Emerson Rosemount CT5400 User manual

Installation, Operations, and Maintenance Manual
D-7010-0045, Rev C
January 2018
Rosemount™ CT5400 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-7010-0045
Rev C, January 2018
© Emerson 2017. 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.

Important information
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section 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 instruction manuals shipped with the analyzer. The
following instruction manual(s) are available and / or referenced within this manual:
Rosemount CT5400 Quick Start Guide: D-7010-0061
All instructions must be saved for future use. Contact your local service center or sales office if you are missing documents.
User information
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section must not be changed, amended, or removed.
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 CT5400 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 instrument
-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 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.
•To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except
when maintenance is being performed by qualified personnel.
•The information contained in this document is subject to change without notice.

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 instruments).
•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.
Authorized personnel
NOTICE
This section is in accordance with IEC 60079-0: 2011 Clause 30. This section must not be changed, amended, or removed.
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 for hazardous areas with the
operating company 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 instrument before reading and understanding this instruction manual and receiving appropriate training.

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 Stand-
ards 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
Quick Start Guide: D-7010-0061
Compliance approvals
This product complies with USA 21 CFR 1040.10. It is also designed and manufac-
tured under an approved quality management system to ISO 9001:2008.
Emerson and the Rosemount CT5400 Gas Analyzer have satisfied the require-
ments for applying the CE marking to the Rosemount CT5400 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 implemen-
tation 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
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.

Safety Information
All authorized users, including installation, operation, and maintenance personnel, must observe the following safety precautions
and warnings.
DANGER!
ELECTRIC SHOCK
The analyzer operates using mains voltage that is dangerous to life. Make sure that the power ON/OFF switch at the rear of the panel
is set to OFF and tagged off before removing the top cover.
The analyzer must be earthed.
Death or personal injury may result if this is not observed.
DANGER!
FAILURE TO LOCK-OUT GAS HANDLING SYSTEM MAY CAUSE DEATH.
Always lock out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling system
when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being
released, causing fire or explosion.
DANGER!
FAILURE TO VENT SAMPLE GAS MAY CAUSE DEATH.
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
analyzer during startup.
The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance. Purging
the sample gas must be done in accordance with the safe working procedures for the site.
Allow the analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING!
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure.
Do not open while energized.
Installation requires access to live parts which can cause death or serious injury.
For safety and proper performance, this instrument must be connected to a properly grounded three-wire source of power.

WARNING!
LASER OPTICAL RADIATION EXPOSURE HAZARD
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.
The use of control or adjustments or performance of procedures other than those specified herein may result in hazardous radiation
exposure.
WARNING!
HAZARDOUS SUBSTANCES
The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.
Gas handling components within the analyzer will 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 according to the applicable local, national, or international health and safety
regulations and pollution regulations.
WARNING!
EXPLOSION HAZARD
Always lock-out tag-out the gas handling system when shutting down the analyzer. Unauthorized operation of the gas handling
system when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being
released, causing fire or explosion.
WARNING!
HEAVY ITEM
Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or
other body parts.
The analyzer weighs 31 kg (68 lb). Always use suitable lifting/moving equipment when moving the analyzer. Wear suitable
protective gloves and protective footwear.
Failure to properly handle the analyzer may cause injury to personnel.
WARNING!
HAZARDOUS GAS
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
punctures from debris blown by the high pressure gas or compressed air.
Always lock out or tag off the calibration gas supply and compressed air supply when shutting down the analyzer.
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
analyzer during startup.
The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance. Purging
the sample gas must be done in accordance with the safe working procedures for the site.
Allow the analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING!
EXPLOSION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type.
CAUTION!
EQUIPMENT DAMAGE
Always follow the startup procedure. Damage to the analyzer may result from a failure to follow this procedure.
Failure to perform pre-system startup checks may cause damage to equipment.
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 measurements are out of tolerance, refer to Chapter 7 for guidance.
CAUTION!
EMC
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case you may be required to
take adequate measures.
CAUTION!
EQUIPMENT DAMAGE
Ensure that the local power voltage where the unit is to be installed corresponds to the unit’s nominal voltage as given on the name
plate label.

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 commencing the start-up process, it is important to ensure that electrical power, sample gas handling facilities, and any
calibration gases that are required are available to the analyzer.