Emerson Rosemount CT5100 Reference Manual
  1. Manuals
  2. Brands
  3. Emerson Manuals
  4. Measuring Instruments
  5. Rosemount CT5100
  6. Reference manual
Emerson Rosemount CT5100 Reference Manual

Emerson Rosemount CT5100 Reference Manual

Continuous gas analyzer
Hide thumbs Also See for Rosemount CT5100:
Table of Contents

Advertisement

Quick Links

Download this manual
Reference Manual
00809-0100-4511, Rev AA
May 2020
™
Rosemount
CT5100
Continuous Gas Analyzer

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Rosemount CT5100 and is the answer not in the manual?

Questions and answers

Related Manuals for Emerson Rosemount CT5100

Summary of Contents for Emerson Rosemount CT5100

  • Page 1 Reference Manual 00809-0100-4511, Rev AA May 2020 ™ Rosemount CT5100 Continuous Gas Analyzer...
  • Page 2 Published by Emerson. All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no liability for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further enhancements while in service may mean that the manual does not reflect your particular system.
  • Page 3 All users must read this page before proceeding! Emerson designs, manufactures and tests its products to meet many national and international standards. The Rosemount CT5100 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.
  • Page 4 Rosemount CT5100 Quick Start Guide Compliance approvals Important The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY. This product complies with USA 21 CFR 1040.10. This product is designed and manufactured under an approved quality management system to ISO 9001: 2015.
  • Page 5 The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and maintenance personnel, must observe the following safety precautions and warnings. The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY. WARNING ELECTRIC SHOCK The analyzer operates using mains voltage, which may cause death or serious injury to personnel.
  • Page 6 Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test. Use only replacement parts and components authorized by Emerson. All replacement parts and components must be certified and approved for use in hazardous areas.
  • Page 7 WARNING FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD 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. Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or service.
  • Page 8 OPTICAL RADIATION EXPOSURE HAZARD There are three types of laser that may be included in the Rosemount CT5100: Quantum Cascade Lasers (QCLs), Interband Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are Class 1. The characteristics of the lasers contained within the analyzer are given in the table below.
  • Page 9 WARNING HAZARD BY WRONG INPUT VOLTAGE Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the installation. 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.
  • Page 10 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.

  • Page 11: Table Of Contents

    6.1 Front panel controls and indicators.................... 57 6.2 Display controller........................58 6.3 Gas Sensor Main screen......................58 6.4 Pressure and Temperature screen....................60 6.5 Help system..........................61 6.6 Main menu..........................62 6.7 BACK button..........................62 Chapter 7 Start-up procedure....................63 7.1 Introduction..........................63 Rosemount CT5100...
  • Page 12 12.11 Replace the 10 Amp solid state relay..................131 12.12 Replace the Ethernet connector...................131 12.13 Replace the laser module.....................132 12.14 Replace the detector module....................134 12.15 Replacing the O detector....................135 12.16 Replace the main terminal board..................138 12.17 Replace the mains power filter.....................139 Emerson.com/Rosemount...
  • Page 13 12.20 Replace the PT100 cell temperature sensor................. 142 12.21 Cleaning the cell mirrors...................... 145 12.22 Spare parts list........................150 Chapter 13 Preventative maintenance..................153 13.1 Cleaning the analyzer......................153 13.2 Maintaining the analyzer......................154 13.3 Scheduled maintenance......................154 Appendix A Engineering drawings.................... 155 Rosemount CT5100...
  • Page 14 Contents Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 15: Chapter 1 Introduction

    May 2020 Introduction Description The Rosemount CT5100 Continuous Gas Analyzer, referred to hereafter as the Rosemount CT5100, 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 10 different types of gas at concentrations ranging from parts per million (ppm) to percentage levels in the process gas stream.

  • Page 16: Qualified Personnel

    Software version The analyzer includes software that is used to control the operation of the analyzer. This manual describes the software version as: 5.7.13. Emerson.com/Rosemount...

