Emerson Rosemount CT5400 Installation, Operation And Maintenance Manual
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Emerson Rosemount CT5400 Installation, Operation And Maintenance Manual

Emerson Rosemount CT5400 Installation, Operation And Maintenance Manual

Continuous gas analyzer
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Installation, Operations, and Maintenance Manual
D-7010-0045, Rev C
January 2018
™
Rosemount
CT5400 Continuous Gas Analyzer

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Summary of Contents for Emerson Rosemount CT5400

  • Page 1 Installation, Operations, and Maintenance Manual D-7010-0045, Rev C January 2018 ™ Rosemount CT5400 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 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.
  • Page 4 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: •...
  • Page 5 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.
  • Page 6 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.
  • Page 7 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.
  • Page 8 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 Identification label (including serial num- Made in the UK Rear panel ber, model number, and USA FDA compli- Manufactured Sept. 2015 ance label Rosemount CT5400 Continuous Gas Analyzer Serial number: CT5400-10008 Model number: CT5400 Glendevon House Castle Business Park Stirling, FK9 4TZ United Kingdom Tel.
  • Page 12 Label type Example Location CAUTION Laser Radiation safety statement Rear panel AC power supply voltage label On analysis cell insulation AC power supply Danger label 1. Rear panel, above mains power input socket 2. On reverse of front panel, next to On/ Off switch AC power supply label Rear panel, below power socket...
  • Page 13 Abbreviations The following abbreviations are used in this manual. Abbreviation Description © 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 Methane Carbon monoxide Carbon dioxide...
  • Page 14 Abbreviation Description Liquid crystal display Light emitting diode 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 Nitrogen National Electrical Code NFPA National Fire Protection Association Nanometer Nitric oxide Nitrogen dioxide...
  • Page 15 Abbreviation Description WEEE Waste electrical and electronic equipment μm Micro-meter...

  • Page 17: Table Of Contents

    Contents Contents Chapter 1 Plan ..........................1 Description ..........................1 Equipment purpose and role ......................1 System overview ..........................2 Customer information ......................... 4 Safety precautions and conditions for safe use ................5 Qualified personnel ........................6 Software version .......................... 6 Gas detection ..........................6 Detailed system specifications .....................
  • Page 18 Scheduled maintenance ......................145 Appendices and reference Appendix A Theory of Operation ....................147 Overview ..........................147 Quantum Cascade Laser measurement principle ..............147 Process analyzer - gas concentration measurements ............... 148 Appendix B Spare parts list ......................149 Rosemount CT5400...
  • Page 19 Contents Appendix C Engineering Drawings ....................151 Engineering drawings ......................151 Installation, Operations, and Maintenance Manual...
  • Page 20 Contents Rosemount CT5400...

  • Page 21: Chapter 1 Plan

    The Rosemount CT5400 Continuous Gas Analyzer, hereafter referred to as the Rosemount CT5400 or the analyzer, is an electronic sensor that uses laser spectroscopy to perform analysis of process gas streams. The function of the analyzer is to detect and measure up to twelve different types of gas at concentrations ranging from parts per million (ppm) to percentage levels in the process gas stream.

  • Page 22: System Overview

    System overview A complete Rosemount CT5400 system consists of a gas handling system, the analyzer, and the associated interconnecting wiring and gas piping. Measurement data from the analyzer can be displayed in the process control center. You must provide the gas handling system and interconnecting wiring and gas piping;...
  • Page 23 Section 1.9 before entering the analyzer. Detailed characteristics of the analyzer are also given in Section 1.9. Table 1-1: Main Items of the Rosemount CT5400 System Item Name or description Supplied by Part number Quantity Notes...

  • Page 24: Customer Information

    Quick Start Guide (D-7010-0052). 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 25: Safety Precautions And Conditions For Safe Use

    Conditions for safe use • This equipment has flamepaths which differ from those in IEC60079-1/EN 60079-1. Cascade Technologies, Ltd (qcl.csc@emerson.com) must be contacted for guidance when maintaining the flamepaths. • The fasteners which secure the cover are non-standard and shall therefore only be replaced by fasteners supplied by the manufacturer for this purpose.

  • Page 26: Qualified Personnel

    Emerson or its distribution partners can provide this training on request. Knowledge of the safety information within this manual and its technically correct implementation are prerequisites for danger-free installation, operation, and maintenance of the analyzer.
  • Page 27 Plan Table 1-2: Physical Characteristics Rosemount CT5400 Value Units Comment External dimensions 482.6 x 673 x 221.5 Length x Width x Height 19 x 26.5 x 8.7 Nominal dimensions Weight Approximate weight 68.34 Table 1-3: General Characteristics Rosemount CT5400 Value...
  • Page 28 Dimensions - Side View Handle swings out 63 mm (2.5 in.) 2 off telescopic slide, 610 mm (24 in.) long, 55 kg (121.3 lb.) max load. 50.8 mm (2 in.) over travel. 9.6 mm (.4 in.) slide thickness. Lock-out. Front disconnect. Rosemount CT5400...
  • Page 29 Plan Figure 1-5: Dimensions - Top View Ventilation. Do not obstruct. Table 1-4: Environmental Characteristics Environmental characteristic Value Units Comment Operating temperature range 0 to 45 °C Ambient temperature 32 to 113 °F Sample gas temperature range 50 to 195 °C Factory set, specify on order 122 to 383...

