Rosemount™ CT5100(Ex)
Continuous Gas Analyzer
Reference Manual
00809-0100-4512, Rev AA
October 2019
Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no
liability for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further
enhancements while in service may mean that the manual does not reflect your particular system.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
Document number: 00809-0100-4512
Rev AA, October 2019
©
Emerson 2019. 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.
Rosemount CT5100(Ex) preliminary information
This section details important user information for the Rosemount CT5100(Ex) Continuous Gas Analyzer.
This article is in accordance with IEC 60079-0: 2011 Clause 30.
This article must not be changed amended or removed.
Important
Users must read, understand, and comply with the following information before proceeding.
All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain,
and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The
following document are available and/or referenced within this manual:
• Quick Start Guide
Save all instructions for future use. Contact your local service center or sales office when missing documents.
Authorized personnel
In-depth specialist knowledge is an absolute requirement for working with and on the analyzer. Personnel installing, operating,
servicing, and maintaining the analyzer must be instructed, trained, qualified, and authorized personnel of the operating company
for hazardous areas and the manufacturer. It is the responsibility of the operating company to:
• Train staff
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Have been trained
• Have read and understand all relevant sections of the product manual before commencing work
• Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate,
maintain, or service this analyzer before reading and understanding this reference manual and receiving appropriate training.
2
Important instructions
Important
All users must read this page before proceeding!
Emerson (Rosemount) designs, manufactures and tests its products to meet many national and international standards. The
Rosemount CT5100(Ex) is a sophisticated technical product, and to ensure it continues to operate as designed and within normal
specifications it MUST be installed, used, and maintained correctly. The following instructions MUST be adhered to and integrated
into your safety program when installing, using, and maintaining Emerson (Rosemount) products.
• Failure to follow the proper instructions may cause:
— Loss of life
— Personal injury
— Damage to property
— Damage to this analyzer
— Warranty invalidation
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson (Rosemount) representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the installation instructions of the appropriate Reference Manual and in accordance with
applicable local and national codes.
• Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson (Rosemount).
• Unauthorized parts and procedures can affect the product’s performance; place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
3
Regulations and standards
This article is in accordance with IEC 60079-0: 2011 Clause 30. This article must not be changed amended or removed.
Regulations / Standards Description
2014/35/EU The Low Voltage Directive
94/9/EC (until 19 April 2016)
2014/34/EU (from 20 April 2016)
(1)
(2)
The ATEX Directive
2014/30/EU The Electromagnetic Compatibility Directive
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive
USA 21 CFR 1040.1 Laser products
NFPA 496 Standard for purged and pressurized enclosures for electrical
equipment
NEC 505 National Electrical Code (issued by ANSI: American National
Standards Institute and NFPA 70: National Fire Protection
Association)
47CFR: 2011 Part 15, Sub Part B Unintentional radiators; conducted and radiated emissions
limits.
IEC 60079-10: 2002-06 Electrical apparatus for explosive gas atmospheres. Part 10:
Classification of hazardous areas
IEC 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (Ingress
protection code)
BS EN 60825-1:2007 Safety of laser products. Equipment classification and
requirements.
BS EN 61010-1 2010
IEC 61010-1 2010
Safety requirements for electrical equipment for
measurements, control, and laboratory use. General
requirements.
IEC 61241-10: 2004-06 Electrical apparatus for use in the presence of combustible
dust. Part 10: Classification of areas where combustible dusts
are or may be present.
BS EN 61326-1: 2013 Electrical equipment for measurement, control, and
laboratory use. EMC requirements. General requirements
IEC 60079-0 Explosive atmospheres: General requirements
IEC 60079-2 Explosive atmospheres: Equipment protection by pressurized
enclosure
IEC 60664-1 Pollution degree
FM3600 (2011) Electrical equipment for use in hazardous (classified) locations
– General requirements
FM3620 (2014) Approval standard for purged andpressurized electrical
equipment for hazardous (classified) locations
CAN/CSA-C22.2 No. 61010-1-12 Safety requirements for electrical equipment for
measurement, control, and laboratory use, part 1: General
requirements
UL Std.No. 61010-1 (3rd edition) Safety requirements for electrical equipment for
measurement, control, and laboratory use - part 1: General
requirements
(1) May affect equipment tested prior to 20 April 2016 but shipped at a later date.
