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Safety Precautions Operators, maintenance personnel, and authorized users must observe the following safety precautions and warnings. DANGER ELECTRIC SHOCK In accordance with IEC 60079-0: 2011 Clause 30. The analyzer 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.
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WARNING FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD In accordance with IEC 60079-0: 2011 Clause 30. Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or service. Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.
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WARNING HAZARDOUS SUBSTANCES The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution. Wear personal protective equipment (PPE) when handling the equipment. Gas handling components within the analyzer 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.
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The analyzer weighs 55 kg (121 lb.) and is designed to be wall mounted. It must be moved in accordance with local safety regulations, however, Emerson recommend that a minimum of two people using suitable tools for transportation and lifting are employed.
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WARNING EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE In accordance with IEC 60079-0: 2011 Clause 30. In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. Take suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area. Clean the device surface by gently wiping it with a damp or antistatic cloth only.
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EXPLOSION HAZARD In accordance with IEC 60079-0: 2011 Clause 30. Use only replacement parts and components authorized by Emerson. All replacement parts and components must be certified and approved for use in hazardous areas. Failure to comply will void certification and may cause an explosion or potentially hazardous situation, which if not avoided, may...
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WARNING EXPLOSION HAZARD BY BATTERY In accordance with IEC 60079-0: 2011 Clause 30. The analyzer contains a battery for data backup purposes. Under normal operating conditions there is no need to replace the battery during the analyzer life time. Battery replacement ™...
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Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this manual, then the fault must be repaired by Emerson.
Quick Start Guide Introduction D-7010-0055 August 2018 Introduction Site selection ™ The Rosemount CT5100(Ex) has a T3 temperature classification. The user must ensure that no combustible gas concentrations will be present, whether on a continual or occasional basis, which have an ignition temperature below the T3 rating of the analyzer. DANGER FIRE AND EXPLOSION The electrical compartment of the must not be opened unless the atmosphere in the area...
Introduction Quick Start Guide August 2018 D-7010-0055 Figure 1-1: Clearance with Door Open ™ Unpacking the Rosemount CT5100 (Ex) Continuous Gas Analyzer This procedure requires a minimum of two people to safely remove the equipment from the shipping container. Prerequisites WARNING LIFTING HAZARD The equipment weighs 55 kg (121 lbs.) and requires a two man lift.
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Quick Start Guide Introduction D-7010-0055 August 2018 WARNING TRANSPORTATION HAZARD Use safety approved lifting equipment. The user must ensure the equipment is tested, meets the lifting ratings for the weight of the equipment, and is in good operational condition. Failure to verify equipment meets the lifting ratings and is in good operational condition may cause injury to personnel or damage the equipment.
Introduction Quick Start Guide August 2018 D-7010-0055 Figure 1-2: Rosemount CT5100 (Ex)- Rear View Showing Lifting Eyes and 4 off Ø10.5 Mounting Holes 6. Place the Rosemount CT5100 (Ex) on a solid, level surface and prepare to wall mount the analyzer. Qualified personnel In-depth specialist knowledge is an absolute requirement for working with and on the analyzer.
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• Read all instructions prior to installing, operating, and servicing the product. • If you do not understand any of the instructions, contact your Emerson (Rosemount) representative for clarification. • Follow all warnings, cautions, and instructions marked on and supplied with the product.
Introduction Quick Start Guide August 2018 D-7010-0055 • 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. •...
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Quick Start Guide Introduction D-7010-0055 August 2018 Figure 1-3: Front View Dimensions A. Lifting eye bolt B. Sample gas input port C. Sample gas return port D. Lifting eye bolt E. 10.5 mm diameter mounting points F. Purge compressed air supply port 3.
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Introduction Quick Start Guide August 2018 D-7010-0055 8. In case extra security is required on the installation of the analyzer by thread locking the fittings, it should only be performed with compounds compatible with the zone classification of the installation location. 9.
