Emerson Rosemount CT5100 Operation Manual
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Emerson Rosemount CT5100 Operation Manual

Continuous gas analyzer
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Operations Manual
D-7010-0046, Rev A
May 2016
Rosemount CT5100 Continuous Gas Analyzer

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Summary of Contents for Emerson Rosemount CT5100

  • Page 1 Operations Manual D-7010-0046, Rev A May 2016 Rosemount CT5100 Continuous Gas Analyzer...
  • Page 2 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.
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 6 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.
  • Page 7 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.
  • Page 8 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.
  • Page 9 Abbreviations The following abbreviations are used in this manual. © Copyright Percent < Less than ° Degree Alternating current Barg Pressure, in units of bars, above or below atmospheric pressure British Standard Celsius European Conformity Code of Federal Regulations Continuous Gas Analyzer Methane Carbon monoxide Carbon dioxide...
  • Page 10 L/min Liters per minute Meter Cubic meter Milliamp Maximum mBar milli-Bar mbps Megabits per second Milligram mg/m Microgram/cubic meter Mid IR Mid Infrared Minute Millimeter Oxygen Nitrogen National Electrical Code NFPA National Fire Protection Association Newton meter Nitric oxide Nitrogen dioxide Nitrous oxide Ammonia Number...

  • Page 11: Table Of Contents

    Contents Contents Chapter 1 Introduction ........................1 Description ..........................1 Customer information ......................... 1 Safety precautions ........................2 Qualified personnel ........................2 Software version .......................... 2 Chapter 2 Theory of Operation ....................... 3 Overview ............................3 Quantum Cascade Laser ......................3 Measurement process ........................3 Chapter 3 Description ........................
  • Page 12 Contents Chapter 9 Gas Calibration Procedures ...................45 Required tools ..........................45 Main menu ..........................45 Zero Calibration ......................... 47 Span gas calibration ........................52 Chapter 10 Preventative Maintenance ................... 59 10.1 Maintenance ..........................59 10.2 Schedule ............................ 59 Rosemount CT5100...

  • Page 13: Chapter 1 Introduction

    For information regarding maintenance, installation, and spare parts, contact your local service representative. Emerson is committed to continuously improving its products and documentation. Every effort will be made to include in the documentation any modifications by the manufacturer. However, it should be noted that this document reflects the supplied sensor at the revision date on the front cover.

  • Page 14: Safety Precautions

    CGA. Only qualified and trained persons have the required specific knowledge to correctly interpret the general safety information, warnings, and procedures given in this manual and apply them to this particular application. Emerson or its distribution partners can provide this training on request.

  • Page 15: Theory Of Operation

    Theory of Operation Theory of Operation Topics covered in this chapter: • Overview • Quantum Cascade Laser • Measurement process Overview The CT5100 CGA is a gas sensor system that can be configured to measure the concentrations of multiple small molecules carried in the gas sample. The types of molecules that are measured depend on the system configuration.
  • Page 16 The variation in the intensity of light in the vicinity of absorption lines for the gases being detected is measured, and the concentration is determined using a comprehensive spectral fitting routine. Rosemount CT5100...

  • Page 17: Chapter 3 Description

    Description Description Topics covered in this chapter: • Equipment purpose and role • System overview • Gas inputs and outputs • Electrical/electronic inputs and outputs • Controls and indicators • Optical description Equipment purpose and role The CT5100 CGA shown in Figure 3-1 is a gas sensor system that can be configured to measure the concentrations of multiple small molecules contained in a gas sample that is...

  • Page 18: System Overview

    CT5100 CGA can be displayed in the process control center. The CT5100 CGA is supplied by Emerson. The gas handling system may be provided by either you or Emerson, depending upon the specific installation. The circuit breakers used to control the application of electrical power to the CT5100 CGA, the interconnecting wires, and gas piping are provided by you.
  • Page 19 4.2. Table 3-1: Main items of the CT5100 CGA installation Item Name or description Supplied by Part number Quantity Notes CT5100 CGA Emerson CT5100 CT5100 CGA software Emerson N/A. Version package, version 4.0 described Software is in manual embedded in the system.

  • Page 20: Gas Inputs And Outputs

    The gas sample that is to be measured for impurities enters the instrument through the sample gas input port (A) located on top of the CT5100 CGA. Once the gas sample has been examined for impurities, it is expelled from the instrument through the sample gas return port (B). Rosemount CT5100...
  • Page 21 Description Figure 3-3: Gas inlet and outlet connectors A. Sample gas input port B. Sample gas return port C. Top cover of CT5100 CGA (cell compartment) D. Laser/electrical compartment The sample supply line must be heated all the way to the sample gas input port on the CT5100 CGA to prevent condensation forming at any point in the sample supply line.

