Emerson Rosemount CT5100 User manual

Quick Start Guide
00825-0100-3511, Rev AA
August 2020
Rosemount ™ CT5100 QSG Continuous
Gas Analyzer

Safety precautions
Important
The precautions in this manual MUST NOT be changed amended or removed. All authorized users,
installation, operation and maintenance personnel, must observe the following safety precautions and
warnings.
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or serious injury to personnel.
Death, personal injury, and/or damage to persons and/or property may result if this is not observed.
Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the
top cover or opening the front cover. The analyzer must be earthed.
Only trained, qualified personnel may install and connect power and signal cables. The installation/
connection must be in accordance with all legislative requirements and applicable standards.
Only qualified personnel, familiar with potential risks, should install the analyzer.
WARNING
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition
source. The interior of a analyzer is always hot unless it has been switched off and allowed to cool
down. A fire may result if this precaution is not observed.
Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.
WARNING
TRANSPORTATION HAZARD
The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/
moving equipment.
Handle the analyzer with caution during unpacking, installation, maintenance, and transport to
prevent crushing of hands, feet, or other body parts.
Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by
air, road, or rail, safeguard the analyzer against movement or break-away during transport by securely
strapping it in place.
Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings
for the weight of the equipment, and is in good operational condition.
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WARNING
FIRE AND EXPLOSION
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not
avoided, may cause death, personal injury, and/or damage to persons and/or property.
Always lock out the gas handling system when shutting down the analyzer.
DO NOT operate the analyzer with doors or covers open.
Refer to local regulations as this may require a competent hot work supervisor to issue a hot work
permit.
When the analyzer is out of order all inputs and outputs connected to external equipment MUST be
shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not
pressurized.
Only properly trained personnel who understand the contents of all applicable manuals and related
instructions should start up the analyzer.
Use only replacement parts and components authorized by Emerson.
The analyzer contains a battery for data backup purposes.
Under normal operating conditions, there is no need to replace the battery during the analyzer life
time. Battery replacement MUST only be conducted by Rosemount Customer Care personnel. It is NOT
a customer serviceable item.
WARNING
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause
an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury,
and/or damage to persons and/or property.
Operators and service personnel do not have access to the laser/electrics or upper cell compartments
for general maintenance or service.
WARNING
BURNS
Some parts of the analyzer may be heated to 374 °F (190°C). To prevent burns, do not touch any of the
hot parts.
Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been
switched off and allowed to cool for at least two hours. Before performing any maintenance on, or in
the vicinity of, the analysis cell, allow the analyzer to cool for at least 12 hours as the analysis cell is
insulated against heat loss.
When handling the analyzer, always wear suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
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WARNING
HAZARDOUS SUBSTANCES
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and
components with extreme caution. Wear personal protective equipment (PPE) when handling the
equipment.
Gas handling components within the analyzer contain particulate matter residue from the sample
gases. Over the life of the the analyzer, the concentration of particulate matter will become enriched
within the gas handling components. When performing repairs and maintenance on the the analyzer:
Handle used gas handling components with extreme caution.
Avoid direct skin contact with used gas handling components.
Do not smoke, drink, or eat in the work area.
Wear goggles or eye shields.
Wear a suitable face mask to protect against inhalation of particulate matter.
Do not wet fingers, eyes, or any exposed skin.
Pack used gas handling components for disposal in sealed packaging and label them
Contaminated.
Dispose of contaminated items as hazardous material in accordance with applicable local,
national, or international health and safety regulations and pollution regulations.
Take special care to ensure that the sample gas return port either returns the sample gas to the
product stream or discharges the sample gas to a location that will not cause a hazard.
WARNING
OPTICAL RADIATION EXPOSURE HAZARD
There are three types of laser that may be included in the Rosemount CT5100: Quantum Cascade
Lasers (QCLs), Interband Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are
Class 1. The characteristics of the lasers contained within the analyzer are given in the table below.
The emitted laser light is invisible (mid-infrared), and the combined laser powers are sufficiently low at
the first accessible aperture that the unprotected eye will not be damaged. This class is eye safe under
all operating conditions.
It is, however, possible to cause damage to the eye through not following correct procedures. Do not
look at the laser with any kind of magnifier or optical measuring device.
Parameter QCL ICL Diode Comment
Operation mode Pulsed Pulsed Pulsed N/A
Lasers per system 1 - 6 1- 6 1- 6 Maximum of 6 lasers per system
Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A
Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first
accessible aperture: < 9.62 mW
Pulse duration < 1 µs < 1 µs < 5 µs N/A
Pulse repetition
frequency
< 100 kHz < 100 kHz < 100 kHz N/A
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.
