detailed system specifications before entering
the analyzer. Detailed characteristics of the analyzer are also given in in Table 4-1.
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Reference Manual Description
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Table 3-1: Main Items of the Rosemount CT5100 Installation
Item Name or description Supplied by Part number Quantity Notes
1 Rosemount CT5100 Emerson Rosemount CT5100 1 N/A
2 Rosemount CT5100 software
package, version 5.x.x.
3 Gas handling system Customer
4 Heated gas sample line hose Customer Customer choice 1 N/A
5 Exhaust line hose (for sample
gas)
6 Reference gas cylinders
(instrument gas) for
calibration purposes
7 Pressure regulator Customer Customer choice 1 per gas
8 Pneumatic T-piece Customer Customer choice 1 Required for
9 Excess flow line Customer Customer choice 1 Required for
10 Power cables to Rosemount
CT5100
11 Cables from Rosemount
CT5100 to control center
Emerson N/A. Software is
embedded in the
system.
Customer choice or
(optionally by
Emerson)
Customer Customer choice 1 N/A
Customer Customer choice Dependent upon
Customer Customer choice 1 N/A
Customer Customer choice 1 N/A
Emerson
1 Version
described in
manual
1 N/A
N/A
number of gases
being measured
Required for
cylinder
calibration
calibration
calibration
12 Main circuit breaker
complete with RCD
Customer Customer choice N/A N/A
3.3 Gas inputs and outputs
The analyzer has one gas input and one gas output. See Figure 3-3.
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Description
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Figure 3-3: Gas Inlet and Outlet Connectors
A. Sample gas return port
B. Sample gas input port
C. Top cover of Rosemount CT5100 (cell compartment)
D. Laser/electrical compartment
Procedure
1. The gas sample that is to be measured for impurities enters the analyzer through
the sample gas input port located on top of the analyzer (see Figure 3-3.).
2. Once the gas sample has been examined for impurities, it is expelled from the
analyzer through the sample gas return port.
3. The sample gas supply line must be heated all the way to the sample gas input port
on the analyzer to prevent condensation forming in the line.
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WARNING
HAZARDOUS GASES
The product stream that the analyzer is examining may be hazardous even at low
concentrations.
Therefore, take special care to ensure that the sample gas return port either returns
the sample gas to the product stream or discharges the sample gas to a location
that will not cause a hazard.
3.4 Connecting the electrical/electronic inputs and outputs
CAUTION
If the equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
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Description Reference Manual
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Figure 3-4: Electrical/Electronic Connectors
A. Power entry point
B. Analog/digital entry point
C. Analog/digital entry point
Electrical/electronic signal connections to the analyzer are made through three electrical
entry points located on the underside of the analyzer, as shown in Figure 3-4. Use the
wiring diagram to make the electrical connections as shown in Engineering drawings and
Figure 3-5.
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Figure 3-5: Signal Cable Outputs
A. To mains input fuses
B. Mains input filter
C. To enclosure earth stud
D. To digital modules
E. To digital modules
F. To analog modules
G. To status relays
H. Digital output terminals
I. Analog or digital output terminals
J. Analog output terminals
K. Status outpput terminals
L. Mains input terminals
Table 3-2: Rosemount CT5100 System Wiring User Connections
Terminal Function
1 Sensor system supply (L)
2 Sensor system supply (N)
3 Earth
11 Digital output 1
12 Digital output 2
13 Digital output 3
14 Digital output 4
15 Digital output 5
16 Digital output 6
17 Digital output 7
18 Digital output 8
19 Digital output 9
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Description Reference Manual
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Table 3-2: Rosemount CT5100 System Wiring User Connections (continued)
Terminal Function
20 Digital output 10
21 Digital output 11
22 Digital output 12
23 Analog output 1
24 Analog output 2
25 Analog output 3
26 Analog output 4
27 Analog output 5
28 Analog output 6
29 Analog output 7
30 Analog output 8
31 Status output 1 (Check function)
32 Status output 2 (Maintenance required)
33 Status output 3 (Out of specification)
34 Status output 4 (Failed)
01 Analog or digital input/output
02 Analog or digital input/output
03 Analog or digital input/output
04 Analog or digital input/output
05 Analog or digital input/output
06 Analog or digital input/output
Electrical power is applied to the analyzer through the power entry point, Figure 3-4.
The power supply is 110 or 230 Vac, 50/60 Hz ± 10%. AC to DC. Power converters inside
the analyzer automatically adjust in response to the input voltage level and ensure that the
correct DC voltage is available inside the unit. The analyzer is electrically protected by an
internal 5 A, 250 VA fast acting fuse on the instrumentation electrical supply line and an
internal 2 A, 250 VA fuse on the purge electrical supply line.
WARNING
Failure to follow this warning may result in personal injury and/or damage to persons
and/or property.
Make sure that the mains supply cable used is of a suitable rating for the unit power
requirements and is of a three core earthed construction.
30 Emerson.com/Rosemount
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