  • Page 30: Optical Description

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 31 Plan Figure 1-6: Front View Showing Lifting Handles A. Front panel left-side handle B. Front panel right-side handle Figure 1-7: Rear View Showing Lifting Handle A. Rear panel handle Place the analyzer on a solid, level surface and prepare to rack mount the analyzer. Installation, Operations, and Maintenance Manual...
  • Page 32 Plan Rosemount CT5400...

  • Page 33: Chapter 2 Install

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.

  • Page 34: Rack Mounting The Analyzer

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 35 Install Figure 2-2: Top and Bottom View - Ventilation A. Top ventilation holes B. Bottom ventilation holes Figure 2-3: Rear View - Ventilation and Handle A. Rear ventilation holes B. Rear panel handle Inspect the analyzer and ensure the unit is correctly mounted in the rack and glides easily on the telescoping slide rails.

  • Page 36: Gas Inputs And Outputs

    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. Rosemount CT5400...

  • Page 37: Connecting The Electrical/Electronic Inputs And Outputs

    Install Connecting the electrical/electronic inputs and outputs Figure 2-5: Electrical / Electronic Connectors Ethernet connector Ventilation holes Sample supply (stainless steel tubing) Sample return (stainless steel tubing) Main power supply Analog outputs (4-20 mA) Digital outputs Status output (10 way connector) Electrical/electronic signal connections to the analyzer are made through electrical connectors located on the rear panel of the instrument, as shown in Figure...
  • Page 38 The results of the gas analysis are output from the instrument through the 4-20 mA analog outputs (Figure 2-5, F) and sent to your process control center. Rosemount CT5400...

  • Page 39: Commissioning The Analyzer

    3 m (9.8 ft.) may cause injury to personnel. Commissioning the analyzer Once the analyzer is fully installed as described, it should be commissioned according to local government regulations and the commissioning plan agreed upon between you and Emerson. Installation, Operations, and Maintenance Manual...
  • Page 40 Install Rosemount CT5400...

  • Page 41: Chapter 3 Startup Procedure

    Always follow the startup procedure. Damage to the Rosemount CT5400 may result from a failure to follow this procedure. The Rosemount CT5400 normally operates continuously. It should only be necessary to start up the instrument under the following circumstances. •...

  • Page 42: Startup Procedure

    On the front panel (Figure 3-1) of the analyzer, set the On/Off switch (B) to I (ON). Check that the switch illuminates. Figure 3-1: Front panel A. Display controller B. Illuminated On/Off switch The startup sequence commences automatically under software control. Rosemount CT5400...
  • Page 43 Startup procedure After a few seconds, the Gas Sensor Main screen (Figure 3-2) appears on the display controller. If it does not, report the fault to the maintenance organization. Figure 3-2: Gas Sensor Main screen Start up the system for returning the sample gas. Start up the gas handling system that conditions the sample gas before it is fed into the analyzer.
  • Page 44 Startup procedure Rosemount CT5400...

  • Page 45: Operating The Analyzer

    Operating the analyzer Operating the analyzer Introduction This section describes the normal operation of the analyzer and how to use the display controller located on the front panel of the analyzer. NOTICE The gas concentrations shown in the following screenshots may be different from those shown in your particular analyzer.

  • Page 46: Front Panel Controls And Indicators

    Front panel controls and indicators There are two controls located on the front panel (Figure 4-3): the display controller (A) and the illuminated On/Off switch (B). Rosemount CT5400...
  • Page 47 Operating the analyzer Figure 4-3: Front panel Display controller Illuminated On/Off switch The front panel On/Off switch (Figure 4-3, B) controls the application of electrical power to the electronic circuits inside the instrument. On the switch, I identifies the On position and O identifies the Off position.

  • Page 48: Rear Panel Controls

    On/Off switch. The function of the rear panel On/Off switch is to control the application of electrical power to the complete instrument. Figure 4-5: Rear Panel On/Off switch - fused socket Display controller Figure 4-6: Front Panel Display Controller LCD display Navigation buttons Rosemount CT5400...
  • Page 49 Operating the analyzer You can control the analyzer through six navigation buttons (Figure 4-6, B) on the display controller. The LCD display (A) can be used to display: Gas concentration measurements obtained Operating temperature and pressure Help screens Step-by-step calibration Diagnostics The navigation buttons (B) are configured to perform different functions according to which software screen is shown on the LCD display.

  • Page 50: Gas Sensor Main Screen

    Gas Sensor Main screen (Figure 4-7) and the Pressure and Temperature screen (Figure 4-8). Press to toggle between the two screens. is a link to the Help system. Press to go to a Help screen (described in Section 4.8). Rosemount CT5400...

  • Page 51: Pressure And Temperature Screen

    Operating the analyzer On the Gas Sensor Main screen, has no function when the analyzer is operating correctly. If, however, the software detects a fault, an error message is displayed. Press to get further information on the error. Pressure and Temperature screen The Pressure and Temperature screen (Figure 4-8) shows pressure and temperature...

  • Page 52: Main Menu

    SYSTEM: Takes you to a screen that allows you to shut down the analyzer or access system information, such as software versions or IP addresses. The main motherboard IP address can also be changed from this menu. Some of these options are not available on older analyzers. Rosemount CT5400...