(2) All equipment tested from 20 April 2016 will be subject to this directive.
4
Associated publications
Quick Start Guide
Compliance approvals
This product complies with USA 21 CFR 1040.10.
This product is designed and manufactured under an approved quality management
system to ISO 9001: 2015.
Emerson and the Rosemount CT5100(Ex) have satisfied the requirements for
applying the CE marking to the Rosemount CT5100(Ex) Gas Analyzer.
This equipment meets all requirements of the EMC and Low Voltage directives.
Explosive / hazardous area protection Emerson has satisfied the requirements of and complies with IEC, ATEX, and North
In accordance with IEC 60079-0: 2011 Clause 30.This statement must not be amended or changed.
Waste disposal
Do not dispose of measuring tools into household waste.
Only for EC countries:
In accordance with European Directive 2012/19/EU for Waste Electrical and Electronic Equipment and its implementation
into national right, measuring tools that are no longer usable must be collected separately and disposed of in an
environmentally correct manner.
American regulators for operation of electrical/electronic equipment in hazardous
locations .
5
Safety and information notices
This article is in accordance with IEC 60079-0: 2011 Clause 30. This article must not be changed amended or removed.
DANGER
WILL CAUSE DEATH
Failure to follow this warning will result in death or serious injury to personnel.
WARNING
DANGER TO PERSONNEL
Failure to follow this warning may result in serious injury to personnel.
CAUTION
MAY CAUSE DAMAGE TO EQUIPMENT
Failure to follow this warning may result in damage to the equipment.
NOTICE
Important or tip messages will appear in this format.
6
Safety Precautions
Operators, maintenance personnel, and authorized users must observe the following safety precautions and warnings.
Safety precautions are in accordance with IEC 60079-0: 2011 Clause 30. The precautions in this manual MUST NOT be
changed amended or removed. All authorized users, installation, operation and maintenance personnel, must observe the
following safety precautions and warnings.
DANGER
ELECTRIC SHOCK
In accordance with IEC 60079-0: 2011 Clause 30.
The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Confirm that the circuit breakers
are set to Off and locked out and tagged out off before removing the top cover or opening the front cover. The analyzer must be
earthed.
Death, personal injury, and/or damage to persons and/or property may result if this is not observed.
DANGER
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during start-up.
The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes 30 seconds at a minimum flow
rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance.
Purge the sample gas in accordance with the safe working procedures for this site.
Allow the analyzer and the system for returning the sample gas to run for five minutes to allow any sample gas in the analyzer to
be returned to the exhaust.
Failure to observe this precaution will cause death, personal injury, and/or damage to persons.
DANGER
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 320 °F (160 °C ) and may present an ignition source. Exercise care when
using oil, paint, cleaning rags, or other flammable substances near the analyzer. A fire may result if this precaution is not observed.
The interior of a analyzer is always hot unless it has been switched off and allowed to cool down.
WARNING
TRANSPORTATION HAZARD
Handle the analyzer with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet, or
other body parts.
The analyzer weighs 121 lb. (55 kg) and should always be lifted and moved using suitable lifting/moving equipment. Wear suitable
protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard the analyzer
against movement or break-away during transport by securely strapping it in place.
7
WARNING
FIRE AND EXPLOSION
In accordance with IEC 60079-0: 2011 Clause 30.
Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in
accordance with NFPA 496 and ISO60079-1/2 and 28.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or
service.
Electrical shock, thermal burns, or loss of vision may occur.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
COMBUSTIBLE GASES
In accordance with IEC 60079-0: 2011 Clause 30.
The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized in
accordance with NFPA 496.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Always lock out the gas handling system when shutting down the analyzer. Unauthorized performance on the analyzer or its
associated pipes/hoses may result in highly flammable gas being released, causing fire or explosion. Failure to lock out gas
handling system may cause death.
WARNING
BURNS
Some parts of the analyzer may be heated to 320 °F (160 °C). To prevent burns, do not touch any of the hot parts. All parts of a
analyzer are always hot unless it has been switched off and allowed to cool down.
Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been switched off and allowed to cool
for at least two hours. Before performing any maintenance on, or in the vicinity of, the analysis cell, allow the analyzer to cool for
at least 12 hours as the analysis cell is insulated against heat loss.