  • Page 17: Glossary And Abbreviations

    For example European Community Electromagnetic compatibility European Union Hours Hertz Water Interband Cascade Laser International Electro-technical Commission Inches Ingress protection IPxx Ingress protection (xx are numbers that define the protection level) Intrinsically safe International Organization for Standardization Thousand Kilogram Rosemount CT5100...
  • Page 18 Nanometer Ammonia Nitric oxide Nitrogen dioxide Nitrous oxide Number Oxygen Personal computer Preventative maintenance Parts per million Pounds per square inch Quantum Cascade Laser Tunable Diode Laser Torr Unit of pressure defined as exactly 1/760 of a standard atmosphere Emerson.com/Rosemount...
  • Page 19 Reference Manual Introduction 00809-0100-4511 May 2020 Abbreviation Description UKAS United Kingdom Accreditation Service United States of America Universal serial bus Volt Volt-ampere Volt alternating current Volt direct current Watt WEEE Waste electrical and electronic equipment µm Micro-meter Rosemount CT5100...
  • Page 20 Introduction Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 21: Theory Of Operation

    Theory of operation Overview The Rosemount CT5100 is a gas sensor system that can be configured to measure the concentrations of multiple small molecules carried in the gas sample. The types of molecules that are measured depend on the system configuration.
  • Page 22 Theory of operation Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 23: Chapter 3 Description

    System overview A complete Rosemount CT5100 system consists of a gas handling system, the analyzer, and the associated interconnecting wiring and gas piping. The customer MUST provide the gas handling system and interconnecting wiring and gas piping.
  • Page 24 Figure 3-2, the items supplied by Emerson are colored blue; the items supplied by the customer are colored purple. The green gas handling system may be provided by Emerson or the customer.

  • Page 25: Gas Inputs And Outputs

    Reference Manual Description 00809-0100-4511 May 2020 Table 3-1: Main Items of the Rosemount CT5100 Installation Item Name or description Supplied by Part number Quantity Notes Rosemount CT5100 Emerson Rosemount CT5100 Rosemount CT5100 software Emerson N/A. Software is Version package, version 5.x.x.
  • Page 26 Figure 3-3: Gas Inlet and Outlet Connectors A. Sample gas return port B. Sample gas input port C. Top cover of Rosemount CT5100 (cell compartment) D. Laser/electrical compartment Procedure 1. The gas sample that is to be measured for impurities enters the analyzer through...

  • Page 27: Connecting The Electrical/Electronic Inputs And Outputs

    Connecting the electrical/electronic inputs and outputs CAUTION If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Rosemount CT5100...
  • Page 28 Electrical/electronic signal connections to the analyzer are made through three electrical entry points located on the underside of the analyzer, as shown in Figure 3-4. Use the wiring diagram to make the electrical connections as shown in Engineering drawings Figure 3-5. Emerson.com/Rosemount...
  • Page 29 H. Digital output terminals I. Analog or digital output terminals J. Analog output terminals K. Status outpput terminals L. Mains input terminals Table 3-2: Rosemount CT5100 System Wiring User Connections Terminal Function Sensor system supply (L) Sensor system supply (N)
  • Page 30 Description Reference Manual May 2020 00809-0100-4511 Table 3-2: Rosemount CT5100 System Wiring User Connections (continued) Terminal Function Digital output 10 Digital output 11 Digital output 12 Analog output 1 Analog output 2 Analog output 3 Analog output 4 Analog output 5...

  • Page 31: Optical Description

    By measuring and analyzing the light detected by the receiver unit, it is possible to accurately determine the concentrations of the target molecules within the gas sample cell. Rosemount CT5100...
  • Page 32 Description Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 33: Chapter 4 Specifications