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Quick Start Guide Introduction D-7010-0055 August 2018 16. To complete the installation the protector cap MUST be removed from the purge vent and the O-ring (E). The vent cap installed, locking in position with the grub screws. Refer to Figure 1-3.
Introduction Quick Start Guide August 2018 D-7010-0055 Figure 1-6: Clearance with Door Open Software version The analyzer includes software that is used to control the operation of the analyzer. This manual describes software version 5.7.13. ™ Rosemount CT5100 Ex...
Figure 2-1, the items supplied by Emerson are colored blue; the items supplied by you are colored purple. The green gas handling system may be provided by Emerson or you. Table 2-1 lists the main items of the system.
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5.7.13 Gas handling Customer Customer Choice system (optionally by or Emerson Emerson) Heated gas sample Customer Customer choice line hose Exhaust line hose Customer Customer choice (for sample gas) Reference gas...
Quick Start Guide Install D-7010-0055 August 2018 Table 2-1: Main Items of the Rosemount CT5100(Ex) Installation (continued) Item Name or Supplied by Part number Quantity Notes description Secondary circuit Customer Customer choice breaker Gas inputs and outputs About this task The analyzer has two gas inputs and one gas output.
Install Quick Start Guide August 2018 D-7010-0055 Figure 2-2: Gas Inlet and Outlet Connectors A. Sample gas return port B. Sample gas input port C. Top cover of Rosemount CT5100(Ex) (cell compartment) D. Purge air supply E. Laser/electrical compartment 3. The sample supply line must be heated all the way to the sample gas input port on the analyzer to prevent condensation forming at any point in the sample supply line.
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Quick Start Guide Install D-7010-0055 August 2018 Figure 2-3: Power Gland A. Purge Power and Alarm Entry Point B. Power Entry Point • A purge electrical and alarm supply that is used to power the overpressure facility in the electrical compartment of the analyzer. Refer to Figure 2-3 (Item A).
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Install Quick Start Guide August 2018 D-7010-0055 Figure 2-4: Power Entry Point Connections ™ Rosemount CT5100 Ex...
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Quick Start Guide Install D-7010-0055 August 2018 Figure 2-5: Purge Power and Alarm Entry Point Connections Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 2-6. The customer supplied power cable for the analyzer instrumentation will be connected to terminals 1 - 3.
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Install Quick Start Guide August 2018 D-7010-0055 For the electrical power wiring use 16 AWG stranded, 3 conductor copper or tin-plated copper power wire, rated for at least 250 Vac, of the required length. Cables must be terminated in the power entry points in accordance with local electrical codes. The full ™...
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Quick Start Guide Install D-7010-0055 August 2018 Figure 2-7: Signal Cable Outputs 2.3.5 Power input cables and circuit breakers WARNING FLAMMABLE/EXPLOSIVE GASES The purge / pressurization cycle expels any flammable or explosive gases from the electrical compartment and MUST be completed before applying electrical power to the rest of the analyzer.
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Install Quick Start Guide August 2018 D-7010-0055 • The main power input circuit breaker can now be SET to ON. • Check that the display controller lights up. The analyzer will then begin to power-up. 2.3.6 Temperature sensor and cell heater The sample cell is controlled to operate at a pre-set temperature.
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Quick Start Guide Install D-7010-0055 August 2018 2.3.11 Commissioning Once the sensor is fully installed as described above, it should be commissioned in accordance with the commissioning plan agreed between Emerson and the customer. Quick Start Guide...
Quick Start Guide Operating the analyzer D-7010-0055 August 2018 Operating the analyzer Front panel controls and indicators ™ The Rosemount CT5100(Ex) is configured from the two control displays located on the front panel. Refer to Figure 3-1. Figure 3-1: Front Panel A.
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Operating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 3-2: Exploded View A. Vent cap B. 3/32 in. socket grub screws C. Protector cap D. Purge vent E. O-ring The protector cap (Figure 3-2, C) must be removed from the purge vent (D) and replaced with the vented cap (A) supplied with the unit.