When handling the analyzer, always wear suitable protective gloves.
Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly
important when working at heights. If you receive a burn, seek medical treatment immediately.
8
WARNING
LASER
The analyzer contains lasers. Opening the analyzer and attempting to perform adjustments or procedures other than those
specified in this manual may result in hazardous optical radiation exposure.
All lasers used within the analyzer are Class 1. The emitted laser light is invisible (mid-infrared), and the combined laser powers are
sufficiently low at the first accessible aperture that the unprotected eye will not be damaged. This class is eye safe under all
operating conditions.
It is, however, possible to cause damage to the eye through not following correct procedures. Do not look at the laser with any
kind of magnifier or optical measuring device.
WARNING
HAZARDOUS SUBSTANCES
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.
Wear personal protective equipment (PPE) when handling the equipment.
Gas handling components within the analyzer contain particulate matter residue from the sample gases. Over the life of the
analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the analyzer:
— Handle used gas handling components with extreme caution.
— Avoid direct skin contact with used gas handling components.
— Do not smoke, drink, or eat in the work area.
— Wear goggles or eye shields.
— Wear a suitable face mask to protect against inhalation of particulate matter.
— Do not wet fingers, eyes, or any exposed skin.
— Pack used gas handling components for disposal in sealed packaging and label them Contaminated.
— Dispose of contaminated items as hazardous material in accordance with applicable local, national, or international health
and safety regulations and pollution regulations.
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may cause death, personal
injury, and/or damage to persons and/or property.
9
WARNING
OPTICAL RADIATION EXPOSURE HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
There are three types of laser that may be included in the Rosemount CT5100(Ex) : Quantum Cascade Lasers (QCLs), Interband
Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are Class 1. The characteristics of the lasers contained within
the analyzer are given in the table below.
Parameter QCL ICL Diode Comment
Operation mode Pulsed Pulsed Pulsed N/A
Lasers per system 1 - 6 1 - 6 1 - 6 Maximum of 6 lasers
Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A
Power < 5 mW < 5 mW < 5 mW Combined power of
Pulse duration < 1 µs < 1 µs < 5 µs N/A
Pulse repetition
frequency
Duty cycle < 5% < 5% < 25% N/A
The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW.
The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of laser safety labels on
the analyzer is specified in Safety and system labels and annotation.
The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous
radiation exposure.
< 100 kHz < 100 kHz < 100 kHz N/A
per system
QCL at first accessible
aperture: < 9.62 mW
WARNING
HAZARDOUS GAS
In accordance with IEC 60079-0: 2011 Clause 30.
The product stream that the analyzer is examining may be hazardous even at low concentrations. Therefore, take special care to
ensure that the sample gas return port either returns the sample gas to the product stream or discharges the sample gas to a
location that will not cause a hazard.
WARNING
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g., damage to eyes and skin or
punctures from debris blown by the high pressure gas or compressed air. Always lock off or tag out the calibration gas supply and
compressed air supply when shutting down the analyzer.
10
WARNING
HEAVY ITEM
In accordance with IEC 60079-0: 2011 Clause 30.
Failure to propery handle the analyzer may cause injury to personnel.
Ensure the wall the analyzer is mounted on is solid, stable, and of suitable material to hold the weight of the analyzer.
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands,
feet, or other body parts.
The analyzer weighs 121 lb. (55 kg).
Emerson recommends that a minimum of two people move and lift the analyzer.
Wear suitable protective gloves and protective footwear.
WARNING
EXPLOSION HAZARD / ELECTRIC SHOCK HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Only trained, qualified personnel may install and connect power and signal cables. The installation/connection must be in
accordance with all legislative requirements and applicable standards.
Failure to follow may cause warranty invalidation, property damage, and/or personal injury or death.
Only qualified personnel, familiar with potential risks, should install the analyzer.
Analyzers providing screw terminals for electrical connections may require working near live parts. Failure to observe this warning
and or follow safety instruction could cause an explosion or potentially hazardous situation, which if not avoided, could result in
death or serious injury.
WARNING
HIGH PRESSURE HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
The maximum inlet purge gas pressure at the inlet valve must not exceed 690 kPa (6.9 bar). Higher pressure may damage the
analyzer enclosure in case of failure of the inlet valve.