    Figure 4-1 Figure 4-2. Table 4-2 gives the general characteristics of the analyzer. Table 4-1: Physical Characteristics Rosemount CT5100 Value Comment External dimensions 22.64 x 11.73 x 28.11 in. Length x width x height 575 x 298 x 714 mm...
  • Page 34 Specifications Reference Manual May 2020 00809-0100-4511 Table 4-2: General Characteristics (continued) Rosemount CT5100 Value Units Comment Near IR source Interband Cascade Laser Diode Laser Laser classification Class 1 BS EN 60825-1: 2007 safety of laser products. Equipment classification and requirements (identical to IEC 60825-1 2007) ¼...
  • Page 35 Reference Manual Specifications 00809-0100-4511 May 2020 Figure 4-1: Rosemount CT5100 Dimensions - Front View Dimensions are in inches (mm). A. Lifting eyelet B. Ventilation C. User interface Rosemount CT5100...
  • Page 36 Specifications Reference Manual May 2020 00809-0100-4511 Figure 4-2: Rosemount CT5100 Dimensions - Top View Dimensions are in inches (mm). A. Lifting eyelet B. Sample return C. Sample inlet Emerson.com/Rosemount...
  • Page 37 Reference Manual Specifications 00809-0100-4511 May 2020 Figure 4-3: Rosemount CT5100 Dimensions - Bottom View Dimensions are in inches (mm). A. Cable glands B. Earth point Table 4-3: Environmental Characteristics Environmental characteristic Value Units Comment Operating temperature range -4 to 131 °F...
  • Page 38 Specifications Reference Manual May 2020 00809-0100-4511 Table 4-3: Environmental Characteristics (continued) Environmental characteristic Value Units Comment Sensor humidity range 10 to 95 Relative humidity (non- condensing) at 113 °F (45 °C) Emerson.com/Rosemount...

  • Page 39: Safety And System Labels And Annotation

    1. Back plate 2. Top right inside of door Ratings label Enclosure side panel Laser radiation CAUTION label Baseplate Laser module identification label On each laser module housing Intrinsically safe label 1. HMI 2. Intrinsically safe sensor barrier Rosemount CT5100...
  • Page 40 Earth identification label Back plate Manufacturer's label On analysis cell heater block Electrical safety label On inside of electrical compartment door AC Power Supply Danger label 1. On outside of electrical compartment door 2. On manifold block of air overpressure system Emerson.com/Rosemount...

  • Page 41: Chapter 5 Install

    Install Site selection The Rosemount CT5100 has a T3 temperature classification which specifies the maximum surface temperature of the analyzer. Ensure that no combustible gas concentrations will be present, whether on a continual or occasional basis, which have an ignition temperature below the T-rating of the analyzer.
  • Page 42 Install Reference Manual May 2020 00809-0100-4511 Figure 5-1: Clearance with Door Open Dimensions are in inches (mm). A. Door open B. Door closed C. Door opening arc Emerson.com/Rosemount...

  • Page 43: Unpacking

    The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/moving equipment. Emerson recommends that a minimum of two people using suitable tools for transportation and lifting are employed.

  • Page 44: Mounting The Analyzer

    7. Ensure that the analyzer is stored in its protective plastic cover until installation. Mounting the analyzer This procedure requires two people to safely move and mount the Rosemount CT5100. Procedure 1. Ensure that there is free space around the analyzer to allow ventilation of the upper part of the analyzer.
  • Page 45 The analyzer weighs 117 lb. (53 kg). Emerson recommends that a minimum of two people move and lift the analyzer. Wear suitable protective gloves and protective footwear. Rosemount CT5100...
  • Page 46 A. Lifting eye bolt B. Sample gas input port C. Sample gas return port D. Lifting eye bolt E. 0.413-in. (10.5 mm) diameter mounting bolts 3. One person should carefully guide the equipment while the other person operates the lifting equipment. Emerson.com/Rosemount...
  • Page 47 6. Remove the lifting eyes and retain them for future use. Threads must be protected with a suitable grease and plastic grommets. After mounting, do not place any additional load on the analyzer. Do not place or leave loose items on flat surfaces. Rosemount CT5100...
  • Page 48 Install Reference Manual May 2020 00809-0100-4511 Figure 5-3: Mounting Details Dimensions are in inches (mm). A. Mounting points Emerson.com/Rosemount...