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Quick Start Guide Operating the analyzer D-7010-0055 August 2018 Figure 3-3: Display Controller Quick Start Guide...
Operating the analyzer Quick Start Guide August 2018 D-7010-0055 The purge control panel (Figure 3-4) is used to program the operation of the overpressure air system that prevents flammable and explosive gases from entering the electrical ™ compartment of the Rosemount CT5100(Ex).
Quick Start Guide Operating the analyzer D-7010-0055 August 2018 Figure 3-5: Display Controller Buttons A. LCD display B. Configurable button C. Scroll button D. Configurable button E. Configurable button F. Scroll button G. Configurable button The other four buttons (B, D, E, and G) are configured to perform different functions according to which the software screen is shown on the LCD display.
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Operating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 3-6: Gas Sensor Main Screen The Gas Sensor Main screen displays the gas concentration measurements obtained by the analyzer. In the example shown in Figure 3-6, the gases nitric oxide (NO), nitrogen dioxide ), oxygen (O ), carbon monoxide (CO), and carbon dioxide (CO ) are being measured,...
Quick Start Guide Operating the analyzer D-7010-0055 August 2018 Figure 3-7: Gas Sensor Main Screen Buttons A. MENU button B. MENU text C. PAGE text D. PAGE button E. HELP button F. HELP text G. STATUS button PAGE (C) is a link between the Gas Sensor Main screen and the Pressure and Temperature screen (described in Pressure and Temperature screen).
Operating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 3-8: Pressure and Temperature screen The reading is the pressure, in Torr, inside the analysis cell. NOTICE A Torr is a non-SI unit of pressure defined as 1/760 of standard atmospheric pressure and is equal to the fluid pressure of 1 mm of mercury.
Quick Start Guide Operating the analyzer D-7010-0055 August 2018 Main menu To access the Main menu (Figure 3-10), press the MENU button on either side of the Gas Sensor Main screen (Figure 3-6) or the Pressure and Temperature screen (Figure 3-8).
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Operating the analyzer Quick Start Guide August 2018 D-7010-0055 ™ Rosemount CT5100 Ex...
Quick Start Guide Start-up procedure D-7010-0055 August 2018 Start-up procedure Introduction CAUTION EQUIPMENT DAMAGE Always follow the start-up procedure. Damage to the may result from a failure to follow this procedure. The normally operates continuously. It should only be necessary to start up the analyzer under the following circumstances.
Start-up procedure Quick Start Guide August 2018 D-7010-0055 Opening the electrical compartment door To gain access to the electrical compartment and the components mounted on the inside of the door, open the door on the front of the as follows: Procedure Using an 8 mm Allen key loosen the compression screw (B) and cam latch screws (C) to unlock the door (A), then open the door.
Quick Start Guide Start-up procedure D-7010-0055 August 2018 Start-up About this task Note The gases shown in the screenshots and the measurements thereof may be different from ™ those shown in your particular Rosemount CT5100(Ex). They indicate the functionality of the software, which is the same regardless of the gases being measured.
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 Figure 4-2: Rosemount CT5100(Ex) Gas Inlet and Outlet and Electrical Connections A. Sample gas return port B. Sample gas input port C. Top cover of Rosemount CT5100(Ex) Continuous Gas Analyzer (cell compartment) D.
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Quick Start Guide Start-up procedure D-7010-0055 August 2018 9. Visually check that the vent cap is fitted to the purge vent (Figure 1-4). UNDER NO CIRCUMSTANCES must the analyzer be started with the protector cap fitted as this will prevent the analyzer from venting during the purge process. WARNING FLAMMABLE/EXPLOSIVE GASES The purge/pressurization cycle expels any flammable or explosive gases from the...
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 circuit breaker, turn off the compressed air supply, and report the fault to the maintenance organization. 13. Observe the P/SV LED (B) on the purge control panel. When the pre-set internal overpressure has been reached, the P/SV LED (B) illuminates orange.
