Emerson Rosemount CT5100 User manual

Reference Manual
00809-0100-4512, Rev AA
October 2019
Rosemount™ CT5100(Ex)
Continuous Gas Analyzer

Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no
liability for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further
enhancements while in service may mean that the manual does not reflect your particular system.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
Document number: 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 [email protected] or Emerson distribution partners.
Send general inquiries to [email protected].
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.
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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.
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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)(1) The ATEX Directive
2014/34/EU (from 20 April 2016) (2)
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.
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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
American regulators for operation of electrical/electronic equipment in hazardous
locations .
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.
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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.
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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.
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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.
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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.
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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
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.
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.
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.
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