  • Page 49: Connecting The Electrical/Electronic Inputs And Outputs

    B. Door closed C. Door opening arc Connecting the electrical/electronic inputs and outputs 5.4.1 AC power Power is connected to the analyzer instrumentation through the power entry point (A) fitted to the base of the analyzer. Refer to Figure 5-5. Rosemount CT5100...
  • Page 50 Install Reference Manual May 2020 00809-0100-4511 Figure 5-5: Power Gland A. Power and signal/exit points B. M6 earth stud The customer supplied circuit breaker, complete with RCD, must be in accordance with local and national standards. Emerson.com/Rosemount...
  • Page 51 Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 5-7. The customer supplied power cable for the analyzer instrumentation will be connected to terminals 1 - 3. Rosemount CT5100...
  • Page 52 Table 5-3: Fuse Requirements Fuse Function Rating Schurter part number Live line 110/240 Vac 3.15 A, 240 V, fast 0001.1009 (following mains filter) acting ceramic Neutral line 110/240 3.15 A, 240 V, fast 0001.1009 Vac (following mains acting ceramic filter) Emerson.com/Rosemount...
  • Page 53 The signal cables are connected to the system through conduit outlets (B and C as shown Figure 3-4). All signal cables are to be minimum 20 AWG tri-rated switchgear cable. Customer supplied conduit and cables are to be terminated in the conduit outlets in accordance with local and national electrical codes. Rosemount CT5100...
  • Page 54 Table 5-4: System Wiring Terminal Function Sensor system supply (L) Sensor system supply (N) Earth Digital output 1 Digital output 2 Digital output 3 Digital output 4 Digital output 5 Digital output 6 Digital output 7 Digital output 8 Emerson.com/Rosemount...
  • Page 55 5.4.6 Temperature sensor and cell heater The sample cell is controlled to operate at a pre-set temperature when it leaves the factory. With the analyzer on, the cell will reach the pre-set operating temperature in approximately 90 minutes. Rosemount CT5100...
  • Page 56 5.4.10 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. Emerson.com/Rosemount...

  • Page 57: Controls And Display Controller

    Controls and display controller 00809-0100-4511 May 2020 Controls and display controller Front panel controls and indicators The Rosemount CT5100 is configured from the control display located on the front panel. Refer to Figure 6-1. Figure 6-1: Front Panel A. Display controller...

  • Page 58: Display Controller

    Controls and display controller Reference Manual May 2020 00809-0100-4511 Display controller The six buttons on the display controller control operation of the Rosemount CT5100: Figure 6-2. Figure 6-2: Display Controller Buttons A. LCD display B. Configurable button C. Scroll up button D.
  • Page 59 6-3, the analyzer is Running and OK (e.g., no faults have been identified). This area Figure of the display shows any errors detected by the software. On the software screens, highlighted items are links to other screens in the software. To access a screen, press the button next to the highlighted item. Rosemount CT5100...

  • Page 60: Pressure And Temperature Screen

    If, however, the software detects a fault, an error message is displayed. Press STATUS to get further information on the error. Pressure and Temperature screen The Pressure and Temperature screen (Figure 6-5) shows pressure and temperature measurements taken inside the analyzer. Emerson.com/Rosemount...

  • Page 61: Help System

    As the help system is context-sensitive, the Help screen that appears is the one that is most appropriate to the software function engaged when HELP was pressed. Figure shows an example of a Help screen. Figure 6-6: Example of a Help Screen Rosemount CT5100...

  • Page 62: Main Menu

    Figure 6-7: Main Menu BACK button On most of the software screens, the top lefthand button (Figure 6-8) is configured as a BACK button. Press BACK to return to the previous screen. Figure 6-8: BACK Button A. BACK button Emerson.com/Rosemount...

  • Page 63: Start-Up Procedure

    • When the analyzer has been switched off as part of a plant shutdown or maintenance Preparation for use Install and fully commission the Rosemount CT5100 before starting it up. WARNING BURN HAZARD Personal injury and/or damage to property may result if these safety precautions are not observed.

