Emerson Rosemount CT4215 Quick Start Manual
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Emerson Rosemount CT4215 Quick Start Manual

Emerson Rosemount CT4215 Quick Start Manual

Leak detection system
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Quick Start Guide
00825-0100-4245, Rev AB
July 2018
™
Rosemount
CT4215 Leak Detection System

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Summary of Contents for Emerson Rosemount CT4215

  • Page 1 Quick Start Guide 00825-0100-4245, Rev AB July 2018 ™ Rosemount CT4215 Leak Detection System...
  • Page 2 Emerson reserves the right to make changes without notice both to this publication and the products which it describes. Document number: 00825-0100-4245 Rev AB, July 2018 ©...
  • Page 3 To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. • When replacement parts are requried, ensure that qualified people use replacement parts specified 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.
  • Page 4 General safety notice/residual risk Installation, operation, and maintenance of the detector 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 This product is designed and manufactured under an approved quality manage- ment system to ISO 9001: 2008. Emerson and the detector have satisfied the requirements for applying the CE marking to the detector. This equipment meets all requirements of the EMC and Low Voltage directives.
  • Page 6 Safety and information notices This article is in accordance with IEC 60079-0: 2011 Clause 30. This article must not be changed amended or removed. 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.
  • 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 detector operates using mains voltage that is dangerous to life. Make sure that the circuit breakers are set to OFF and tagged off before removing the top cover or opening the front cover.
  • Page 8 The detector weighs 119 kg (268 lb.) and is designed to be floor mounted. It must be moved in accordance with local safety regulations. Emerson recommends that a minimum of two people using suitable tools for transportation and lifting are employed.
  • Page 9 This is because the repair, replacement, and alignment of the optical components requires the use of special optical testcalibration equipment and procedures. When an item is unserviceable, and no replacement procedure is given in this manual, Emerson must repair the fault.
  • Page 10 Symbols displayed on and inside the detector To minimize risk, labels displaying warning signs are fixed to the transmitter. You must understand their meaning, take suitable precautions, and read all instructions given in the accompanying manuals before conducting any operations. The following table gives examples and definitions of each symbol used.

  • Page 11: Table Of Contents

    Contents Contents Chapter 1 Equipment and accessories ....................1 Typical installation ......................... 1 System connections ........................2 Typical sample head ........................4 Air preparation plate ........................5 Upper enclosure ..........................6 Chapter 2 Installation ........................7 Installation requirements ....................... 7 Installation instructions ........................ 10 Chapter 3 Startup ...........................14 Chapter 4...
  • Page 12 Contents CT4215...

  • Page 13: Equipment And Accessories

    Equipment and accessories Equipment and accessories Typical installation ™ Figure 1-1 shows a typical installation for a Rosemount CT4215 on a food handling line. ™ Figure 1-1: Rosemount CT4215 Parts Sample head : draws air from around the packaged product into the measurement cell. Analysis cell: the laser beam and sample gas pass through here for analysis.

  • Page 14: System Connections

    Equipment and accessories System connections ™ Figure 1-1 shows a typical installation for a Rosemount CT4215 on a food handling line. Figure 1-2 shows the external connections of the packaged leak detection system. These are located at floor level on the rear of the unit. Figure 1-2: External Connections Ethernet...
  • Page 15 Equipment and accessories Table 1-1: External Connections Letter Designation Type Max rating Description Ethernet RJ45 Ethernet Communication with sensor Status, 24 Vdc (line stop) Bulgin 4P female 250 Vac/dc, 6 A Customer supplied 24 V signal when line is run- ™...

  • Page 16: Typical Sample Head

    Equipment and accessories Typical sample head The sample head is used to draw air from around the product and deliver it to the measurement cell. To ensure a high air flow rate, the sample head is connected to the leak detector using a ¾- in.

  • Page 17: Air Preparation Plate

    Equipment and accessories Air preparation plate The customer supplied compressed air is filtered to remove impurities and is pressure- regulated. The assembly shown in Figure 1-4 is mounted inside the leak detector control system cabinet. Figure 1-4: Compressed Air Preparation Plate Shut off valve Pressure regulator with 40 µm filter 0.1 µm filter...

  • Page 18: Upper Enclosure

    Equipment and accessories Upper enclosure The upper enclosure is accessible with an 8 mm Allen key and comprises the following components shown in Figure 1-5. The upper enclosure is the main area for maintenance access. Figure 1-5: Upper enclosure Measurement cell with insulating jacket Manual purge button Cell lid clamps Cell input mirror, directs laser into cell...

  • Page 19: Chapter 2 Installation

    > 176 °F (80 °C). ™ Emerson does not supply a switching system with the instrument. The customer must supply a suitably rated switch or circuit breaker to be included with this installation. Check the installation of the switch for conformity in accordance with national/local regulations and standards by inspection.
  • Page 20 Installation Figure 2-1: Line Installation Location Figure 2-2: Ground Fixing CT4215...
  • Page 21 Installation Figure 2-3: Installation of Reject Mechanism Figure 2-4: Sample Head Installation Quick Start Guide...