Failure to observe this warning could cause a potentially hazardous situation which if not avoided, could result in death or serious
injury.
WARNING
EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE
In accordance with IEC 60079-0: 2011 Clause 30.
In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Take
suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area.
Clean the device surface by gently wiping it with a damp or antistatic cloth only.
Failure to observe this warning and or follow safety instruction could cause an explosion or potentially hazardous situation, which
if not avoided, could result in death or serious injury.
11
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes 30 seconds at
a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
POSSIBLE EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
DO NOT operate the analyzer with doors or covers open.
Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit.
Failure to observe this warning and or follow safety instruction could cause an explosion or potentially hazardous situation, which
if not avoided, could result in death or serious injury.
WARNING
HAZARD BY WRONG INPUT VOLTAGE
In accordance with IEC 60079-0: 2011 Clause 30.
Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the
installation.
Pressurized analyzers for hazardous locations DO NOT provide wide range power supplies.
This type of analyzer is always setup for a specific rated input voltage; see nameplate label.
Ensure the voltage at site of installation meets the rated analyzer input voltage.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to
external equipment MUST be shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up
the analyzer.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
12
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
During the pre-purge phase, all inputs and outputs connected to external equipment MUST be shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.
The internal backup battery is still connected and associated circuitry remains powered.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Do not open while an explosive atmosphere may be present.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD
In accordance with IEC 60079-0: 2011 Clause 30.
Use only replacement parts and components authorized by Emerson.
All replacement parts and components must be certified and approved for use in hazardous areas.
Failure to comply will void certification and may cause an explosion or potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.
WARNING
EXPLOSION HAZARD BY BATTERY
In accordance with IEC 60079-0: 2011 Clause 30.
The analyzer contains a battery for data backup purposes.
Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement
MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
13
WARNING
LOOSE ITEMS
Do not place any loose items on top of the system or inside the compartments when doors / covers are open.
Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers.
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
WARNING
MAINTENANCE/MODIFICATIONS
In accordance with IEC 60079-0: 2011 Clause 30.
On completion of any maintenance and or modifications verify:
— All tools and equipment are removed.
— No contamination (water/dust) is in the compartments.
— Analyzer is wiped clean.
— Vents are clear and not obstructed.
— Verify that system is in a safe state for operation.
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
WARNING
TRANSPORTATION HAZARD
Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings for the weight of the
equipment, and is in good operational condition.
Failure to verify equipment meets the lifting ratings and is in good operational condition may cause injury to personnel or damage
the analyzer.
WARNING
PHYSICAL ACCESS
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
CAUTION
EQUIPMENT DAMAGE
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the
analyzer are in place.
Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any calibration gases that are
required are available to the analyzer.
Failure to perform pre-system start-up checks may cause damage to equipment.
14
CAUTION
EQUIPMENT DAMAGE
Always follow the start-up procedure. Damage to the analyzer may result from a failure to follow this procedure.
CAUTION
EQUIPMENT DAMAGE
Always follow the shutdown procedure. Damage to the analyzer may result from a failure to follow this procedure.
CAUTION
UNSERVICEABLE EQUIPMENT
If the pressure and temperature screen does not display measurements similar to those shown in Figure 6-6 and Figure 6-8, refer
to Troubleshooting and diagnostics.
CAUTION
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
CAUTION
EMC
As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is
unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical
components requires the use of special optical test/calibration equipment and procedures.
Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this
manual, then the fault must be repaired by Emerson.
