Emerson Rosemount CT4215 User manual

Reference Manual
00809-0100-4245, Rev AC
July 2022
Rosemount™ CT4215 Leak Detection System

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.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
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 further assistance or technical support, contact your local Emerson distribution partner or
[email protected].
Send general inquiries to [email protected].
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Important information
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 leak detection system. To install, start up,
operate, maintain, and service the leak detector in a safe manner, it is MANDATORY to read all additional instruction manuals
shipped with the unit.
User information
Important
All users must read this page before proceeding!
Emerson designs, manufactures, and tests its products to meet national and international standards. To ensure the product,
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, operating, and
maintaining the leak detector
•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 the instructions, contact [email protected] for additional 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 correct 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 ONLY parts specified and supplied 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.
•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.
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General safety notice/residual risk
Installation, operation, and maintenance of the leak detection system must be in accordance with these instructions.
Authorized personnel
Personnel installing, operating, servicing, and maintaining the leak detection system must be instructed, trained and qualified
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 and competent.
•Read and understand all relevant sections of the product manual before commencing work
•Know the safety mechanisms and regulations
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Regulations and standards
Regulation/standards Description
IEC 60825-1:2014 Ed 3 Safety of laser products - Part 1: Equipment classification and requirements.
IEC 61010-1:2010 +AMD1:2016 CSV UL
Std.No. 61010-1 (3rd edition)
Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements.
IEC 61326-1: 2020 Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 1: General requirements.
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive.
2014/30/EU The Electromagnetic Compatibility Directive.
2014/35/EU The Low Voltage Directive.
FDA 21 CFR 1040.10 Performance standards for light-emitting products – Sec. 10 :Laser products.
NFPA 70 (2021) National Electrical Code (issued by ANSI: American National Standards Institute and
NFPA 70: National Fire Protection Association).
Compliance approvals
Important
The analyzer is designed for use in Non Hazardous areas ONLY.
This product is designed and manufactured under an approved quality management
system to ISO 9001: 2015.
Emerson have satisfied the requirements for applying the CE and UKCA marking to
this product. This equipment meets all requirements of the EMC and Low Voltage
directives.
Waste disposal
Do not dispose of in 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.
In accordance with the European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment (WEEE) disposal of the leak detection system when no longer
serviceable must be collected separately and disposed of in an environmentally
correct manner.
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Hazard messages
This document uses the following criteria for hazard messages based on ANSI standards Z535.6-2011 (R2017).
DANGER
Serious injury or death will occur if a hazardous situation is not avoided.
WARNING
Serious injury or death could occur if a hazardous situation is not avoided.
CAUTION
Minor or moderate injury will or could occur if a hazardous situation is not avoided.
NOTICE
Data loss, property damage, hardware damage, or software damage can occur if a situation is not avoided. There is no credible
risk of physical injury.
Physical access
NOTICE
Unauthorized personnel can potentially cause significant damage and/or misconfiguration of end users' equipment. Protect
against all intentional or unintentional unauthorized use.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access
to protect users' assets. This is true for all systems used within the facility.
Safety precautions
The precautions in this manual MUST NOT be changed amended or removed. All
authorized users, installation, operation and maintenance personnel, must observe
the safety precautions and warnings.
The analyzer is NOT designed for use in Hazardous areas.
DANGER
ELECTRIC SHOCK
Serious injury or death will occur.
The leak detection system operates using mains voltage and must be switched off and the
power cable removed before opening the analyzer.
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WARNING
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 119 kg (263 lb) and should only be moved by a
minimum of two people using suitably rated lifting/moving equipment .
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed.
WARNING
HIGH PRESSURE AIR
Serious injury or death could occur.
The compressed air supply operate at pressures that can cause injury.
WARNING
HAZARD BY WRONG SUPPLY VOLTAGE
Serious injury or death could occur.
The rated voltage for the leak detector is fixed during the manufacture and defined on the
ratings label fitted to the unit.