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Quick Start Guide Start-up procedure D-7010-0055 August 2018 Results At the end of the start-up 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 start-up procedure is now complete.
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 NOTICE On/Off circuit breakers There are no On/Off switches on the analyzer. The application of electrical power to the analyzer is controlled through a customer provided 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 analyzer.
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Quick Start Guide Start-up procedure D-7010-0055 August 2018 CAUTION Under no circumstance MUST the top two buttons on the display controller be pressed simultaneously. This will override the system code supplied with the analyzer and display the default program screen for the controller. Figure 4-7: Default Program Screen This will lock the software controlling the Rosemount CT5100(Ex) requiring the analyzer to be shutdown externally and restarted risking a possible corruption of the software and loss...
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 Figure 4-8: Purge Control Panel 4.4.2 Gas sensor main screen When the analyzer is switched on, at the end of the start-up procedure, the Gas Sensor Main screen (Figure 4-9) appears. The Gas Sensor Main screen is the screen that is normally displayed.
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Quick Start Guide Start-up procedure D-7010-0055 August 2018 and for each gas, the concentration detected is in parts per million (ppm) or percentage as applicable. The NO reading is the total nitrogen oxide reading, a combination of nitric oxide (NO) and nitrogen dioxide (NO At the end of the start-up procedure, the gas measurements initially appear as 0.00 until the first readings are taken.
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 error message is displayed. Press the STATUS button to get further information on the error. 4.4.3 Pressure and temperature screen The Pressure and Temperature screen (Figure 4-11) shows pressure and temperature measurements taken inside the analyzer. Figure 4-11: Pressure and Temperature Screen The Cell reading is the temperature, in °C, of the analysis cell.
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Quick Start Guide Start-up procedure D-7010-0055 August 2018 4.4.4 Help system The analyzer software includes a context-sensitive help system. Press the HELP button, which is available on most of the software screens, to open the help system. The help system contains a number of different Help screens, each conveying a different message.
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Start-up procedure Quick Start Guide August 2018 D-7010-0055 4.4.6 BACK button On most of the software screens, the top left-hand button (Figure 4-14) is configured as a BACK button (A). Press the BACK button to return to the previous screen. Figure 4-14: BACK Button A.
Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Calibrating the analyzer Required tools ™ The gas concentrations measured by the Rosemount CT5100(Ex) can be validated against a known sample gas or calibrated to match it by using the following Gas Calibration procedure.
Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 CAUTION EQUIPMENT DAMAGE Under no circumstance MUST the top two buttons on the display controller be pressed simultaneously. This will override the system code supplied with the analyzer and display the default program screen for the controller. Figure 5-1: Default Program Screen This will lock the software controlling the Rosemount CT5100(Ex) requiring the analyzer to be shutdown externally and restarted risking a possible corruption of the software and loss...
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-2: Main Menu A. Gas service (calibration and maintenance options) B. SEL text C. SEL button D. Scroll up button E. Scroll up arrow F. Scroll down arrow G. Scroll down button Figure 5-3: Pressure and Temperature Screen 2.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-4: Gas Service (PER GAS) 5. Use the middle buttons ( and ) to scroll up or down to select PER GAS 6. Press the SEL button. Figure 5-5: Select Gas (NO) 7.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-6: Action Figure 5-7: Calibration 10. Using the LEFT, RIGHT, INCR (increase) and DECR (decrease) buttons to enter the desired offset (in the example above, -0.06ppm). 11. Press OK to confirm. The factory default offset is zero, and under normal circumstances, the offset should never be a positive number.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-8: Input Type Figure 5-9: Calibration 13. Using the LEFT, RIGHT, INCR (increase) and DECR (decrease) buttons to enter the desired offset (in the example above, 1.06ppm). 14. Press OK to confirm. The factory default span factor is one, and under normal circumstances, the offset should be between 0.8 and 1.2.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Press the SEL button. Figure 5-10: Main Menu (GAS SERVICE) 3. Use the middle buttons ( and ) to scroll up or down to select PER GAS. Press the SEL button. Figure 5-11: Gas Service Menu (PER GAS) 4.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-12: Select Gas (NO) 5. Use the middle buttons ( and ) to scroll up or down to select RUN ZERO. Figure 5-13: Action screen for NO (RUN ZERO) 6. Press the CAL button to calibrate, or the VER button to verify. Figure 5-14 displays as the calibration progresses.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Once complete the program will automatically open the Result screen (Figure 5-15). Figure 5-15: Result Screen 7. Press OK. The Verify next screen displays. Figure 5-16: Verify Next Step Screen 8. Press DONE to finish. •...