15
16
Reference Manual Contents
00809-0100-4512 October 2019
Contents
Chapter 1 Introduction.................................................................................................................21
1.1 Description.....................................................................................................................................21
1.2 Customer information....................................................................................................................21
1.3 Safety precautions and conditions for safe use............................................................................... 21
1.4 Qualified personnel........................................................................................................................ 23
1.5 Software version.............................................................................................................................24
1.6 Glossary and abbreviations.............................................................................................................24
Chapter 2 Theory of operation..................................................................................................... 27
2.1 Overview........................................................................................................................................ 27
2.2 Laser measurement principle..........................................................................................................27
2.3 Gas concentration measurements..................................................................................................27
Chapter 3 Description.................................................................................................................. 29
3.1 Equipment purpose and role.......................................................................................................... 29
3.2 System overview............................................................................................................................ 29
3.3 Gas flow through analyzer.............................................................................................................. 32
3.4 Connecting the electrical/electronic inputs and outputs.................................................................34
3.5 Optical description......................................................................................................................... 37
Chapter 4 Specifications...............................................................................................................39
4.1 Gas detection................................................................................................................................. 39
4.2 Detailed system specifications........................................................................................................39
4.3 Safety and system labels and annotation........................................................................................ 42
Chapter 5 Install...........................................................................................................................47
5.1 Site selection.................................................................................................................................. 47
5.2 Unpacking...................................................................................................................................... 48
5.3 Mounting the analyzer....................................................................................................................50
5.4 Connecting the electrical/electronic inputs and outputs.................................................................56
Chapter 6 Controls and display controller.....................................................................................67
6.1 Front panel controls and indicators.................................................................................................67
6.2 Display controller........................................................................................................................... 69
6.3 Gas Sensor Main screen.................................................................................................................. 70
6.4 Pressure and Temperature screen.................................................................................................. 72
6.5 Help system....................................................................................................................................73
6.6 Main menu..................................................................................................................................... 74
6.7 BACK button...................................................................................................................................74
Chapter 7 Start-up procedure.......................................................................................................75
7.1 Introduction................................................................................................................................... 75
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October 2019 00809-0100-4512
7.2 Preparation for use......................................................................................................................... 75
7.3 Start-up..........................................................................................................................................76
7.4 Front panel controls and indicators.................................................................................................80
Chapter 8 Operating the analyzer.................................................................................................85
8.1 Introduction................................................................................................................................... 85
8.2 Normal operation........................................................................................................................... 85
Chapter 9 Shutdown procedure................................................................................................... 87
9.1 Shutdown procedure safety precautions ........................................................................................87
9.2 Shutdown procedure......................................................................................................................88
Chapter 10 Gas calibration............................................................................................................. 93
10.1 Required tools.............................................................................................................................. 93
10.2 Main menu calibration routines.................................................................................................... 94
Chapter 11 Troubleshooting and diagnostics............................................................................... 113
11.1 Using the Built-in-Self-Test (BIST) fault diagnostics.....................................................................113
11.2 Faults menu................................................................................................................................116
11.3 Failure diagnosis principles.........................................................................................................118
11.4 Repairable faults.........................................................................................................................118
11.5 Tools and test equipment...........................................................................................................119
11.6 General troubleshooting and diagnostics information................................................................119
11.7 Diagnostics menu.......................................................................................................................119
11.8 Visual examination..................................................................................................................... 122
11.9 Functional failure diagnostics..................................................................................................... 122
Chapter 12 Repair and replacement............................................................................................. 127
12.1 Repair policy...............................................................................................................................127
12.2 Opening the electrical compartment door................................................................................. 127
12.3 Closing the electrical compartment door................................................................................... 128
12.4 Replacing the fuses.....................................................................................................................129