  • Page 53: Back Button

    Operating the analyzer Figure 4-10: Main menu 4.10 BACK button On most of the software screens, is configured as a BACK button. Press to return to the previous screen. Installation, Operations, and Maintenance Manual...
  • Page 54 Operating the analyzer Rosemount CT5400...

  • Page 55: Verifying Gas Concentrations

    Verifying Gas Concentrations Verifying Gas Concentrations Verification Verification flows the known gas concentration through the analyzer and gives you a display of the measurement, the cylinder value, and the difference between the two. You can use verification to confirm that the analyzer is within tolerance. If it is out of tolerance, perform a calibration (see Section 6.3).
  • Page 56 The Select Type screen (Figure 5-2) opens. Figure 5-2: Select Type Screen to move the cursor until the ZERO verification option is selected, as shown in Figure 5-2. To perform a verification, press The Manual/Automatic screen (Figure 5-3) opens. Rosemount CT5400...
  • Page 57 Verifying Gas Concentrations Figure 5-3: Manual/Automatic Screen Press for manual verification. Press for automatic verification. NOTICE Pressing will automatically allow configuration verification in a future release of GasSensor-3 software. The Verify Zero screen (Figure 5-4) opens. Figure 5-4: Verify Zero Screen Allow the concentrations to stabilize and wait for two minutes after stabilization.
  • Page 58 If the reading is outside tolerance, the instrument should be zero calibrated. Refer to Section 6.3.1. In either case, press to return to the Calibration / Verification Complete screen (Figure 5-6). Figure 5-6: Calibration / Verification Complete Screen Rosemount CT5400...

  • Page 59: Span Verification

    Verifying Gas Concentrations To perform a zero verification for another gas, press The software returns to the Select gas screen (Figure 5-1). Repeat the actions in steps 6-13 for the next gas. To perform a span verification, press . Then follow the span verification procedure in Section 5.1.2.
  • Page 60 Main menu Press The Select gas screen (Figure 5-8) opens. Figure 5-8: Select gas Screen to move the cursor until the gas that you wish to span verify is selected. Press The Select Type screen (Figure 5-9) opens. Rosemount CT5400...
  • Page 61 Verifying Gas Concentrations Figure 5-9: Select Type screen until the SPAN verification option is selected, as shown in Figure 5-9. To perform a verification, press The Mode selection screen opens (Figure 5-10) for manual or automatic verification. Figure 5-10: Mode selection Screen Press for manual verification.
  • Page 62 NOTICE The cylinder concentration must be entered in ppm. Press to proceed to the next step. The Verify span screen (Figure 5-12) opens. Figure 5-12: Verify span Screen Rosemount CT5400...
  • Page 63 Verifying Gas Concentrations Press to cancel the manual verification. Press to finish. Repeat steps 5-9. Press for automatic verification. This opens the valve (where applicable) and flows the span gas. Allow the concentrations to stabilize and wait for two minutes after stabilization. This screen gives a reading of the concentration of the selected gas that is present, as measured by the instrument.
  • Page 64 If you wish to perform a zero verification, press . Then follow the zero verification procedure in Section 5.1.1. If you are finished verifying the analyzer, press The software returns to the Gas Sensor Main screen (Figure 4-7). The span verification procedure is now complete. Rosemount CT5400...

  • Page 65: Gas Calibration Procedures

    Gas Calibration Procedures Gas Calibration Procedures Required tools To calibrate the analyzer, you need the following items: • Nitrogen gas of instrument gas purity for use as a zero calibration gas • Suitable span calibration gases for each gas measured •...

  • Page 66: Calibration

    Connect an excess flow line to the unused port on the T-piece and route the excess flow line to a suitable extractor. On the display controller of the analyzer, browse to the Main menu as described in Section 4.9. Rosemount CT5400...
  • Page 67 Gas Calibration Procedures Figure 6-2: Main menu Using ,select GAS SERVICE. Press The Select gas screen (Figure 6-3) opens. Figure 6-3: Select gas Screen to move the cursor until the gas that you wish to zero calibrate is selected. Press The Select Type screen (Figure 6-4) opens.
  • Page 68 ZERO calibration option is selected (see Figure 6-4). To perform a calibration, press The Mode selection screen (Figure 6-5) opens. Figure 6-5: Mode selection Screen Press for manual calibration. Press for automatic calibration. The Calibrate zero screen (Figure 6-6) displays. Rosemount CT5400...
  • Page 69 Gas Calibration Procedures Figure 6-6: Calibrate zero Screen Press to confirm. The Result screen (Figure 6-7) displays. Figure 6-7: Result Screen Press to finish the process. Allow the concentrations to stabilize and wait for two minutes after stabilization. This screen gives a reading of the concentration of the selected gas that is present as an impurity in the nitrogen calibration gas, as measured by the instrument.
  • Page 70 The automatic re-calibration of the instrument's zero point starts, and the offset shown on the screen (-0.852 ppm (vol) in Figure 6-8) is applied to the instrument. Press the UP or DOWN button to abort the calibration process. When the calibration is complete, Figure 6-9 is displayed. Rosemount CT5400...