  • Page 64: Start-Up Procedure

    Start-up procedure NOTICE The gases shown in the screenshots and the measurements thereof may be different from those shown in your Rosemount CT5100. They indicate the functionality of the software, which is the same regardless of the gases being measured. NOTICE To stop the start-up procedure at any time, set the main circuit breaker to OFF.
  • Page 65 The control PC that forms part of the analzyer is configured to automatically load the necessary gas sensor software and configuration files. The software automatically starts the start-up sequence. After a few seconds, the Gas Sensor Main Screen appears on the display controller. Rosemount CT5100...
  • Page 66 At the end of the start-up procedure, that 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. Emerson.com/Rosemount...

  • Page 67: Front Panel Controls And Indicators

    The circuit breaker is a simple two-pole ON/OFF circuit breaker that must be set to ON to permit the safe operation of the analyzer. The display controller primarily controls operation of the analyzer (Figure 7-4). Rosemount CT5100...
  • Page 68 It is essential that only trained, qualified personnel operate the controls on the analyzer. Figure 7-5: Default Program Screen Emerson.com/Rosemount...

  • Page 69: Operating The Analyzer

    The analyzer is usually only switched off for maintenance. During normal operation, either the Gas Sensor Main screen (Figure 8-1) or the Pressure and Temperature screen (Figure 8-2) is shown on the display controller. To toggle between these two screens, press PAGE.. Rosemount CT5100...
  • Page 70 Operating the analyzer Reference Manual May 2020 00809-0100-4511 Figure 8-1: Gas Sensor Main Screen Figure 8-2: Pressure and Temperature Screen Emerson.com/Rosemount...

  • Page 71: Chapter 9 Shutdown Procedure

    When handling the analyzer, always use suitable protective gloves. If you receive a burn, seek medical treatment immediately. Rosemount CT5100...

  • Page 72: Shutdown Procedure

    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). 3. Turn off the gas used to purge the analyzer. Emerson.com/Rosemount...
  • Page 73 4. Press MENU on the display controller in either the Gas Sensor Main screen (Figure 9-1) or the Pressure and Temperature screen (Figure 9-2). Figure 9-1: Gas Sensor Main Screen Figure 9-2: Pressure and Temperature Screen The Main menu (Figure 9-3) opens. Rosemount CT5100...
  • Page 74 5. On the display controller, select System as shown in Figure 9-3. 6. Press SEL (select). The System screen opens. Refer to Figure 9-4. Figure 9-4: System Screen A. BACK button B. SELECT button C. Scroll up button D. HELP button E. Scroll down button Emerson.com/Rosemount...
  • Page 75 8. Press YES. The analyzer shuts down. 9. Set the external secondary circuit breaker to Off. Lock-out and tag-out the secondary circuit breaker. 10. Set the external main circuit breaker to Off. Lock-out and tag-out the main circuit breaker. Rosemount CT5100...
  • Page 76 Shutdown procedure Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 77: Chapter 10 Gas Calibration

    This will lock the software controlling the analyzer requiring the analyzer to shut down externally and restart, risking a possible corruption of the software and loss of the analyzer operation during the shutdown and restart process. It is essential that only trained, qualified personnel operate the controls on the analyzer. Rosemount CT5100...