12.5 Replacing the TEC board.............................................................................................................133
12.6 Replacing the peripheral board...................................................................................................135
12.7 Replacing the motherboard........................................................................................................137
12.8 Replacing the Ethernet in/out relay modules.............................................................................. 139
12.9 Lower (main) DIN rail electronic components.............................................................................140
12.10 Replacing a DC power supply....................................................................................................141
12.11 Replace the 10 Amp solid state relay........................................................................................ 143
12.12 Replacing the Ethernet connector............................................................................................ 143
12.13 Replacing the laser module...................................................................................................... 144
12.14 Replacing the detector module................................................................................................ 146
12.15 Replacing the O2 detector........................................................................................................ 147
12.16 Replacing the main terminal board...........................................................................................149
12.17 Replacing the mains power filter.............................................................................................. 151
xviii Rosemount CT5100(Ex)
Reference Manual Contents
00809-0100-4512 October 2019
12.18 Removing the top cover........................................................................................................... 151
12.19 Replacing the PT100 gas temperature sensor...........................................................................152
12.20 Replacing the pressure sensor.................................................................................................. 155
12.21 Cleaning the cell mirrors...........................................................................................................156
12.22 Spare parts list..........................................................................................................................162
Chapter 13 Preventative maintenance......................................................................................... 163
13.1 Maintaining the analyzer............................................................................................................ 163
13.2 Scheduled maintenance............................................................................................................. 163
Chapter 14 ATEX/IECEX assessment report summary....................................................................165
14.1 Certification overview................................................................................................................ 165
14.2 Applicant's name and address.................................................................................................... 165
14.3 Manufacturer's name and address.............................................................................................. 165
14.4 Trademark..................................................................................................................................165
14.5 Product name/model number.................................................................................................... 165
14.6 Rating.........................................................................................................................................165
14.7 Assessment standards................................................................................................................ 166
14.8 Markings.................................................................................................................................... 166
14.9 Conditions of certification/special conditions for safe use...........................................................169
14.10 Conditions of certification for the replacement of simple devices.............................................170
Appendix A Engineering drawings................................................................................................ 173
Reference Manual xix
Contents Reference Manual
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xx Rosemount CT5100(Ex)
Reference Manual
00809-0100-4512 October 2019
Introduction
1 Introduction
1.1 Description
The Rosemount™ CT5100(Ex) Continuous Gas Analyzer, referred to hereafter as the
Rosemount CT5100(Ex) Continuous Gas Analyzer or Rosemount CT5100(Ex), is an
electronic sensor that uses laser spectroscopy to perform analysis of process gas streams.
The function of the analyzer is to detect and measure up to 10 different types of gas at
concentrations ranging from parts per million (ppm) to percentage levels in the process
gas stream.
The analyzer meets all current requirements for operation in potentially explosive
environments.
Note
This manual is intended for the personnel who install, operate, and maintain the
equipment.
1.2 Customer information
This manual contains all the important information that must be followed to ensure the
correct operation and safety of personnel when operating the analyzer.
For information regarding installation, consult Install and the Quick Start Guide.
Emerson is committed to continuously improving its products and documentation. Every
effort will be made to include in the documentation any modifications by the
manufacturer. However, this document reflects the supplied analyzer at the revision date
on the front cover.
Should you require further information, or should particular problems arise that are not
covered in this manual, you can request additional help from Cascade Technical Support
(cascade.support@emerson.com) or Emerson distribution partners. Further contact
details for Emerson can be found on the back page of this manual.
1.3 Safety precautions and conditions for safe use
WARNING
Before installing or performing any maintenance on the analyzer, read and understand the
safety information given in the preliminary information of this manual.
The analyzer described in this manual has been quality control tested and left the
manufacturer in pristine condition. To achieve the correct and safe operation of this
product, it must be transported, installed, operated, and maintained as described by the
manufacturer.
All lasers used within the analyzer are Class 1. The emitted laser light is invisible (midinfrared) and the pulse duration so short that the unprotected eye will not be damaged.
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Introduction
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Reference Manual
The nature of the laser beam path and beam width further ensures that it should be
impossible to cause any eye damage. The analyzer has warning labels at appropriate
positions in accordance with USA 21 CFR 1040.10.
Conditions for safe use (Europe)
• The maximum sample gas temperature that the analyzer can operate with is 320 °F
(160 °C).
• The purge controller keypad mounted on the front of the equipment shall not be
exposed to direct UV light sources or direct sunlight. Example methods of protection
include, but are not limited to, indoor applications away from UV sources and outdoor
locations under shading. As part of regular inspections, if damage to or deterioration of
the membrane keypad is detected, take the unit out of service for repair or
replacement.
• The purge controller bypass function shall only be enabled during setup or
maintenance and only when the area is known to be non-hazardous.
• The equipment shall be installed in an area of not more than pollution degree 2 as
defined in IEC 60664-1.
• The cable glands used in the equipment are only suitable for use in areas with a low risk
of mechanical damage and must be suitably protected.
• The purge controller automatically monitors the internal pressure of the enclosure and
will output any fault conditions onto contact K2. It is the end user's responsibility to
connect this contact to a suitable facility such as an alarm or an automatic shutdown
system.
• For correct operation, the on-site pressurizing air supply must be capable of providing
at least 25 L/min for leakage compensation.
• When using the analyzer variant fitted with the Elmess gas cell heater certified as BVS
14ATEXE155U and IECEx BVS 14.0106U, the equipment top compartment should be
cooled with a source of compressed air at a minimum flow rate of 280 L/min.
