Emerson Rosemount CT5100 User manual

Reference Manual
00809-0100-4511, Rev AA
May 2020
Rosemount™ CT5100
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: 00809-0100-4511
Rev AA, May 2020
© Emerson 2020. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic,
mechanical, photocopying, recording, or otherwise without the express prior written permission of the copyright holder.
If you require additional technical assistance, request help from [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.
Preliminary information
This section details important user information for the Rosemount CT5100 Continuous Gas Analyzer.
Important
Users must read, understand, and comply with the following information before proceeding.
All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain,
and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The
following information is also available and/or referenced in the Rosemount CT5100 Quick Start Guide: 00825-0100-4511.
Save all instructions for future use. Contact your local service center or sales office when missing documents.
Authorized personnel
In-depth specialist knowledge is an absolute requirement for working with and on the analyzer. Personnel installing, operating,
servicing, and maintaining the analyzer must be instructed, trained, qualified, and authorized personnel of the operating company
for hazardous areas and the manufacturer. It is the responsibility of the operating company to:
•Train staff
•Observe safety regulations
•Follow the safety instructions and procedures in the product manual
Operators must:
•Have been trained
•Have read and understand all relevant sections of the product manual before commencing work
•Know the safety mechanisms and regulations
WARNING
To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate,
maintain, or service this analyzer before reading and understanding this document and receiving appropriate training.
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Important instructions
Important
All users must read this page before proceeding!
Emerson designs, manufactures and tests its products to meet many national and international standards. The Rosemount
CT5100 is a sophisticated technical product, and to ensure it continues to operate as designed and within normal specifications it
MUST be installed, used, and maintained correctly. The following instructions MUST be adhered to and integrated into your safety
program when installing, using, and maintaining Emerson products.
•Failure to follow the proper instructions may cause:
—Loss of life
—Personal injury
—Damage to property
—Damage to this analyzer
—Warranty invalidation
•Read all instructions prior to installing, operating, and servicing the product.
•If you do not understand any of the instructions, contact your Emerson representative for clarification.
•Follow all warnings, cautions, and instructions marked on and supplied with the product.
•Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
•Install your equipment as specified in the installation instructions of the appropriate Reference Manual and in accordance with
applicable local and national codes.
•Connect all products to the proper electrical and pressure sources.
•To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
•When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
•Unauthorized parts and procedures can affect the product’s performance; place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
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Regulations and standards
Regulations/standards Description
2014/35/EU The Low Voltage Directive
2014/30/EU The Electromagnetic Compatibility Directive
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive
USA 21 CFR 1040.1 Laser products
NEC 505 National Electrical Code (issued by ANSI: American National Standards
Institute and NFPA 70: National Fire Protection Association)
BS EN 60825-1:2007 Safety of laser products. Equipment classification and requirements
(identical to IEC 608250-1 2007)
BS EN 61010-1 2010
IEC 61010-1 2010
Safety requirements for electrical equipment for measurements,
control, and laboratory use. General requirements
BS EN 61326-1: 2013 Electrical equipment for measurement, control, and laboratory use.
EMC requirements. General requirements
Associated publications
Rosemount CT5100 Quick Start Guide
Compliance approvals
Important
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
This product complies with USA 21 CFR 1040.10.
This product is designed and manufactured under an approved quality management
system to ISO 9001: 2015.
Emerson and the Rosemount CT5100 have satisfied the requirements for applying
the CE marking to the Rosemount CT5100 Gas Analyzer.
This equipment meets all requirements of the EMC and Low Voltage directives.
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
DANGER
WILL CAUSE DEATH
Failure to follow this warning will result in death or serious injury to personnel.
WARNING
DANGER TO PERSONNEL
Failure to follow this warning may result in death or serious injury to personnel.
CAUTION
MAY CAUSE DAMAGE TO EQUIPMENT
Failure to follow this warning may result in damage to the equipment.
NOTICE
Important or tip messages will appear in this format.
Safety precautions
Important
The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and
maintenance personnel, must observe the following safety precautions and warnings.
The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.
WARNING
ELECTRIC SHOCK
The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Death, personal injury, and/or
damage to persons and/or property may result if this is not observed.
Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the top cover or opening the front
cover. The analyzer must be earthed.
Only trained, qualified personnel may install and connect power and signal cables. The installation/connection must be in
accordance with all legislative requirements and applicable standards.
Only qualified personnel, familiar with potential risks, should install the analyzer.
DANGER
EXPLOSION HAZARD
Failure to observe this precaution will cause death, personal injury, and/or damage to persons.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during prolonged shutdowns.
The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes and 30 seconds at a minimum
flow rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance.