  • Page 22: Installation Instructions

    WARNING! LIFTING HAZARD The system weighs 268 lb. (119 kg). Beware of collision injury and topple injury when moving. ™ Emerson recommends using a forklift to move the system. WARNING! CRUSH HAZARD Be careful not to crush hands and feet when moving the system.
  • Page 23 Installation Figure 2-5: Line Installation Location Ground the instrument. a. Lower the feet to the ground. b. Raise the unit a few inches off the ground. c. Remove the wheel brackets. d. Lower the unit to the floor. e. Use the feet to level of unit if required. f.
  • Page 24 Installation Figure 2-6: Ground Fixing Refer to the fastener manufacturer's guide for fixing instructions and torque. g. Place the cap covers over the access holes. Attach the light gate to the track. a. Drill the location hole(s) into the track side faces in the approximate positions required for input gate.
  • Page 25 Installation Attach the reject mechanism. WARNING! DRILL INJURY Be careful to avoid injuring hands and eyes when drilling. Wear correct PPE at all times. a. Drill two location holes into the track side face in the approximate positions required for the reject mechanism. Use track location T slots if available (no drilling required).

  • Page 26: Chapter 3 Startup

    When production begins, turn the blower isolator to the ON position. NOTICE ™ Emerson recommends that the blower is switched off when the production line is not running. This will extend the lifetime of the sample air filter. Press the Reset button on the front of the console and ensure there is a green light on the beacon.

  • Page 27: Chapter 4 Operation

    Operation Operation The packaged Leak Detection System is designed to run autonomously with minimal user interaction required. After the startup procedure in Chapter 3, the system needs only a green light to run. There are up to three components mounted onto the packaged production line. The layout of the line is shown schematically in Figure 4-1.

  • Page 28: Leak Detector Manager (Ldm) Software

    Operation Leak detector manager (LDM) software The LDM software is designed to give clear information at-a-glance. Figure 4-2: LDM Home screen Start/Stop Monitoring: Automatically starts monitoring during startup. Pressing the button again will pause the system and stop measuring. Configure: Accesses the settings and parameters of the system and is password protected. Reset Alarms: Clears alarms and resets status alarms to green.
  • Page 29 Operation Figure 4-3: Concentration Tab Figure 4-3 shows the Concentration tab with one leaking package passing through. When the blue line reaches the upper threshold (red line), the sensor sends a rejection signal to the PLC and then the rejection solenoid to remove the faulty pack from the line. The lower threshold is typically approximately 80 percent of the upper threshold and prevents the system from missing a marginal leak.
  • Page 30 Operation Figure 4-4: UNIT Tab Figure 4-4 shows the UNIT tab when a leaking pack has passed through. The plot shows all data points between the input and output gate and records the size of the rejection spike. CT4215...

  • Page 31: Data Logging And Reporting

    Operation Data logging and reporting The system can store production statistics like packs processed and number of rejects. This can be transferred from the HMI on a USB stick to be analyzed elsewhere. To enable the Reporting screen, click the Reports tab. The Reporting screen is password protected, and the password will be supplied or changed during installation.
  • Page 32 Operation Figure 4-6: Sample Report File • Client/Product/Batch: These are entered during the creation of the log file. • Date/Time: The timestamp for each unit; this is set by the PC. • Leak (abs): The maximum concentration value for each unit. If this value is greater than the upper threshold, this package will be rejected.

  • Page 33: Status Lamps / Errors

    Operation Status lamps / errors There are a number of errors that the Leak Detection System monitors, which may occur during the normal operation of the system. The errors are displayed as an illuminated lamp on the front of the enclosure. All errors latch and are cleared by the RESET button on the front of the enclosure.
  • Page 34 Operation Figure 4-8: LDM Software Errors System Ready: Shows when the system is ready for use. This is red during system start up. System Healthy: The system can become unhealthy if the gate in/out count is different or if there have been n consecutive rejects (the default value is five consecutive rejects).

  • Page 35: Line Stop

    Operation Figure 4-9: Consecutive Rejects Error Line stop The control system provides a signal that can stop the production line if there are errors on the system. The signal is sent to the STATUS connector shown in Figure 1-2. The connection is a volt- free contact and can be configured in Normally Closed (NC) and Normally Open (NO) from a customer supplied 24 V.

  • Page 36: Plc Configuration Screen

    Operation PLC configuration screen CAUTION! EQUIPMENT DAMAGE The PLC settings directly control the analysis and rejection of defective containers. Only trained personnel should change the settings listed below. The PLC screen has password protection in order to prevent unauthorized access. The credentials are provided to the relevant department during installation.
  • Page 37 Operation Table 4-2: PLC Configuration Parameters Parameter name Description Range Pack Length The length of time a pack takes to pass 0 - 2000 ms the input gate. This timer is a de- bounce to prevent double counting of uneven packs. Measurement Start The delay between the pack passing 0 - 9000 ms...
  • Page 38 Operation CT4215...
  • Page 39 Operation Quick Start Guide...
  • Page 40 2018 Emerson. 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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