• The Elmess gas cell heater, certified as BVS 14ATEXE155U and IECEx BVS 14.0106U,
may only be used in combination with the ESI Technology gas cell pressure transducer,
certified as TRAC12ATEX0060X and IECEx TRC 12.0025X.
Conditions for safe use (North America)
• The maximum sample gas temperature that the analyzer can operate with is 176 °F (80
°C).
• The purge controller keypad mounted on the front of the equipment shall not be
exposed to direct UV light sources or direct sunlight. Example methods of protection
include, but are not limited to, indoor applications away from UV sources and outdoor
locations under shading. As part of regular inspections, if damage to or deterioration of
the membrane keypad is detected, take the unit out of service for repair or
replacement.
• The purge controller bypass function shall only be enabled during setup or
maintenance and only when the area is known to be non-hazardous.
• The cable glands used in the equipment are only suitable for use in areas with a low risk
of mechanical damage and must be suitably protected.
22 Rosemount CT5100(Ex)
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00809-0100-4512 October 2019
• The purge controller provided with this equipment provides alarm signals at various
contacts as described in the equipment instructions. The alarms relate to low-flow and
loss of purged air supply, and must be connected to the end-user's remote, monitored
alarm system.
• For correct operation, the on-site pressurizing air supply must be capable of providing
at least 25 L/min for leakage compensation.
• This assessment does not cover reliable function, performance, or other properties of
the equipment not related to safety.
• The equipment is to be installed using wire no larger than the protective earth wire.
• Equipment is only to be installed by manufacturer trained personnel.
• If at any time there is a conflict between the system safety provisions and any relevant
local (national or regional) requirements, the local requirements always take
precedence.
• Equipment is not to be used with flammable liquids.
• The relief valve sealing cap must be fitted to maintain IP66 when the unit is in a non-
operational state.
Introduction
• Equipment is subject to acceptance of the local inspection authorities having
jurisdiction.
• The equipment is intended for use only with air of instrument quality; all piping up to
and including the shut-off valve adjacent to the equipment must be protected against
mechanical damage.
• The protective gas supply to the equipment must be marked with the warning as
detailed in NFPA496 Clause 4.12.5.
• When installing conduit for power and data connections, the end-user must select
suitably certified conduit.
General safety notice/residual risk
Installation, operation, and maintenance of the analyzer must be in accordance with these
instructions.
When operated as intended and all applicable safety instructions are observed, an element
of risk will remain, including, but not limited to, the following:
• Explosion protection measures may become ineffective on the occurrence of one
failure (for Category 3 analyzers).
• The emission of gases hazardous to health may be possible when all gas connections
have been correctly made.
• To avoid exposure to the dangers of residual risks, take particular care when installing,
operating, maintaining, and servicing the analyzer.
1.4
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Qualified personnel
In-depth specialist knowledge is an absolute requirement for working with and on the
analyzer. Personnel installing, operating, servicing, and maintaining the analyzer must be
Introduction Reference Manual
October 2019 00809-0100-4512
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 .
1.6 Glossary and abbreviations
Table 1-1: Abbreviations
Abbreviation Description
©
% Percent
< Less than
° Degree
AC Alternating current
ATEX Explosive atmospheres
Barg Pressure, in units of bars, above or below atmospheric pressure
BS British Standard
C Celsius
CDA Compressed dry air
Copyright
CE European Conformity
CFR Code of Federal Regulations
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Table 1-1: Abbreviations (continued)
Abbreviation Description
CGA Continuous Gas Analyzer
CH
CO
4
2
Methane
Carbon dioxide
DC Direct current
Deg Degree (temperature)
e.g. For example
EC European Community
EMC Electromagnetic compatibility
EU European Union
Hrs Hours
Hz Hertz
H2O Water
ICL Interband Cascade Laser
IEC International Electro-technical Commission
in. Inches
IP Ingress protection
IPxx Ingress protection (xx are numbers that define the protection level)
IS Intrinsically safe
ISO International Organization for Standardization
k Thousand
kg Kilogram
kHz Kilo hertz
L Liter
lb. Pound
LCD Liquid crystal display
LED Light emitting diode
L/min Liters per minute
m Meter
3
m
Cubic meter
mA Milliamp
Max Maximum
mBar milli-Bar
mbps Megabits per second
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Introduction Reference Manual
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Table 1-1: Abbreviations (continued)
Abbreviation Description
mg Milligram
3
mg/m
Mid IR Mid Infrared
min Minute
mm Millimeter
Milligram/cubic meter
N
2
NEC
®
Nitrogen
National Electrical Code
NFPA National Fire Protection Association
nm Nanometer
NH
3
Ammonia
NO Nitric oxide
NO
2
Nitrogen dioxide
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
WEEE Waste electrical and electronic equipment
µm Micro-meter
26 Rosemount CT5100(Ex)
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2 Theory of operation
2.1 Overview
The Rosemount™ CT5100(Ex) is a gas sensor system that can be configured to measure the
concentrations of multiple small molecules carried in the gas sample. The types of
molecules that are measured depend on the system configuration.