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The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10.
The use of controls or adjustments or performance of procedures other than those specified herein
may result in hazardous radiation exposure.
WARNING
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g.,
damage to eyes and skin punctures from debris blown by the high pressure gas or compressed air.
Always lock off or tag out the calibration gas supply and compressed air supply when shutting down
the analyzer.
The maximum gas pressure valve must not exceed 100 psig (690 kPa).
WARNING
HAZARD BY WRONG INPUT VOLTAGE
Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an
explosion, injury, or damage to the installation. Failure to observe this warning could cause an
explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury,
and/or damage to persons and/or property.
This type of analyzer is always setup for a specific rated input voltage; see nameplate label.
Ensure the voltage at site of installation meets the rated analyzer input voltage.
WARNING
MAINTENANCE/MODIFICATIONS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided,
could result in death or serious injury.
On completion of any maintenance and or modifications verify:
All tools and equipment are removed.
No contamination (water/dust) is in the compartments.
Analyzer is wiped clean.
Vents are clear and not obstructed.
Verify that system is in a safe state for operation.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end
users’ equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true for
all systems used within the facility.
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CAUTION
EQUIPMENT DAMAGE
Failure to perform pre-system start-up checks may cause damage to equipment.
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and
pneumatic connections to the analyzer are in place.
Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the analyzer.
Always follow the Start-up procedure.
Always follow the Shutdown procedure.
CAUTION
UNSERVICEABLE EQUIPMENT
If the pressure and temperature screen does not display measurements similar to those shown in
Figure 7-1 and Figure 7-2 .
CAUTION
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in
which case the user may be required to take adequate measures.
As a general principle, if any optical component other than the cell assembly, the laser modules, and
the detectors is unserviceable, the analyzer must be repaired by Emerson. This is because the repair,
replacement, and alignment of the optical components requires the use of special optical test/
calibration equipment and procedures.
Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement
procedure is given in this manual, then the fault must be repaired by Emerson.
Contents
Introduction.................................................................................................................................7
Description................................................................................................................................ 10
Specifications.............................................................................................................................12
Install......................................................................................................................................... 18
Controls and display controller...................................................................................................32
Start-up procedure.....................................................................................................................39
Operating the analyzer...............................................................................................................45
Shutdown procedure................................................................................................................. 47
Engineering drawings.................................................................................................................52
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1 Introduction
1.1 Description
The Rosemount™ CT5100 Continuous Gas Analyzer, referred to hereafter as
the Rosemount CT5100, or analyzer, is an electronic sensor that uses laser
spectroscopy to perform analysis of process gas streams.
Important
The Rosemount CT5100 is designed for use in Non Hazardous areas ONLY.
1.2 Customer information
This manual contains all the important information that must be followed to
ensure the correct operation and safety of personnel when operating the
analyzer.
For information regarding installation, consult Install .
Emerson is committed to continuously improving its products and
documentation. Every effort will be made to include in the documentation
any modifications by the manufacturer. However, this document reflects the
supplied analyzer at the revision date on the front cover.
Should you require further information, or should particular problems arise
that are not covered in this manual, you can request additional help from
Cascade Technical Support ([email protected]) or Emerson
distribution partners. Further contact details for Emerson can be found on
the back page of this manual.
1.3 Safety precautions and conditions for safe use
WARNING
SAFE USE PRECAUTIONS
Before installing or performing any maintenance on the analyzer, read and
understand the safety information given in the preliminary information of
this manual.
The analyzer described in this document has been quality control tested and
left the manufacturer in pristine condition. To achieve the correct and safe
operation of this product, it must be transported, installed, operated, and
maintained as described by the manufacturer.
All lasers used within the analyzer are Class 1. The emitted laser light is
invisible (mid-infrared) and the pulse duration so short that the unprotected
eye will not be damaged.
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The nature of the laser beam path and beam width further ensures that it
should be impossible to cause any eye damage. The analyzer has warning
labels at appropriate positions in accordance with USA 21 CFR 1040.10.
General safety notice/residual risk
Installation, operation, and maintenance of the analyzer must be in
accordance with these instructions.
When operated as intended and all applicable safety instructions are
observed, an element of risk will remain, including, but not limited to, the
following:
•The emission of gases hazardous to health may be possible when all gas
connections have been correctly made.