  • Page 22: Electrical/Electronic Inputs And Outputs

    Power conduit Electrical/electronic connections to the CT5100 CGA are made through three electrical conduits located on the underside of the instrument, as shown in Figure 3-4. Use the wiring diagram to make the electrical user connections as shown below. Rosemount CT5100...
  • Page 23 Description Terminal Function SENSOR SYSTEM SUPPLY (L) SENSOR SYSTEM SUPPLY (N) EARTH PURGE ALARM CONTACTS (Not used) PURGE SYSTEM SUPPLY (L) (Not used) PURGE SYSTEM SUPPLY (N) (Not used) EARTH PURGE SOLENOID (L) (Not used) PURGE SOLENOID (N) (Not used) EARTH DIGITAL OUTPUT 1 DIGITAL OUTPUT 2...

  • Page 24: Controls And Indicators

    2 m and 5 m through multiple reflections along the length of the cell. The laser beams exit the cell at the opposite end from where they entered and are directed using a second optical block to a receiver. Rosemount CT5100...
  • Page 25 Description By measuring and analyzing the light detected by the receiver unit, it is possible to accurately determine the concentrations of the target molecules within the gas sample cell. Operations Manual...
  • Page 26 Description Rosemount CT5100...

  • Page 27: Chapter 4 Specifications

    Specifications Specifications Topics covered in this chapter: • Gas detection • Detailed system specifications • Safety and system labels and annotation Gas detection The CT5100 CGA is highly configurable in the gases that can be detected and their range of concentrations.
  • Page 28 Swagelok type, factory-configured, specify on order Outlet (Exhaust) gas port 6 mm or 1/4 in. Swagelok type, factory-configured, specify on order connector Measurement result signals 4 to 20 4 or 8 channel outputs, specify on order 10/100 Mbps Ethernet Rosemount CT5100...
  • Page 29 Specifications Figure 4-1: CT5100 Continuous Gas Analyzer dimensions - front view Operations Manual...

  • Page 30: Safety And System Labels And Annotation

    Sensor humidity range 10 to 95 Relative humidity (non- condensing) at 45 °C (113 °F) Operating altitude 0 to 2,000 Safety and system labels and annotation The labels and annotation applied to the CT5100 CGA are specified in Table 4-4. Rosemount CT5100...
  • Page 31 Specifications Table 4-4: Safety and system labels Label type Example Location Identification label Front panel (including serial number and model number Fuse identification 1. Back plate label 2. Top right inside of door Ratings label Enclosure side panel Laser radiation Baseplate CAUTION label Laser module...
  • Page 32 Specifications Table 4-4: Safety and system labels (continued) Label type Example Location Intrinsically safe label 1. HMI 2. Intrinsically safe sensor barrier Terminal label Top left inside of door Earth identification Back plate label Rosemount CT5100...
  • Page 33 Specifications Table 4-4: Safety and system labels (continued) Label type Example Location Manufacturer's label On analysis cell heater block Electrical safety label On inside of electrical compartment door AC Power Supply 1. On outside of Danger label electrical compartment door 2.
  • Page 34 Specifications Rosemount CT5100...

  • Page 35: Chapter 5 Controls And Display Controller

    Controls Controls Topics covered in this chapter: • Introduction • Operating states • Startup procedure • Shutdown procedure • Front panel controls and indicators • Display controller • Gas sensor main screen • Pressure and Temperature screen • Help system •...

  • Page 36: Shutdown Procedure

    Always follow the shutdown procedure. Damage to the CT5100 CGA may result from a failure to follow the shutdown procedure. Front panel controls and indicators The CT5100 CGA is configured from the two control displays located on the front panel (Figure 5-1). Rosemount CT5100...
  • Page 37 Controls Figure 5-1: Front panel Display controller NOTICE On/Off circuit breakers There are no On/Off switches on the CT5100 CGA. The application of electrical power to the instrument is controlled through an external circuit breaker. The circuit breaker is a simple 2-pole on/off circuit breaker that must be set to On to permit the safe operation of the CT5100 CGA.

  • Page 38: Display Controller

    Configurable button Configurable button Scroll button Configurable button Operation of the CT5100 CGA is controlled through the six buttons on the display controller: Figure 5-3. The LCD display (A) can be used to display: The gas concentration measurements obtained Rosemount CT5100...