The analyzer can be configured to detect and measure up to 10 gases, with ranges varying
from volume to percent (%) volume levels. A detailed description of the system is given in
Detailed system specifications .
2.2 Laser measurement principle
The Rosemount CT5100(Ex) can use up to six lasers to detect and measure gases. Each
laser can measure between one and three gases. Inside the laser, which is about the size of
a pin head, electrons cascade down a series of quantum wells, producing a photon at each
step.
This cascade of electrons can produce between 20 and 100 photons per electron, giving
the lasers a higher output power than traditional semi-conductor lasers.
The lasing wavelength of the laser is determined by adjusting the physical thickness of the
semiconductor layers, giving access to high power lasers covering the mid-infrared
spectral region. The lasers have no need for cryogenic cooling, have excellent spectral
quality in chirped mode, and have good tuneability.
2.3 Gas concentration measurements
In the Rosemount CT5100(Ex), gas concentrations are measured using optical absorption
spectroscopy. The laser light sources are operated to produce wavelength sweeps that
cover the absorption lines of the gases to be measured.
Sample gas, which may contain impurity gases that are to be detected and measured, is
conditioned and drawn into the analyzer. Inside the analyzer, the sample gas is fed into an
analysis cell, where the beams from the laser are passed through the gas. The analysis cell
contains a set of mirrors that bounce the light back and forth many times, which lengthens
the path of the lasers through the gas.
On exiting the analysis cell, the light is detected by a receiver unit. The variation in the
intensity of light in the vicinity of absorption lines for the gases being detected is
measured, and the concentration is determined using a comprehensive spectral fitting
routine.
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Description
3 Description
3.1 Equipment purpose and role
The types of molecules that are measured depend on the system configuration.
Figure 3-1: Rosemount™ CT5100(Ex) Continuous Gas Analyzer
The analyzer can be configured to detect and measure up to 10 different gases, depending
on the combination of laser modules fitted.
3.2 System overview
A complete Rosemount CT5100(Ex) system consists of a gas handling system, the
analyzer, and the associated interconnecting wiring and gas piping.
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Description
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Reference Manual
The Rosemount CT5100(Ex) is supplied by Emerson. The gas handling system may be
provided by either you or Emerson, depending upon the specific installation. The circuit
breakers used to control the application of electrical power to the analyzer, the
interconnecting wires, and gas piping are provided by you.
In Figure 3-2, the items supplied by Emerson are colored blue; the items supplied by you
are colored purple. The green gas handling system may be provided by Emerson or you.
Table 3-1 lists the main items of the system.
Figure 3-2: Complete Rosemount CT5100(Ex) Installation
A. Gas handling system
B. Instrument air
C. Sample supply line
D. Sample return (exhaust) line
E. Rosemount CT5100(Ex)
F. Electrical power
G. Two pole main isolator
H. Purge power
I. Control center
J. Measurement data
The analyzer contains an optical system with multiple lasers and a series of optical
components that provide an optical path, a heated multi-pass analysis cell, and sample
and outlet ports that can be connected to a gas handling system and control and analysis
electronics. The number of lasers installed depends upon customer requirements. The
complete system operates from 110 to 230 Vac 5050/60 Hz supply.
The analyzer uses mid-infrared optical absorption spectroscopy to measure gas
concentrations. The light sources are lasers, which are operated to produce wavelength
30 Rosemount CT5100(Ex)
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