  • Page 78: Main Menu Calibration Routines

    1. To get the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or Pressure and Temperature screen (Figure 10-3). NOTICE Press BACK to cancel the procedure and return to the previous screen. Figure 10-2: Gas Sensor Main Screen Emerson.com/Rosemount...
  • Page 79 Figure 10-4: Main Menu Use the Main menu (Figure 10-4) to access the software routines and screens necessary for this process. 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Rosemount CT5100...
  • Page 80 4. Use the middle buttons ( and ) to scroll up or down to select PER GAS. 5. Press SEL. Figure 10-6: Select Gas (NO) 6. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g., NO). 7. Press SEL. Emerson.com/Rosemount...
  • Page 81 The factory default offset is zero, and under normal circumstances, the offset should never be a positive number. If it is shown as positive, press LEFT until the space to the left of the number is highlighted, then select INCR to change it to a minus (–) sign. Rosemount CT5100...
  • Page 82 Procedure 1. To get to the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or the Pressure and Temperature screen (Figure 10-3). Note To cancel the procedure, press BACK to return to the previous screen. Emerson.com/Rosemount...
  • Page 83 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press SEL. Figure 10-11: Main Menu (GAS SERVICE) 3. Use the middle buttons ( and ) to scroll up or down to select PER GAS. Press SEL. Figure 10-12: Gas Service Menu (PER GAS) Rosemount CT5100...
  • Page 84 4. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g., NO). Press SEL. Figure 10-13: Select Gas (NO) 5. Use the middle buttons ( and ) to scroll up or down to select RUN ZERO. Figure 10-14: Action Screen for NO (RUN ZERO) Emerson.com/Rosemount...
  • Page 85 Gas calibration 00809-0100-4511 May 2020 6. Press CAL to calibrate, or VER to verify. Figure 10-15 displays as the calibration progresses. Figure 10-15: Calibration Once complete, the program will automatically open the Result screen . Figure 10-16: Result Screen Rosemount CT5100...
  • Page 86 1. Gas Sensor MainTo get to the Main menu, press the MENU button on the screen (Figure 10-2) or the Pressure and Temperature screen (Figure 10-3). Note To cancel the procedure and return to the previous screen, press BACK. Emerson.com/Rosemount...
  • Page 87 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press SEL. Figure 10-18: Main Menu (GAS SERVICE) 3. Use the middle buttons ( and ) to scroll up or down to select PER GAS. Press the SEL button. Figure 10-19: Gas Service (PER GAS) Rosemount CT5100...
  • Page 88 Gas calibration Reference Manual May 2020 00809-0100-4511 4. Use the middle buttons ( and ) to scroll up or down to select the desired gas (e.g. NO). Press SEL. Figure 10-20: Select Gas (NO) Emerson.com/Rosemount...
  • Page 89 5. Use the middle buttons ( and ) to scroll up or down. Select RUN SPAN. Press CAL to calibrate, or VER to verify. Figure 10-21: Action (RUN SPAN) The Calibration screen show as the calibration progresses. Figure 10-22: Calibration Rosemount CT5100...
  • Page 90 8. Press OK. The Result screen displays. Figure 10-24: Result Emerson.com/Rosemount...
  • Page 91 1. To get to the Main menu, press MENU on the Gas Sensor Main screen (Figure 10-2) or the Pressure and Temperature screen (Figure 10-3). NOTICE To cancel the procedure and return to the previous screen, press BACK. Rosemount CT5100...
  • Page 92 Gas calibration Reference Manual May 2020 00809-0100-4511 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press SEL. Figure 10-26: Main Menu (GAS SERVICE) Emerson.com/Rosemount...
  • Page 93 The system will work through the zero and span calibration process for all readings. The Please wait screen will be displayed. This takes approximately one minute per gas depending on the purge time. Figure 10-28: Calibration The Finished screen displays when the zero and span calibration processes complete. Rosemount CT5100...
  • Page 94 10-3). NOTICE To cancel the procedure and return to the previous screen, press BACK. 2. Use the middle buttons ( and ) to scroll up or down to select GAS SERVICE. Press SEL. Figure 10-30: Main Menu (GAS SERVICE) Emerson.com/Rosemount...
  • Page 95 This section applies to systems configured to perform automatic calibration at timed intervals only. 4. To adjust the frequency of automatic calibration, use the middle buttons ( and ) to scroll up or down 5. Select AUTO PERIOD. 6. Press SEL. Figure 10-32: Calibr param (AUTO PERIOD) Rosemount CT5100...
  • Page 96 9. To adjust the length of time for the span gas to flush the cell, use the middle buttons ( and ) to scroll up or down and select PURGE TIME. Figure 10-34: Calibr param (PURGE TIME) 10. Press SEL. Emerson.com/Rosemount...
  • Page 97 May 2020 11. To change the time between opening the valve and performing the calibration, use the LEFT, RIGHT, INCR (increase), and DECR (decrease) buttons to set the number and time interval. Figure 10-35: Purge Time 12. Press OK. Rosemount CT5100...
  • Page 98 Gas calibration Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 99: Troubleshooting And Diagnostics