  • Page 71: Span Calibration

    Gas Calibration Procedures Figure 6-9: Calibration Complete Screen Press to display the Calibrate gas screen (Figure 6-4) and perform a span calibration on the same gas (see Section 6.3.2). Press to perform a zero calibration for another gas. The software Select gas screen (Figure 5-1) displays.
  • Page 72 Press The Select type screen (Figure 6-11) opens. Figure 6-11: Select Type Screen to move the cursor until SPAN is selected (Figure 6-11). To perform a calibration, press The Mode selection screen (Figure 6-12) opens. Rosemount CT5400...
  • Page 73 Gas Calibration Procedures Figure 6-12: Mode selection screen Press to perform a manual calibration. The Span input screen (Figure 6-13) opens. Figure 6-13: Span input Screen to highlight each digit in turn; then use to increase or decrease the value until the concentration displayed matches the cylinder you are using.
  • Page 74 If the reading is outside tolerance, press ENTER The analyzer returns to its factory-set calibration. Allow a minute to ensure the readings are stable. If the reading is now within tolerance, no further action is required. Press to abort the span calibration process. Rosemount CT5400...
  • Page 75 Gas Calibration Procedures If the calibration of the analyzer remains outside of tolerance, you can adjust the calibration by pressing This brings up a Calibrate screen (Figure 6-16). Figure 6-16: Calibrate - re-calibrate with New ZERO offset screen To proceed with the automatic re-calibration, press The automatic re-calibration of the instrument's span calibration starts, and the offset shown on the screen (in Figure 6-17...

  • Page 76: Reference Gas - Suggested Concentration Ranges

    . The software returns to the Main menu shown in Figure 6-2. Reference gas - suggested concentration ranges Calibration gas ranges are recommended to be between 80% and 100% of the full range of the analyzer. Please contact Emerson if you require assistance. Rosemount CT5400...

  • Page 77: Troubleshooting And Diagnostics

    Emerson. All other items must be repaired or replaced by the manufacturer. You can gain access to repairable and replaceable parts by removing the top and or bottom covers of the analyzer.
  • Page 78 The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.

  • Page 79: Using The Built-In-Test (Bit) Fault Diagnostics

    Troubleshooting and diagnostics 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.
  • Page 80 Pressure and Temperature Screen When the analyzer is running correctly, the STATUS displays Running and OK (see Figure 7-1). If a fault is detected the STATUS display in the bottom left-hand corner of the screen changes from OK to a flashing Rosemount CT5400...
  • Page 81 Troubleshooting and diagnostics Figure 7-3: Fault Status - Analyzer Running Screen If the analyzer stops the STATUS changes to Stopped, and OK changes to a ?. Figure 7-4: Fault Status - Analyzer Stopped From either the Gas sensor main screen (see Figure 7-1) or the Pressure and Temperature screen (see...
  • Page 82 Faults Screen - No Faults Detected If the faults are identified by the BIT, the display controller indicates the fault. The precise data displayed varies depending upon where the fault has occurred in the analyzer. Figure 7-7: Faults Detected Screen Rosemount CT5400...
  • Page 83 Troubleshooting and diagnostics Press to list the fault listed. Press to display the Fault diagnostic information screen. Figure 7-8: Cell heater Temperature Out of Range Examine the data shown on the Fault screen to determine if the suspect component has failed or is operating outside of its correct parameters. If you do not have the necessary information to determine if the suspect component is faulty, contact your local Customer Care representative.

  • Page 84: Visual Examination

    Customer Care representative. Visual examination A visual examination of the analyzer is recommended as the next step in failure diagnosis if the BIT fails to identify the problem. Rosemount CT5400...

  • Page 85: Failure Diagnostics

    Troubleshooting and diagnostics 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.
  • Page 86 One gas read- Refer to step 4. out invalid. Single gas read- Check which Any gas. Check fault Fault reading Use Fault to ac- ing invalid. gas. reading. active. cess further di- agnostic infor- mation; con- tact Cascade Technologies, Ltd. Rosemount CT5400...
  • Page 87 Troubleshooting and diagnostics Table 7-1: Functional failure diagnostics table (continued) Recommen- Step Symptom Test Result ded actions Result Cause Fault reading Unknown. not displayed. Contact Cas- cade Technolo- gies, Ltd. Analysis cell Adjust inlet Pressure re- No further ac- Pressure re- Pressure was pressure out of valve to...

  • Page 88: Repairable Items

    Troubleshooting and diagnostics Repairable items The major items that are repairable without Emerson's assistance are listed in Spare parts list. In all cases, the repair is by direct replacement of the faulty item with a known serviceable item purchased from Emerson . If any items other than those listed require service, Emerson must perform the repair.

  • Page 89: Removing The Top Cover

    Troubleshooting and diagnostics Table 7-2: Required Tools (continued) 5.0 mm Hex Socket (Allan key) 7.0 mm Spanner 8.0 mm Spanner 14 mm Spanner 16 mm Spanner Small snap on ratchet Small flat blade screwdriver (used for wiring terminals) Multi-meter - used to perform continuity checks on electrical wiring during an inspection. Control drawing Wiring diagrams - Appendix C...
  • Page 90 The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.
  • Page 91 Troubleshooting and diagnostics Figure 7-12: Removing the Top Cover Top cover M5 x 12 mm button head socket screws (4) Chassis assembly M5 flat washers (4) Procedure Set the ON/OFF switches on the front and back panel to OFF. Allow the analyzer to cool for at least two hours. Allow it to cool for twelve hours if replacing the analysis cell.