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 NOTICE Pressing the BACK button will cancel the procedure and return the user to the previous screen. 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press the SEL button.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-19: Select Gas (NO) 5. Use the middle buttons ( and ) to scroll up or down. Select RUN SPAN. Press the CAL button to calibrate, or the VER button to verify. Figure 5-20: Action (SPAN) 6.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-21: Calibration 8. Press OK to confirm. Once complete the program will automatically open Span Factor For NO (Figure 5-22). Figure 5-22: Span Input Note that if an excessively high or low span factor is calculated (<0.7 or > 1.3), for example if the calibration gas is a different concentration from that set above, it will be rejected and the previous span factor will be displayed and will continue to be used.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-23: Result 10. Press DONE to finish. Refer to Figure 5-24. Figure 5-24: Calibration Complete This completes the process and the display will return to the Main menu. 5.2.3 To calibrate all gases (zero and span) Prerequisites On systems with valve control, it is possible to run a calibration on all gases.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 NOTICE Pressing the BACK button will cancel the procedure and return the user to the previous screen. 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press the SEL button.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-27: Calibration On completion, the Finished screen (Figure 5-28) will display. Figure 5-28: Calibration (finished) 5. Press BACK. This completes the process and the display will return to the Main menu. 5.2.4 To change the automatic calibration settings Procedure...
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-29: Main Menu (GAS SERVICE) 3. Use the middle buttons ( and ) to scroll up or down to select CALIBR PARAMS or VERIFY PARAMS for validation settings). Press the SEL button. Figure 5-30: Gas Service (CALIBR PARAMS) 4.
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Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Figure 5-31: Calibr param (AUTO PERIOD) 5. To change the time and the units (days, hours, min and sec) between calibrations: Use the LEFT, RIGHT, INCR (increase) DECR (decrease) buttons to set the number and time interval.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-33: Calibr param (Purge time) 7. To change the time between opening the valve and performing the calibration: Use the LEFT, RIGHT, INCR (increase) DECR (decrease) buttons to set the number and time interval.
Quick Start Guide Calibrating the analyzer D-7010-0055 August 2018 Closing the electrical compartment door The procedure for closing and locking the door to the electrical compartment is the reverse of the opening procedure. CAUTION EQUIPMENT DAMAGE Do not start up or try to operate the unless it is physically secure and all electrical and pneumatic connections to the are in place.
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Calibrating the analyzer Quick Start Guide August 2018 D-7010-0055 Figure 5-35: Electrical Compartment Door A. Electrical compartment door B. 1 off compression latch C. 2 off cam latches 1. Close the electrical compartment door. 2. Using an 8 mm Allen key tighten the compression screw (B) and cam latch screws (C) to lock the door (A), See Figure 5-35.
Quick Start Guide Engineering Drawings D-7010-0055 August 2018 Engineering Drawings Engineering drawings ™ Use the wiring diagrams for the Rosemount CT5100(Ex) analyzer to assist with troubleshooting faults. These diagrams may be used to locate the position of a wiring connector should it become disconnected. Table A-1: List of Engineering Drawings Drawing number Description...
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