•To avoid exposure to the dangers of residual risks, take particular care
when installing, operating, maintaining, and servicing the analyzer.
1.4 Qualified personnel
In-depth specialist knowledge is an absolute requirement for working with
and on the analyzer. Personnel installing, operating, servicing, and
maintaining the analyzer must be instructed, trained, qualified, and
authorized personnel of the operating company for hazardous areas and the
manufacturer.
It is the operating company's responsibility to:
•Train staff
•Observe safety regulations
•Follow the safety instructions and procedures in the product manual
Operators must:
•Be trained
•Read and understand all relevant sections of the product manual before
commencing work
•Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this
equipment and on-site property, do not install, operate, maintain, or service
this analyzer before reading and understanding this reference manual and
receiving appropriate training.
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1.5 Software version
The analyzer includes software that is used to control the operation of the
analyzer. This document describes the software version as: 5.7.13.
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2 Description
2.1 System overview
A complete Rosemount™ CT5100 system consists of the analyzer, and the
associated interconnecting wiring and gas piping.
The customer MUST provide the gas handling system and interconnecting
wiring and gas piping.
The circuit breaker used to control the application of electrical power to the
analyzer, the interconnecting wires, and gas piping are provided by the
customer.
In Figure 2-1, the items supplied by Emerson are colored blue; the items
supplied by the customer are colored purple. The green gas handling system
may be provided by Emerson or the customer.
Figure 2-1: Rosemount CT5100 Installation
A. Gas handling system
B. Sample supply line
C. Sample return (exhaust) line
D. Rosemount CT5100
E. Electrical power
F. Two pole main isolator complete with RCD
G. Control center
H. Measurement data
The analyzer contains an optical system with multiple lasers and a series of
optical components that provide an optical path, a heated multi-pass
analysis cell, and sample inlet and outlet ports that can be connected to a
gas handling system and control and analysis electronics. The number of
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lasers installed depends upon customer requirements. The complete system
operates at either 110 or 240 Vac 50/60 Hz supply.
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3 Specifications
3.1 Detailed system specifications
Table 3-1 gives the physical characteristics of the analyzer. Schematic
diagrams of the sensor and mounting points are shown in Figure 3-1 and
Figure 3-2. Table 3-2 gives the general characteristics of the analyzer.
Table 3-1: Physical Characteristics
Rosemount CT5100 Value Comment
External dimensions 22.64 x 11.73 x 28.11 in.
575 x 298 x 714 mm
Length x width x height
Nominal dimensions
Weight 117 lb.
53 kg
Approximate weight
Table 3-2: General Characteristics
Rosemount CT5100 Value Units Comment
Instrument supply voltage 110 to 240 Vac 50/60 HZ ±10%
Peak power consumption 500 W Max consumption per
gas analyzer
Continuous steady-state
power consumption
300 W Once the gas analyzer
has stabilized and the
analysis cell has reached
the temperature set
point
Electrical compartment
enclosure
N/A N/A 304 stainless steel
Optical compartment
enclosure
N/A N/A Polyester TGIC free
powder coated 304
stainless steel
Wetted materials N/A N/A AISI 316 (EN 1.4401
grade) stainless steel
tubing and fittings
including thermowell
and pressure diaphragm,
PFA coated aluminum
cell body, PTFE seals,
protected gold coated
mirrors, CaF2 windows,
and FKM (typically
Viton™) or FFKM
(typically Kalrez™) O-
rings
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Table 3-2: General Characteristics (continued)
Rosemount CT5100 Value Units Comment
Measurement technique N/A N/A Mid infrared (IR)
absorption spectroscopy
Mid IR source N/A N/A Quantum Cascade Laser
Near IR source Interband Cascade Laser
Diode Laser
Laser classification Class 1 BS EN 60825-1: 2007
safety of laser products.
Equipment classification
and requirements
(identical to IEC 60825-1
2007)
Inlet gas port connector ¼
6
in.
mm
Swagelok® type, factory-
configured, specify on
order
Outlet (exhaust) gas port
connector
¼
6
in.
mm
Swagelok type, factory-
configured, specify on
order
Measurement result signals 4 to 20 mA 4 or 8 channel outputs,
specify on order
Communication 10/100 Mbps Ethernet
Warm-up time 90 minutes N/A
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Figure 3-1: Rosemount CT5100 Dimensions - Front View
Dimensions are in inches (mm).