  • Page 92: Removing The Bottom Cover

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.

  • Page 93: Replacing The Lcd Display

    Troubleshooting and diagnostics Refer to Figure 7-13 and proceed as follows: Figure 7-13: Removing the Bottom Cover Bottom cover M5 x 12 mm button head socket screws (4) M5 flat washers (4) Procedure Set the ON/OFF switches on the front and back panel to OFF. Allow the analyzer to cool for at least two hours.
  • Page 94 ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 95 Make sure the display bezel seal is present and free from cuts. Unpack and visually inspect the replacement LCD display for damage. If damage has occurred, contact your local Emerson Customer Care Representative. Insert the display into the front panel.

  • Page 96: Replacing The Usb Circuit Board

    The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.
  • Page 97 Troubleshooting and diagnostics WARNING! BURNS Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down. Some parts of the analyzer may be heated to 190 °C (374 °F).
  • Page 98 Earth Ground Connection A. Earth lead B. M4 nut C. Tag connector D. Threaded spacer (front panel part) E. USB circuit board F. M4 flat washer G. M4 spring washer Disconnect the USB cable (F) from the USB PCB (A). Rosemount CT5400...
  • Page 99 Troubleshooting and diagnostics Figure 7-16: Removing the USB PCB A. USB PCB B. Threaded spacer (part of front panel) C. M4 flat washer D. M4 spring washer E. M4 nut F. USB cable Remove and retain the three nuts (E), spring washers (D), and flat washers (C). Remove the USB PCB.

  • Page 100: Replacing The Power Socket Fuses

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 101 Troubleshooting and diagnostics WARNING! BURNS Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down. Some parts of the analyzer may be heated to 190 °C (374 °F).

  • Page 102: Replacing The Internal Fuses

    Start up the analyzer by turning the ON/OFF switches to the ON position. 7.12 Replacing the internal fuses The analyzer contains a number of internal fuses. The same procedure is used to replace all of the internal fuses; therefore, the replacement of only one is described. Rosemount CT5400...
  • Page 103 Troubleshooting and diagnostics 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.
  • Page 104 1 A, 250 V, 5 x 20 mm, fast-acting Line heater controllers No tools are required to remove the fuse. Place a finger on the catch at the top of fuse holder and lift up the upper part of the fuse holder. Rosemount CT5400...
  • Page 105 Troubleshooting and diagnostics Figure 7-19: Fuse block sub-assembly (fuse holder partially opened) WARNING! ELECTRIC SHOCK Only replace fuses with fuses of the same type and rating. Failure to do so may result in personal injury. Refer to Figure 7-20. Fully raise the upper part of the fuse holder (B) and then push out the old fuse (A).
  • Page 106 Table 7-3 and make sure that the fuse is of the correct type and rating. Lower the upper part of the fuse holder, ensure that it clicks into place when fully lowered. Remove the Lock-Out /Tag-out tag . Rosemount CT5400...

  • Page 107: Replacing The Fans

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 108 Remove and retain the nuts, spring washers, and flat washers (D, E, and F). Remove and retain the fan finger guard (A). Remove and discard the unserviceable fan (B). Examine the replacement fan for damage. If it is damaged, contact your local Emerson Customer Care representative. Rosemount CT5400...

  • Page 109: Replacing The Terminal Electric Cooler (Tec) Board

    The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.
  • Page 110 B. Ribbon cable connector C. TEC board D. Spacer E. M3 flat washer F. M3 spring washer G. M3 x 6 mm socket head cap screw H. Ribbon cable to Motherboard Wiring harness Wiring harness to USB port K. Motherboard Rosemount CT5400...
  • Page 111 Troubleshooting and diagnostics Disconnect the wiring harness (I) from the TEC Board (C). A wiring harness to the USB port (J) obstructs the removal of the TEC Board. Disconnect the wiring harness (J) from the motherboard (K). Remove and retain the four screws (G) and associated spring washers (F), flat washers (E), and spacers (D) that secure the TEC Board to the mounting plate (A).

  • Page 112: Replacing The Peripheral Pca Board

    The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.
  • Page 113 Troubleshooting and diagnostics Figure 7-23: Peripheral PCA Board A. Peripheral PCA board B. Gas/cell temperature monitoring harness C. Gas/cell temperature monitoring harness D. Gas/cell temperature monitoring harness E. Wiring harness to cell heater relay F. Ribbon cable to motherboard G. Wiring harness to fan A H.
  • Page 114 Refit the top cover as described in Section 7.25. Reinstall the analyzer in the rack. This step requires two people to properly lift and transport it to the rack. Remove Lock-Out Tag-Out labels. Apply power to restart the analyzer. Rosemount CT5400...

  • Page 115: Replacing The Motherboard

    Troubleshooting and diagnostics 7.16 Replacing the motherboard Complete the following steps to replace the motherboard. Observe all safety precautions before starting this procedure. 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.
  • Page 116 P. 12 V power in connector J16 Q. 12 V power input wiring harness R. 12 V power output wiring harness S. Laser module ribbon cable T. Serial port wiring harness U. HMI display wiring harness V. Connector J22 Rosemount CT5400...
  • Page 117 Troubleshooting and diagnostics On the motherboard, disconnect the TEC board ribbon cable (I) from connector J12 (E). Disconnect the USB wiring harness (H) from the USB connector J21 (J). Disconnect the TRIGGER OUT wiring harness (L) from connector J32 (K). Disconnect the laser module ribbon cables (S) from the motherboard.