Purge the sample gas in accordance with the safe working procedures for this site.
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WARNING
FLAMMABLE SUBSTANCES
Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition source. The interior of a
analyzer is always hot unless it has been switched off and allowed to cool down. A fire may result if this precaution is not observed.
Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.
WARNING
TRANSPORTATION HAZARD
The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/moving equipment.
Handle the analyzer with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet, or
other body parts.
Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard
the analyzer against movement or break-away during transport by securely strapping it in place.
Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings for the weight of the
equipment, and is in good operational condition.
WARNING
FIRE AND EXPLOSION
Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,
personal injury, and/or damage to persons and/or property.
Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized .
The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable
concentration of combustible gases or materials or unless all equipment within the protected enclosure is de-energized.
Always lock out the gas handling system when shutting down the analyzer.
After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes and 30
seconds at a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar.
DO NOT operate the analyzer with doors or covers open.
Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit.
When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to
external equipment MUST be shut off.
This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.
Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up
the analyzer.
Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test.
Use only replacement parts and components authorized by Emerson.
All replacement parts and components must be certified and approved for use in hazardous areas.
The analyzer contains a battery for data backup purposes.
Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement
MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.
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WARNING
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially
hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.
Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or
service.
WARNING
BURNS
Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly
important when working at heights.
Some parts of the analyzer may be heated to 374 °F (190°C). To prevent burns, do not touch any of the hot parts. All parts of a
analyzer are always hot unless it has been switched off and allowed to cool down.
Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been switched off and allowed to cool
for at least two hours. Before performing any maintenance on, or in the vicinity of, the analysis cell, allow the analyzer to cool for
at least 12 hours as the analysis cell is insulated against heat loss.
When handling the analyzer, always wear suitable protective gloves.
If you receive a burn, seek medical treatment immediately.
WARNING
HAZARDOUS SUBSTANCES
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may cause death, personal
injury, and/or damage to persons and/or property.
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.
Wear personal protective equipment (PPE) when handling the equipment.
Gas handling components within the analyzer contain particulate matter residue from the sample gases. Over the life of the the
analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the the analyzer:
—Handle used gas handling components with extreme caution.
—Avoid direct skin contact with used gas handling components.
—Do not smoke, drink, or eat in the work area.
—Wear goggles or eye shields.
—Wear a suitable face mask to protect against inhalation of particulate matter.
—Do not wet fingers, eyes, or any exposed skin.
—Pack used gas handling components for disposal in sealed packaging and label them Contaminated.
—Dispose of contaminated items as hazardous material in accordance with applicable local, national, or international health
and safety regulations and pollution regulations.
Take special care to ensure that the sample gas return port either returns the sample gas to the product stream or discharges the
sample gas to a location that will not cause a hazard.
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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.
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
HIGH PRESSURE GAS AND AIR
The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g., damage to eyes and skin
punctures from debris blown by the high pressure gas or compressed air.
Always lock off or tag out the calibration gas supply and compressed air supply when shutting down the analyzer.
The maximum gas pressure valve must not exceed 100 psig (690 kPa).
WARNING
EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE
In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Failure to
observe this warning and or follow safety instructions could cause an explosion or potentially hazardous situation, which if not
avoided, could result in death or serious injury.
Take suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area.
Clean the device surface by gently wiping it with a damp or antistatic cloth only.
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WARNING
HAZARD BY WRONG INPUT VOLTAGE
Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the
installation. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may
cause death, personal injury, and/or damage to persons and/or property.
This type of analyzer is always setup for a specific rated input voltage; see nameplate label.
Ensure the voltage at site of installation meets the rated analyzer input voltage.
WARNING
LOOSE ITEMS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
Do not place any loose items on top of the system or inside the compartments when doors / covers are open.
Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers.
WARNING
MAINTENANCE/MODIFICATIONS
Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
On completion of any maintenance and or modifications verify:
—All tools and equipment are removed.
—No contamination (water/dust) is in the compartments.
—Analyzer is wiped clean.
—Vents are clear and not obstructed.
—Verify that system is in a safe state for operation.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could
be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
CAUTION
EQUIPMENT DAMAGE
Failure to perform pre-system start-up checks may cause damage to equipment.
Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the
analyzer are in place.
Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any calibration gases that are
required are available to the analyzer.
Always follow the Start-up procedure.
Always follow the Shutdown procedure.
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CAUTION
UNSERVICEABLE EQUIPMENT
If the pressure and temperature screen does not display measurements similar to those shown in Figure 8-1 and Figure 8-2, refer
to Troubleshooting and diagnostics.
CAUTION
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is
unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical
components requires the use of special optical test/calibration equipment and procedures.
Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this
manual, then the fault must be repaired by Emerson.
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