    Similarly, if the BIST detects a fault and the Pressure and Temperature screen (Figure 11-2) is being displayed, the STATUS display in the bottom left-hand corner of the screen will change from OK to flashing the word FAILURE. Rosemount CT5100...
  • Page 100 Controls and display controller provides details of how to use the controls on the display controller and functions of the BACK and HELP buttons. 2. You can also access the FAULTS menu through the Main Menu (Figure 11-3) as follows: Emerson.com/Rosemount...
  • Page 101 B. SEL text C. SEL button D. Scroll Up button E. Scroll Up arrow F. Scroll Down arrow G. Scroll Down button b) Using the Scroll Up button (D) and Scroll Down button (G), select FAULTS. Refer to Figure 11-3. Rosemount CT5100...
  • Page 102 Troubleshooting and diagnostics Reference Manual May 2020 00809-0100-4511 c) Press SEL(C). The Faults menu opens. Figure 11-4: Faults Menu - No Faults Indicated Emerson.com/Rosemount...

  • Page 103: Use The Faults Menu

    Figure 11-5: Faults Menu - No Faults Indicated Procedure 1. Press REFR to refresh the fault list. A. BACK button B. Fault list C. SEL button D. Scroll Up button E. HELP button F. REFR button G. Scroll Down button Rosemount CT5100...

  • Page 104: Failure Diagnosis Principles

    If you do not have the necessary information to determine if the suspect component is faulty, contact cascade.support@emerson.com for advice and assistance. If there are more parameters than can be displayed on the available screen space, a PAGE message will appear in the top right-hand corner of the screen, and the top right-hand button will become the associated PAGE button.

  • Page 105: Repairable Faults

    In general, if any optical component other than the cell assembly, laser module, and the detector are deemed unserviceable, the analyzer must be repaired by Emerson personnel. The repair, replacement, and alignment of the optical components requires the use of specialized optical test/calibration equipment and procedures to ensure the correct operation of the unit.

  • Page 106: Tools And Test Equipment

    General troubleshooting and diagnostics information The Rosemount CT5100 is specifically designed to run unattended indefinitely, to automatically resolve system issues, and to recover from power failures and return to a normal working state. This troubleshooting guide is intended to assist maintenance personnel when the analyzer has not appeared to be working normally for a period of more than five minutes.
  • Page 107 3. Use the Scroll Up and Scroll Down buttons to highlight a component for the BIST to further investigate. 4. Once you have highlighted the component you wish to diagnose, press SEL to select it. In the example in Figure 11-7, LASER 1 is highlighted. The Diagnostics screen for that component opens. Rosemount CT5100...
  • Page 108 If you do not have the necessary information to determine if the suspect component is faulty, contact Emerson for advice and assistance. If there are more parameters than can be displayed on the available screen space, a...

  • Page 109: Visually Examine The Analyzer

    If the Built-in-Self Test and the visual examination fail to identify the fault, perform the failure diagnostics and recommended actions. 11.9.1 No illuminated LEDs on Power supply unit (PSU) when analyzer switched ON. Recommended actions 1. Check mains power is available. 2. If OK, replace PSUs. Rosemount CT5100...
  • Page 110 3. If the interconnecting cable is OK, replace BEKA display panel. 11.9.6 NAMUR relay light-emitting diode (LED) is OFF and no FAILURE reported on BEKA Recommended actions 1. Check power connections from peripheral board to relay. 2. If the interconnecting cable is working, replace NAMUR relay. Emerson.com/Rosemount...
  • Page 111 1. Ensure laser modules are working properly (check laser current, voltage, and TEC readings on Gas Sensor 3); replace if necessary. 2. Check the cable between motherboard and detector TEC PCB (14- way ribbon cable); replace if necessary. Rosemount CT5100...
  • Page 112 11.9.12 BEKA display shows FAILURE status Condition The Faults page shows CELL HEATER fault due to temperature being out of range with cell temperature reading either a constant value (short circuit) or a high value of 21,000 and above. Emerson.com/Rosemount...
  • Page 113 NAMUR relays not working Recommended actions 1. Check power supply to peripheral board. 2. Check 20-way ribbon cable from motherboard to peripheral board. 3. Check connections to sensors and relays. 4. If all are OK, replace peripheral board. Rosemount CT5100...
  • Page 114 2. Ensure the 12 V PSU and 12 Vdc fuse are OK; if 12 Vdc fuse is not working, replace it. 3. Ensure connection to BEKA from motherboard is intact; if is not, replace it. 4. Check other outputs (digital and analog) are OK (if available). 5. If all interconnecting cables are OK, replace the motherboard PCB. Emerson.com/Rosemount...