  • Page 118: Replacing The Din Rail

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 119 Troubleshooting and diagnostics WARNING! BURNS Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down. Some parts of the analyzer may be heated to 190 °C (374 °F).
  • Page 120 Discard the unserviceable analog input unit. Inspect the replacement unit for damage. If damage has occurred, contact your local Emerson Customer Care Representative. Insert the replacement analog input unit in its correct location on the DIN rail. Press the small lever on the underside of the unit and push the unit onto the DIN rail.

  • Page 121: Replacing The Dc Power Supply

    The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment. Wear suitable protective gloves and protective footwear.

  • Page 122: Replacing The Temperature Controller

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 123 Troubleshooting and diagnostics WARNING! BURNS Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down. Some parts of the analyzer may be heated to 190 °C (374 °F).

  • Page 124: Replacing The Ethernet Switch

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 125 Troubleshooting and diagnostics WARNING! BURNS Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down. Some parts of the analyzer may be heated to 190 °C (374 °F).
  • Page 126 Remove the analyzer from the rack using two people to lift the analyzer and place it on a clean workbench. On the Ethernet switch (B), disconnect the Ethernet cable that links the Ethernet switch to the analog input unit from Ethernet connector number 1 (A). Rosemount CT5400...

  • Page 127: Replacing The Laser Modules

    Troubleshooting and diagnostics Disconnect the Ethernet cable that links the Ethernet switch to the external Ethernet port from Ethernet connector number 4 (C). Disconnect the Ethernet cable that links the Ethernet switch to the motherboard from Ethernet connector number 5 (D). Disconnect the wiring harness (E) from the Ethernet switch.
  • Page 128 All the laser modules are physically identical, but are NOT interchangeable as they differ in internal settings. Each laser module is a sealed unit and can only be repaired by Emerson. Repair therefore consists of removing the unserviceable laser module and returning it to Emerson for repair.
  • Page 129 Troubleshooting and diagnostics Figure 7-28: Removing a Laser Module A. Base plate B. Pin C. Laser module D. Captive screw E. Ribbon cable F. Captive screw Inspect the replacement laser module for damage. Fit the replacement laser module in position on the base plate (A). The laser module must mate with the two locating pins (B) on the Base Plate.

  • Page 130: Replacing The Gas Temperature Sensor

    7-29, use your fingers to push inwards the insulation around the analysis cell until the tube fitting (A) is exposed. Release the tube fitting (A) and slide it up the gas temperature sensor thermocouple (C). Remove the thermocouple and tube fitting. Rosemount CT5400...
  • Page 131 Troubleshooting and diagnostics Figure 7-29: Replacing the gas temperature sensor A. Stainless steel 316 male connector, Let-Lok tube fitting, 6 mm x male ISO tapered thread 1/4 B. Gas temperature sensor wiring harness C. Gas temperature sensor thermocouple Inspect the replacement gas temperature sensor thermocouple (C) and associated tube fitting (A) for signs of damage.

  • Page 132: Replacing The Pressure Sensor

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.
  • Page 133 Troubleshooting and diagnostics Refer to Figure 7-30. Carefully cut the two cable ties that secure the insulation (A) in position. Remove and retain the insulation. Figure 7-30: Pressure sensor A. Insulation B. M3 x 6 mm countersunk socket head screw C.

  • Page 134: Replacing The Thermal Cut-Out

    Tag or otherwise identify all wiring harnesses before disconnecting. Refer to Figure 7-31. Open up the insulation around the analysis cell. Pull open the two side flaps (B and D) and the two end flaps (C); then fold out the top insulation (A). Rosemount CT5400...
  • Page 135 Troubleshooting and diagnostics Figure 7-31: Opening the analysis cell insulation A. Top insulation B. Insulation side flap C. Insulation end flaps D. Insulation side flap Refer to Figure 7-32. Pull the insulation (E) away from the side of the analysis cell (B). Installation, Operations, and Maintenance Manual...
  • Page 136 Discard the unserviceable thermal cut-out. Inspect the replacement thermal cut-out for damage. If damage has occurred, contact your local Emerson Customer Care representative. Route the wiring harness (F) through the hole in the side of the insulation (E). Using a soldering iron with a rating of 35 Watts or less, solder the wiring harness to the terminals of the thermal cut-out (A).

  • Page 137: Replacing The Gas Input Line

    Troubleshooting and diagnostics Figure 7-33: Insulated analysis cell Refit the top cover as described in Section 7.25. Reinstall the analyzer in the rack. This step requires two people to properly lift and transport to the rack. Apply power to restart the analyzer. 7.21 Replacing the gas input line Replacing the gas input line.
  • Page 138 E. Stainless steel 316 tube adapter, tube stub 6 mm x male ISO tapered thread 1/4 in. (gas in, gas out) SS-6-MTA-1-4RT F. Analysis cell insulation Inspect the gas input line for damage. If it is damaged, contact your local Customer Care representative. Rosemount CT5400...

