Emerson Rosemount CT5100 User manual

Operations Manual
D-7010-0046, Rev A
May 2016
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: D-7010-0046
Rev A, May 2016
© Emerson 2016. 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 Technical Support ([email protected]) or
Emerson distribution partners.
General inquiries about this or other Cascade Technologies products should be sent to [email protected].
All trademarks used within this document are the property of their respective owners.

Preliminary Information
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)
EN 6223: 2008 EMC Safety Standard
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
Maintenance Manual (D-7010-0009)
Quick Start Guide (D-7010-0052)
Compliance approvals
This product complies with USA 21 CFR 1040 .10. It is also designed and manufactured under an approved
quality management system to ISO 9001:2008.
CE marking
Emerson and the CT5100 Continuous Gas Analyzer have satisfied the requirements for applying the CE
marking to the CT5100 Continuous 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.

Safety and information notices
The following notices are used throughout this publication:
DANGER!
MAY 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 injury to personnel.
CAUTION!
MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT
Failure to follow this warning may result in injury to personnel or cause damage to the equipment.
NOTICE
Important or tip messages will appear in this format.

Safety Precautions
Operators, maintenance personnel, and authorized users must observe the following safety precautions and warnings.
DANGER!
ELECTRIC SHOCK
The CT5100 Continuous Gas Analyzer (CT5100 CGA) operates using mains voltage, which may cause death or serious injury to
personnel. Make sure 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.
Death, personal injury, and/or damage to persons and/or property may result if this is not observed.
WARNING!
FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD
Operators and service personnel do not have access to the laser/electrical and the upper cell compartments for maintenance or
service.
Electrical shock or thermal burns may occur.
WARNING!
FLAMMABLE SUBSTANCES
Some parts of the CT5100 CGA may reach temperatures of 190 °C (374 °F) and may present an ignition source. Exercise care when
using oil, paint, cleaning rags, or other flammable substances near the CT5100 CGA. A fire may result if this precaution is not
observed. The interior of a CT5100 CGA is always hot unless it has been switched off and allowed to cool down.
WARNING!
EXPLOSION HAZARD
Always lock out the gas handling system when shutting down the CT5100 CGA. Unauthorized performance on the CT5100 CGA 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!
EXPLOSION HAZARD
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the CT5100
CGA during startup.
The sample gas in the pipes leading to the CT5100 CGA must be purged to prevent hazards to personnel during maintenance. You
must purge the sample gas in accordance with the safe working procedures for this site.
Allow the CT5100 CGA and the system for returning the sample gas to run for five minutes to allow any sample gas in the instrument
to be returned to the exhaust.
Failure to vent sample gas may cause death.

WARNING!
BURNS
Some parts of the CT5100 CGA may be heated to 190 °C (374 °F). To prevent burns, do not touch any of the hot parts. All parts of a
CT5100 CGA are always hot unless it has been switched off and allowed to cool down.
Before fitting, removing, or performing any maintenance on the CT5100 CGA, make sure 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 CT5100 CGA to
cool for at least twelve hours as the analysis cell is insulated against heat loss.
When handling the CT5100 CGA, always use 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 a burn is received, seek medical treatment immediately.
WARNING!
OPTICAL RADIATION EXPOSURE HAZARD
The CT5100 CGA contains lasers. Opening the CT5100 CGA and attempting to perform adjustments and procedures other than those
specified in this manual may result in hazardous optical radiation exposure.
All lasers used within the CT5100 CGA are Class 1. 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.
Failure to follow the correct procedures may cause damage to the eye. Do not look at the lasers with any kind of magnifier or optical
measuring device.
There are three types of laser that may be included in the CT5100 CGA: Quantum Cascade Lasers (QCLs), Interband Cascade Lasers
(ICLs), and diode lasers. The lasers within the CT5100 CGA are Class 1. The characteristics of the lasers contained within the CT5100
CGA are given in the table below.
Parameter QCL ICL Diode Comment
Operation mode Pulsed Pulsed Pulsed
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
Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first accessible
aperture: < 9.62mW
Pulse duration < 1 µs < 1 µs < 5 µs
Pulse repetition
frequency
< 100 kHz < 100 kHz < 100 kHz
Duty cycle < 5% < 5% < 25%
The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW.
The CT5100 Continuous Gas Analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of
laser safety labels on the CT5100 Continuous Gas Analyzer is specified in Section 4.3.
The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation
exposure.

WARNING!
HAZARDOUS SUBSTANCES
The CT5100 CGA may contain hazardous substances. Always handle CT5100 CGA assemblies and components with extreme caution.
Wear personal protective equipment (PPE) when handling the equipment.
Gas handling components within the CT5100 CGA contain particulate matter residue from the sample gases. Over the life of the
CT5100 CGA, the concentration of particulate matter will become enriched within the gas handling components. When performing
repairs and maintenance on the CT5100 CGA:
•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.
•Keep food and beverages away from the CT5100 Continuous Gas Analyzer.
•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.
WARNING!
TRANSPORTATION HAZARD
Handle the CT5100 CGA with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet,
or other body parts.
The CT5100 CGA weighs 50.3 kg (111 lb.) and should always be lifted and moved using suitable lifting/moving equipment. Wear
suitable protective gloves and protective footwear. When preparing the CT5100 CGA for transport by air, road, or rail, safeguard the
CT5100 CGA against movement or break-away during transport by securely strapping it in place.
WARNING!
HAZARDOUS GAS
The product stream that the CT5100 CGA is examining may be hazardous even at low concentrations. Special care should therefore
be taken 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
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 CT5100 CGA.
CAUTION!
EQUIPMENT DAMAGE
Do not power up or try to operate the CT5100 CGA unless it is physically secure and all electrical and pneumatic connections to the
CT5100 CGA are in place.
Before commencing the startup process, it is important to ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the CT5100 CGA.
Failure to perform pre-system startup checks may cause damage to equipment.

CAUTION!
EQUIPMENT DAMAGE
Always follow the startup procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.
CAUTION!
EQUIPMENT DAMAGE
Always follow the shutdown procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.
CAUTION!
LASER RADIATION
Invisible laser radiation. Do not stare into beam. Class 1 laser.
Failure to follow the correct procedures may cause damage to the eye.
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.

Abbreviations
The following abbreviations are used in this manual.
©Copyright
% Percent
< Less than
° Degree
AC Alternating current
Barg Pressure, in units of bars, above or below atmospheric pressure
BS British Standard
C Celsius
CE European Conformity
CFR Code of Federal Regulations
CGA Continuous Gas Analyzer
CH4Methane
CO Carbon monoxide
CO2Carbon 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
IPxx Ingress protection (the xx are numbers that define the level of protection)
ISO International Organisation for Standardisation
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
m3Cubic meter
mA Milliamp
Max Maximum
mBar milli-Bar
mbps Megabits per second
mg Milligram
mg/m3Microgram/cubic meter
Mid IR Mid Infrared
min Minute
mm Millimeter
O2Oxygen
N2Nitrogen
NEC National Electrical Code
NFPA National Fire Protection Association
nm Newton meter
NO Nitric oxide
NO2Nitrogen dioxide
N2O Nitrous oxide
NH3Ammonia
No. Number
O2Oxygen
PC Personal computer
PM Preventative maintenance
ppm Parts per million
psi Pounds per square inch
QCL Quantum Cascade 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
W Watt
WEEE Waste electrical and electronic equipment
μm Micro-meter