  • Page 39: Gas Sensor Main Screen

    Controls The operating temperature and pressure Help screens Step-by-step calibration and diagnostics The two scroll buttons (C and F) are used to scroll through the information on the LCD display. The right-hand scroll button (C) is used to scroll up, and the left-hand scroll button (F) is used to scroll down.
  • Page 40 On the gas sensor main screen, the STATUS button (G) has no function when the CT5100 CGA is operating correctly. If, however, the software detects a fault, an error message is displayed. Press the STATUS button to get further information on the error. Rosemount CT5100...

  • Page 41: Pressure And Temperature Screen

    Controls Pressure and Temperature screen The Pressure and Temperature screen (Figure 5-6) shows pressure and temperature measurements taken inside the CT5100 CGA. Figure 5-6: Pressure and Temperature screen The Cell reading is the temperature, in °C, of the analysis cell. The Gas reading is the temperature, in °C, of the gas within the analysis cell.

  • Page 42: Calibration

    CT5100 CGA. Figure 5-8: Main menu 5.11 BACK button On most of the software screens, the top left-hand button (Figure 5-9) is configured as a BACK button. Press the BACK button to return to the previous screen. Rosemount CT5100...
  • Page 43 Controls Figure 5-9: BACK button BACK button Operations Manual...
  • Page 44 Controls Rosemount CT5100...

  • Page 45: Chapter 6 Startup Procedure

    Startup Procedure Startup Procedure Topics covered in this chapter: • Introduction • Preparation for use • Startup Introduction This section describes the startup procedure for the CT5100 CGA. CAUTION! EQUIPMENT DAMAGE Always follow the startup procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.

  • Page 46: Startup

    Make sure that the external main circuit breaker is set to Off. Visually examine the gas ports (if necessary, refer to Figure 6-1) to make sure that the sample supply line and the sample return line are correctly attached. Rosemount CT5100...
  • Page 47 Startup Procedure Figure 6-1: CT5100 CGA Gas Supply Lines A. Sample gas input port B. Sample gas return port C. Top cover of CT5100 CGA (cell compartment) D. Laser/electrical compartment E. Power conduit F. Analog/digital conduit G. Analog/digital conduit Visually check that the electrical connections have been made to the three conduit hubs at the base of the instrument.
  • Page 48 CT5100 CGA. At the end of the startup procedure, the gas measurements initially appear as 0.00 ppm until the first readings are taken. After a few seconds, the initial gas concentrations are displayed. The startup procedure is now complete. Rosemount CT5100...

  • Page 49: Chapter 7 Operation

    Operating Procedure Operating Procedure Topics covered in this chapter: • Introduction • Normal operation Introduction This section describes the normal operation of the CT5100 CGA. Chapter 5 of this manual describes how to use the display controller located on the front panel of the CT5100 CGA. NOTICE The gas concentrations shown in the following screenshots may be different from those shown in your particular CT5100 CGA.
  • Page 50 On both the Gas Sensor main screen and the Pressure and Temperature screen, the STATUS button has no function when the CT5100 CGA is operating correctly. If, however, the software detects a fault, an error message is displayed; press the STATUS button to get further information on the error. Rosemount CT5100...

  • Page 51: Chapter 8 Shutdown Procedure

    Shutdown Procedure Shutdown Procedure Topics covered in this chapter: • Introduction • Shutdown procedure Introduction This chapter describes the shutdown procedure for the CT5100 CGA. CAUTION! EQUIPMENT DAMAGE Always follow this shutdown procedure. Damage to the CT5100 CGA may result from a failure to follow this procedure.

  • Page 52: Shutdown Procedure

    Allow the CT5100 CGA and 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. Rosemount CT5100...
  • Page 53 Shutdown Procedure Purge any sample gas in the pipe/hose from the gas handling system to the CT5100 CGA using factory air or nitrogen supply. Allow the CT5100 CGA to run for five minutes with the purge gas connected, so that any sample gas in the instrument is vented to the exhaust.
  • Page 54 D. HELP button E. Scroll down button Use the scroll up (C) and scroll down (E) buttons to select Shutdown as shown in Figure 8-4. Then press the SEL (select) button (B). The Shutdown screen (Figure 8-5) appears. Rosemount CT5100...
  • Page 55 Shutdown Procedure Figure 8-5: Shutdown screen Press the YES button. The CT5100 CGA shuts down. Check that the screen of the display controller goes blank. Set the external secondary circuit breaker to Off. Lock out and tag out the secondary circuit breaker.
  • Page 56 Shutdown Procedure Rosemount CT5100...

  • Page 57: Gas Calibration Procedures

    The CT5100 CGA and its installation have to be configured to allow zero and span calibration procedures to be used. If you are unable to complete the steps below, contact Emerson for further assistance.
  • Page 58 G) can be used to scroll between the menu options (A). When the option you want is highlighted (VERIFY is the example shown in Figure 9-1), press the SEL (select) button (C) to go to the first screen of that software routine. Rosemount CT5100...