A. Lifting eyelet
B. Ventilation
C. User interface
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Figure 3-2: Rosemount CT5100 Dimensions - Top View
Dimensions are in inches (mm).
A. Lifting eyelet
B. Sample return
C. Sample inlet
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Figure 3-3: Rosemount CT5100 Dimensions - Bottom View
Dimensions are in inches (mm).
A. Cable glands
B. Earth point
Table 3-3: Environmental Characteristics
Environmental
characteristic
Value Units Comment
Operating temperature
range
-4 to 131
-20 to 55
°F
°C
Ambient temperature
Sample gas temperature
range
131 to 374
50 to 190
°F
°C
Factory set, specify on
order
Sample gas particulate
density
5 mg/m3Maximum
Sample gas particulate size 10 µm Maximum
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Table 3-3: Environmental Characteristics (continued)
Environmental
characteristic
Value Units Comment
IP code IP66 (electrical
compartment
enclosure)
IP20 (optical
compartment
enclosure)
N/A IP to IEC 60529
Sensor humidity range 10 to 95 % Relative humidity (non-
condensing) at 113 °F (45
°C)
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4 Install
4.1 Site selection
The Rosemount CT5100 has a T3 temperature classification which specifies
the maximum surface temperature of the analyzer.
WARNING
FIRE AND EXPLOSION
Death, personal injury, and/or damage to persons and/or property may
result if this is not observed.
The analyzer's electrical compartment must not be opened unless the
atmosphere in the area is known to be below the ignitable concentration of
combustible gases or materials, or unless all equipment within the protected
enclosure is de-energized.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or
serious injury to personnel. Failure to observe this precaution will cause
death, personal injury, and/or damage to persons and/or property.
Ensure that the circuit breakers are set to Off and locked out and tagged out
off before removing the top cover or opening the front cover.
The analyzer is intended to be installed in a suitable Division 2 shelter to
protect it from the elements.
Provide sufficient space around the analyzer to allow the maintenance and
servicing of the unit.
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4.2 Unpacking
This procedure requires a minimum of two people to safely remove the
equipment from the shipping container.
WARNING
HEAVY INSTRUMENT - LIFTING HAZARD
Handle the analyzer with caution during unpacking, installation,
maintenance, and transport to prevent crushing of hands, feet, or other
body parts.
The analyzer weighs and should always be lifted and moved using suitable
lifting/moving equipment. Emerson recommends that a minimum of two
people using suitable tools for transportation and lifting are employed.
Wear suitable protective gloves and protective footwear.
CAUTION
EQUIPMENT DAMAGE
Failure to observe this caution may cause damage to the equipment.
When preparing the analyzer for transport by air, road, or rail, safeguard the
analyzer against movement or break-away during transport by securely
strapping it in place.
WARNING
EXPLOSION HAZARD
Installing and wiring the analyzer must comply with all relevant national
legislative requirements and regulations.
Consider all safety instructions within this manual and all associated analyzer
instruction manuals.
WARNING
EXPLOSION HAZARD
Installing the analyzer requires opening the enclosure and working at the
open unit. This is permitted only when both the analyzer and connected
external circuitry are de-energized.
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
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WARNING
HEAVY ITEM
Failure to propery handle the analyzer may cause injury to personnel.
Ensure the wall the analyzer is mounted on is solid, stable, and of suitable
material to hold the weight of the analyzer.
Handle the analyzer with caution during unpacking, installing,
maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
Emerson recommends that a minimum of two people move and lift the
analyzer.
Wear suitable protective gloves and protective footwear.
CAUTION
SHOCK AND VIBRATION
Damage to the analyzer may result from a failure to follow this caution.
The analyzer contains sensitive electronic equipment. It MUST NOT be
subjected to any shock and or vibration.
Procedure
1. On receipt of goods, look for any visible damage to the analyzer and
verify that all items shipped were received. Record on the goods
receipt note any damage or missing items, noting both the item(s)
and quantity missing.
2. Visually inspect the exterior of the analyzer for signs of damage,
corrosion, gas leaks, or signs of previously overheating.
3. Report anything found to the maintenance organization.
4. Attach suitably rated and tested lifting slings to the safety
engineered lifting eye bolts mounted on top of the analyzer.
5. One person should carefully guide the equipment from the
horizontal to vertical position while the other person lifts the
equipment.
6. Use safety approved and tested lifting equipment to remove the
analyzer from the shipping container and place it on a solid, level
surface.
7. Ensure that the analyzer is stored in its protective plastic cover until
installation.
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