The voltage at the installation site must meet the rated voltage required.
WARNING
MAINTENANCE
Serious injury or death could occur.
Only authorized maintenance personnel can carry out repair work on the leak detection
system.
On completion verify:
All tools and equipment are removed.
No contamination (water/dust) is in the compartments.
Leak detector is wiped clean.
Vents are clear and free from obstruction.
Verify that system is in a safe state for operation.
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CAUTION
LASER / OPTICAL PATH
Minor or moderate injury will or could occur
Operators do not have access to the internal laser or electrics during normal operation.
Maintenance personnel must only access the internal laser or electrics after the analyzer
has been turned off.
Opening the leak detection system and attempting to perform adjustments other than
those specified in this manual may result in Class 3R optical radiation exposure. Do not
look at the laser with any kind of magnifier or optical measuring device.
Use of controls or adjustments or performance of procedures other than those specified
herein may result in hazardous radiation exposure.
CAUTION
EQUIPMENT DAMAGE
Minor or moderate injury will or could occur
Always follow the procedures detailed in the manual otherwise damage to the leak
detector may result.
Only authorized personnel can operate the leak detection system.
Do not operate the leak detection system unless it is physically secured in position and all
electrical and sample gas connections are in place.
CAUTION
AIR SUPPLY
Minor or moderate injury will or could occur
Air provided must be connected from a pressure regulated clean, filtered and moisture
free supply source.
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Safety and system labels and annotation
Labels are applied to the analyzer in the positions shown below.
Location Label Type Label fitted
A
Identification label
(including the Serial No.
(S/N), Model No. and
Date of Manufacture
(DoM).
or
B AC Supply Voltage or
CChassis earth terminal
location N/A
DLaser radiation CAUTION
label
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Location Label Type Label fitted
ELaser module
identification label
FFuse and circuit breaker
identification label.
G
Isolate before removing
cover DANGER Label
AC Supply Voltage or
Electrical safety label.
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Contents
Chapter 1 Leak detection overview.......................................................................................... 13
1.1 System overview........................................................................................................................13
Chapter 2 Equipment and accessories...................................................................................... 15
2.1 Upper and lower enclosures.......................................................................................................15
2.2 Main operating controls and displays ........................................................................................ 16
2.3 Analysis cell and purge...............................................................................................................17
2.4 Electrical back plate................................................................................................................... 18
2.5 Air preparation plate..................................................................................................................20
2.6 Blower and electrical shut off..................................................................................................... 21
2.7 Leak detector interface connections.......................................................................................... 22
2.8 Leak detector installed examples............................................................................................... 24
2.9 Sample head types.....................................................................................................................25
Chapter 3 Installation...............................................................................................................27
3.1 Site selection............................................................................................................................. 27
3.2 Unpacking................................................................................................................................. 29
3.3 Installing the leak detector........................................................................................................ 33
3.4 Electrical, signal, compressed air in and sample gas connection details......................................38
Chapter 4 Start-up procedure...................................................................................................43
Chapter 5 Shut down procedure...............................................................................................47
Chapter 6 Software interface description................................................................................. 49
6.1 Leak detector manager..............................................................................................................49
6.2 Data logging and reporting........................................................................................................59
6.3 Status lamps / errors.................................................................................................................. 62
6.4 Status........................................................................................................................................ 64
6.5 PLC configuration...................................................................................................................... 64
Chapter 7 Maintaining the leak detector.................................................................................. 77
7.1 Scheduled maintenance............................................................................................................ 77
7.2 Purging the analysis cell.............................................................................................................77
7.3 Cleaning the cell mirrors............................................................................................................ 78
7.4 Replace the sample gas inlet filter..............................................................................................82
7.5 Replacing a fuse.........................................................................................................................83
Chapter 8 Troubleshooting and diagnostics............................................................................. 87
Appendix A Specification............................................................................................................ 93
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Contents Reference Manual
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1 Leak detection overview
The CT4215 Leak Detection System, hereafter referred to as CT4215 or the leak detector,
is an electronic sensor that uses laser spectroscopy to identify gasses used in the food and
beverage industries as product is carried along a conveyor belt at high speed.