  • Page 59: Zero Calibration

    Gas Calibration Procedures Zero Calibration Zero calibration is calibrating the CT5100 CGA so that when no sample gas is flowing through it the gas concentrations measured by the instrument are zero. Zero calibration is done by calibrating the CT5100 CGA measurements against a known sample gas using the following procedure: Run the CT5100 CGA at a stable temperature for at least thirty minutes prior to commencing this procedure.
  • Page 60 D. CANCEL button Flow the zero gas at a pressure of +.05 Bar Gauge from the nitrogen cylinder into the CT5100 Continuous Gas Analyzer. Refer to Figure 9-4. To proceed with the zero calibration, press the GO button (B). Rosemount CT5100...
  • Page 61 Gas Calibration Procedures NOTICE To halt the zero calibration and return to the Main menu (Figure 9-1), press the CANCEL button (D). Allow the concentrations to stabilize and wait for two minutes after stabilization. When the two minutes have elapsed, observe the display controller. It displays a Verify zero measurement screen similar to that shown in Figure 9-5.
  • Page 62 Refer to Figure 9-7. If the calibration of the CT5100 CGA remains outside of tolerance, press the CAL button (E) to adjust the calibration. This brings up the confirmation screen, an example of which is shown in Figure 9-6. Rosemount CT5100...
  • Page 63 Gas Calibration Procedures Figure 9-7: Calibration/verification complete screen A. GAS button B. DONEbutton C. HELP button D. TYPE button Refer to Figure 9-7. To proceed with the automatic re-calibration, press the OK button (B). To halt the calibration and return to the Main menu (Figure 9-1), press the CANCEL button (D).

  • Page 64: Span Gas Calibration

    On the display controller of the CT5100 CGA, browse to the Main menu as described Section 9.2. Refer to Figure 9-1. Select VERIFY using the scroll up (D) and scroll down (G) buttons. Press the SEL button. The Verify gas screen (Figure 9-9) opens. Rosemount CT5100...
  • Page 65 Gas Calibration Procedures Figure 9-9: Verify gas screen A. BACK button B. SEL (Select) button C. Scroll up button D. HELP button E. Gas type F. Scroll down button Use the scroll up (C) and scroll down (F) buttons to move the cursor until the gas that you wish to span calibrate is highlighted by the cursor.
  • Page 66 Continue until the number on the screen is identical to the gas concentration of the reference gas cylinder. When the number on the screen is identical to the gas concentration of the reference gas cylinder, press the OK button (B). The Verify Span screen (Figure 9-12) appears. Rosemount CT5100...
  • Page 67 Gas Calibration Procedures Figure 9-12: Verify span screen A. BACK button B. GO button C. HELP button D. CANCEL button Flow the reference gas, at a pressure of +.05 Bar Gauge, from the reference gas cylinder into the CT5100 CGA. Refer to Figure 9-12.
  • Page 68 H. RES (Reset) button If the reading is within tolerance, no further action is required. Press the DONE button (C) to end the span verification/calibration process. The display controller proceeds to the Calibration/verification complete screen (refer Figure 9-14 and Step 20). Rosemount CT5100...
  • Page 69 Gas Calibration Procedures Figure 9-14: Calibration/verification complete screen A. GAS button B. DONE button C. HELP button D. TYPE button If the reading is outside tolerance, press the RES (Reset) button (H). The CT5100 CGA returns to its factory-set calibration. Repeat steps 4-16 of this span calibration procedure to check that the CT5100 CGA is within tolerance.
  • Page 70 9-9). Repeat steps 9-20 for the next gas. If you are finished calibrating the CT5100 CGA, press the DONE button. The software returns to the Main menu shown in Figure 9-1. The span verification/calibration procedure is now complete. Rosemount CT5100...

  • Page 71: Chapter 10 Preventative Maintenance

    Preventative Maintenance Preventative Maintenance Topics covered in this chapter: • Maintenance • Schedule 10.1 Maintenance This section describes the preventative maintenance for the CT5100 CGA. 10.2 Schedule This schedule lists the tasks required by the CT5100 CGA and the recommended frequency.
  • Page 72 Preventative Maintenance Rosemount CT5100...
  • Page 73 Preventative Maintenance Operations Manual...
  • Page 74 Emerson Process Management The Emerson logo is a trademark and service mark of Emerson Glendevon House Electric Co. Rosemount is a mark of one of the Emerson Process Castle Business Park Management family of companies. All other marks are the property Stirling, FK9 4TZ of their respective owners.

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