  • Page 139: Replacing The Gas Output Line

    Troubleshooting and diagnostics Refer to Figure 7-34. Use your fingers to push the analysis cell insulation (F) inwards until the port for the gas input line is exposed. Fit the gas input line (B) to the analysis cell and secure and seal the joint with the tube adapter (E). Apply a small quantity of Loctite 567 liquid PTFE compound to the threads of the tube adapter before it is fitted.
  • Page 140 It is only necessary to disconnect the wiring harness (F) from the gas output line if the gas output line is being replaced. If the gas output line is being removed to gain access to other components, do not disconnect the wiring harness. Rosemount CT5400...

  • Page 141: Replacing The Analysis Cell

    Troubleshooting and diagnostics If necessary, disconnect the wiring harness (F) from the gas output line. Inspect the gas output line for damage. Refer to Figure 7-35. If necessary, connect the wiring harness (F) to the gas output line (H). Use your fingers to push the analysis cell insulation (D) inwards until the port to the gas output line is exposed.
  • Page 142 Refer to Figure 7-37. Remove and retain the four M6 x 20 mm socket head cap screws (D) and associated M6 spring washers (B) and M6 flat washers (C). Lift the analysis cell (A) off the optical baseplate. Rosemount CT5400...
  • Page 143 Troubleshooting and diagnostics Figure 7-37: Removing the analysis cell A. Analysis cell (in insulation) B. M6 spring washer C. M6 flat washer D. M6 x 20 mm socket head cap screw Inspect the replacement analysis cell for damage. If damaged, contact your local Customer Care representative.

  • Page 144: Cleaning The Analysis Cell Mirrors

    Remove and retain the four screws attaching the top cover to the chassis. Open the insulation around the analysis cell. Pull open the two side flaps (B and D) and the two end flaps (C) and then fold out the top insulation (A). Rosemount CT5400...
  • Page 145 Troubleshooting and diagnostics Figure 7-38: Opening the analysis cell insulation A. Top insulation B. Insulation side flap C. Insulation end flaps D. Insulation side flap Using a 2.5 mm Allen wrench, remove and retain the six socket head cap screws and associated spring washers and flat washers that secure the lid on the cell;...
  • Page 146 Insulated analysis cell Refit the top cover as described in Section 7.25. Reinstall the analyzer in the rack. This step requires two people to properly lift and transport it to the rack. Apply power to restart the analyzer. Rosemount CT5400...

  • Page 147: Installing The Top Cover

    ™ The analyzer weighs 31 kg (68 lb). Emerson recommends that the analyzer is only moved and lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.

  • Page 148: Downloading Data For Diagnostics And Service

    (hierarchical data format) HDF5 format log file. The data is not used by operators or maintainers of the analyzer. Send the data to Emerson; we can analyze the data to monitor the health of the analyzer and to debug any faults.
  • Page 149 Troubleshooting and diagnostics Figure 7-40: Gas Sensor Main Screen Note The gas concentrations shown in the screenshots may be different from those shown on your particular analyzer. They indicate the functionality of the software, which is the same regardless of the gases or gas concentrations being measured.
  • Page 150 Troubleshooting and diagnostics Insert a USB Flash Drive into the USB port on the analyzer's front panel. Figure 7-42: USB Access Port A. USB flash drive access port Press The Service menu screen displays. Rosemount CT5400...
  • Page 151 Troubleshooting and diagnostics Figure 7-43: Service Menu Screen Scroll to USB DATA DUMP using The USB Dump routine checks that a USB Flash Drive is correctly fitted to the USB port on the on the front panel. If there is no USB Flash Drive in the USB port or the USB flash drive is not fitted correctly, an error message displays.
  • Page 152 Release USB Flash Drive If, for any reason it is necessary to repeat the data download, then press either the USB Dump - Dump finished screen (see Figure 7-45) or USB Dump - USB released screen (see Figure 7-46). Rosemount CT5400...

  • Page 153: Downloading Data Using Tftp

    Troubleshooting and diagnostics 7.27.2 Downloading data using TFTP Trivial File Transfer Protocol (TFTP) data download is performed under the control of the analyzer software, using TFTP routines built into the software. Prerequisites To download the data by TFTP, you must have a laptop computer that has been set up to a suitable IP address and has the required software (PuTTY) and (TightVNC Viewer) installed.
  • Page 154 Troubleshooting and diagnostics Figure 7-48: Main menu to scroll to DATA SERVICE. Figure 7-49: DATA SERVICE menu Press The Service Menu screen displays. Rosemount CT5400...
  • Page 155 Troubleshooting and diagnostics Figure 7-50: Service Screen Connect a laptop to the Ethernet port on the rear panel of the analyzer (A). Figure 7-51: Electrical/Electronic Connectors A. Ethernet connector B. Ventilation holes C. Sample supply (stainless steel tubing) D. Sample return (stainless steel tubing) E.
  • Page 156 From the Service Menu screen, use to scroll to TFTP TRANSFER. Press The TFTP Dump screen displays. Figure 7-52: TFTP Dump Screen Press to start the TFTP data transfer. The TFTP Dump Progress screen displays. Figure 7-53: TFTP Transfer Progress Screen Rosemount CT5400...
  • Page 157 Troubleshooting and diagnostics When the data download completes, the TFTP Transfer Successful screen displays. Figure 7-54: TFTP Transfer Successful Screen Installation, Operations, and Maintenance Manual...
  • Page 158 Troubleshooting and diagnostics Rosemount CT5400...