The function of the leak detector is to identify micro leakages from Modified Atmosphere
Packages (MAP). The leak detector uses a Laser calibrated to measure the gas within the
modified atmosphere, e.g. CO2, N2O or Ethanol, to identify leaking packages. The leak
detection system is installed together with a custom sampling head designed for the
product range and a where required a reject mechanism to remove the defective goods
from the production line.
This document is intended for the personnel who install, operate, and maintain the leak
detector.
1.1 System overview
The leak detector can be installed along side existing production lines and comprises an all
metal stainless steel enclosure containing the analyzer, PLC control system, compressed
air and vacuum gas sample handling systems.
Depending on the product line being monitored by the leak detector additional systems
can be added as follows.
1. Sample Head suitable for the product line being monitored.
2. Input Gates used to count product into and out of system.
3. Rejector to remove defective product from the production line .
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A. Leak detector system.
B. PLC display screen.
C. HMI touch screen.
D. Status beacon.
E. Product line direction.
F. Input gate.
G. Rejector.
H. Sample head.
I. Reject chute (Collection bin customer supplied).
J. Circuit breakers.
K. AC supply.
L. Customer connections.
M. Compressed air line connections.
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2 Equipment and accessories
2.1 Upper and lower enclosures
A. Lower enclosure door with PLC control panel fitted.
B. Upper enclosure door with HMI panel LED and reset buttons.
C. Upper enclosure fitted with the analysis cell and cell purge.
D. 1st compartment fitted with the electrical back plate and electronics panel.
E. 2nd compartment fitted with the air preparation panel.
F. 3rd compartment fitted with the sample air motor and electrical shut off.
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2.2 Main operating controls and displays
A. USB port 2.
B. USB port 1.
C. Air fault indicator.
D. Reset button.
E. Main HMI display screen.
F. PLC screen.
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2.3 Analysis cell and purge
The assembly shown is mounted in the upper enclosure.
A. Manual purge button.
B. Gas sample inlet from the production line.
C. Toggle clamp.
D. Gas sample outlet connected to the blower motor.
E. Cell output mirrors, directing the laser beam from the cell into the detector.
F. Detector.
G. One of two purge connections for the output mirrors inside the cell.
H. Sample gas analysis cell.
I. Laser module.
J. Cell input mirrors, directing the laser beam into the cell.
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2.4 Electrical back plate
The assembly shown is mounted in the 1st compartment of the lower enclosure.
A. Electronics panel.
B. Electrical back plate upper DIN rail.
C. Electrical back plate lower DIN rail.
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Figure 2-1: Upper DIN rail components
A. Earth terminal block.
B. 6A MCB breaker.
C. End stop.
D. Terminals.
E. 24V power supply.
F. 12V power supply.
G. PLC.
Figure 2-2: Lower DIN rail components
A. Earth terminal block.
B. Earth terminal block.
C. Fuse terminals.
D. Double terminals.
E. Terminals.
F. Relays.
G. 24V opto-relay.
H. 12V opto-relay.
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2.5 Air preparation plate
Dry filtered compressed air from the factory will be connected to the leak detector. The air
supply will pass through the air preparation plate mounted in the 2nd compartment of the
lower enclosure. It will be filtered, dried and pressure-regulated before being used to
purge the analysis cell when needed or the reject system if attached.
The assembly shown is
A. Ethernet hub.
B. Factory compressed air in.
C. Shut off valve.
D. Pressure regulator with 40 µm filter.
E. 0.1 µm filter.
F. Membrane dryer.
G. Pressure switch (MPa).
H. Filtered air out.
I. Reject solenoid.
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