  • Page 159: Chapter 8 Shutdown Procedure

    Shutdown procedure Shutdown procedure Shutdown procedure safety precautions This chapter describes the analyzer's shutdown procedure. CAUTION! EQUIPMENT DAMAGE Always follow this shutdown procedure. Damage to the analyzer may result from a failure to follow this procedure. The analyzer normally operates continuously. It should only be necessary to shut down the instrument in the following circumstances: •...

  • Page 160: Shutdown Procedure

    Always lock out or tag off the calibration gas supply and compressed air supply when shutting down the analyzer. Rosemount CT5400...
  • Page 161 Shutdown procedure Turn off the calibration gas supply to the analyzer. Lock-out and tag-out the compressed air supply. Press on the display controller in either the Gas Sensor Main screen (Figure 8-1) or the Pressure and Temperature screen (Figure 8-2). Figure 8-1: Gas Sensor Main Screen Figure 8-2:...
  • Page 162 SYSTEM as shown in Figure 8-3. Then press The System screen (Figure 8-4) opens. Figure 8-4: System Shutdown Screen to select SHUTDOWN as shown in Figure 8-4. Then press The Shutdown screen (Figure 8-5) displays. Rosemount CT5400...
  • Page 163 Shutdown procedure Figure 8-5: Shutdown Screen Press to confirm. The analyzer displays the Shutdown screen (Figure 8-6) and then stops running. Figure 8-6: Shutdown Screen Once the heartbeat icon stops blinking, it is safe to power off the analyzer. Installation, Operations, and Maintenance Manual...
  • Page 164 Shutdown procedure Rosemount CT5400...

  • Page 165: Chapter 9 Preventative Maintenance

    Preventative maintenance Preventative maintenance Maintaining the analyzer This section describes the preventative maintenance of the analyzer. Scheduled maintenance This schedule lists the tasks required by the analyzer and the recommended frequency. Variation in customer sites may require these activities to be performed more or less often than indicated.
  • Page 166 Preventative maintenance Rosemount CT5400...

  • Page 167: Appendix A Theory Of Operation

    Theory of Operation Appendix A Theory of Operation Overview ™ The Rosemount CT5400 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. The analyzer can be configured to detect and measure up to twelve gases, with ranges varying from volume to percent (%) volume levels.

  • Page 168: Process Analyzer - Gas Concentration Measurements

    On exiting the analysis cell, the light is detected by a receiver unit. 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 CT5400...

  • Page 169: Appendix B Spare Parts List

    Spare parts list Appendix B Spare parts list Part number Description P-5000-0953 Serial text (data) display, general purpose, panel mounting M-3000-0754 5000 laser module right-angle output (Type A) M-3000-1133 5000 laser module right-angle output (Type B) M-3000-0914 CT5400 cell assembly P-5000-1443 Schurter001.1009 fuse, fast-acting, ceramic, 5.1 A M-1000-2468...
  • Page 170 Table B-1: 2 year recommended spare parts list (continued) Part number Part description Recommended quantity P-5000-0938 Temperature controller P-5000-0415 Thermostat P-5000-0900 Temperature sensor P-5000-0366 Temperature sensor P-5000-0924 Relay P-5000-0310 P-5000-1443 Fuse 3.15 A P-5000-0264 240 V cartridge heater Rosemount CT5400...
  • Page 171 These diagrams may be used to locate the position of a wiring connector should it become disconnected. Engineering drawings Table C-1: Engineering drawings Drawing number Description W-2000-0028 (Sheets 1-3) Rosemount CT5400 wiring diagram for 19 in. rack mount unit Installation, Operations, and Maintenance Manual...
  • Page 172 Engineering Drawings Rosemount CT5400...
  • Page 173 THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE SHEET DESCRIPTION: CASCADE TECHNOLOGIES LTD DO NOT SCALE PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON GLENDEVON HOUSE-CASTLE BUSINESS PARK BALLOON I.D. NO. PROCESS MANAGEMENT AND CANNOT BE COPIED, COMMUNICATED DO NOT ALTER CT5400 19"...
  • Page 174 THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE SHEET DESCRIPTION: CASCADE TECHNOLOGIES LTD DO NOT SCALE PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON GLENDEVON HOUSE-CASTLE BUSINESS PARK BALLOON I.D. NO. PROCESS MANAGEMENT AND CANNOT BE COPIED, COMMUNICATED DO NOT ALTER CT5400 19"...
  • Page 175 THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE SHEET DESCRIPTION: CASCADE TECHNOLOGIES LTD DO NOT SCALE PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON GLENDEVON HOUSE-CASTLE BUSINESS PARK BALLOON I.D. NO. PROCESS MANAGEMENT AND CANNOT BE COPIED, COMMUNICATED DO NOT ALTER CT5400 19"...
  • Page 176 2017 Rosemount. All rights reserved. youtube.com/RosemountMeasurement The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a google.com/+RosemountMeasurement mark of one of the Emerson family of companies. All other marks are the property of their AnalyticExpert.com respective owners.

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