  • Page 115: Repair And Replacement

    In all cases the repair must be by direct replacement of the faulty item with a known serviceable item purchased from Emerson. NOTICE 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.
  • Page 116 Repair and replacement Reference Manual May 2020 00809-0100-4511 Figure 12-1: Electrical Compartment Door A. Electrical compartment door B. 1 off compression latch C. 2 off cam latches Emerson.com/Rosemount...

  • Page 117: Close The Electrical Compartment Door

    12.4 Replace the fuses The analyzer contains internal fuses. This procedure is used to replace all internal fuses; therefore, the replacement of only one is described. Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. Rosemount CT5100...
  • Page 118 3. No tools are required to remove the fuse. Place a finger on the catch on the upper part of the fuse holder and lift up the upper part of the fuse holder as shown in Figure 12-2. Emerson.com/Rosemount...
  • Page 119 When lowering the upper part of the fuse holder, ensure that it “clicks” into place when fully lowered. 6. Close the door of the electrical compartment and restart the analyzer. Rosemount CT5100...
  • Page 120 Neutral line 110/230 Vac 3.15 A, 250 V, fast 0001-1009 (following mains filter) acting ceramic Analyzer 12 Vdc supply 5 A, 250 V, fast acting 0001.1011 rail ceramic Analyzer 24 Vdc supply 3.15 A, 250 V, fast 0001-1009 rail acting ceramic Emerson.com/Rosemount...

  • Page 121: Replace The Tec Board

    F. Wiring harness (to detector module) G. Backplate H. Connector for ribbon cable Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. 2. Open the door of the electrical compartment. 3. Tag or otherwise identify all wiring harnesses before disconnecting. Rosemount CT5100...
  • Page 122 10. Fit the TEC board (A) in position on the backplate (G) in the same orientation. Using the packaging from the replacement TEC board, send the unserviceable TEC board to Emerson for evaluation. 11. Secure the TEC board by fitting the four screws (D) and associated spring washers (C) and flat washers (B) that were retained during the removal procedure.

  • Page 123: Replace The Peripheral Board

    H. M3 x 6 mm socket head cap screw I. Relay wiring harness J. Gas/cell temperature monitoring harness K. Gas/cell temperature monitoring harness L. Gas/cell temperature monitoring harness Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. Rosemount CT5100...
  • Page 124 17. Secure the TEC board ribbon cable (D) to the connector of the peripheral board ribbon cable (B) with a cable tie (C). 18. Connect the 12 V power wiring harness (E) to the peripheral board (A). 19. Close the door of the electrical compartment and restart the analyzer. Emerson.com/Rosemount...

  • Page 125: Replace The Motherboard

    D. M3 x 6 mm socket head cap screw E. TEC board ribbon cable F. TRIGGER OUT connector J32 G. TRIGGER OUT connector J31 H. TRIGGER OUT wiring harness I. TRIGGER OUT wiring harness J. Ribbon cable connector J7 Rosemount CT5100...
  • Page 126 15. Inspect the replacement motherboard for signs of damage or delamination. 16. Place the motherboard in position on the backplate and secure by fitting the six screws (D) and the associated spring washers (C) and flat washers (A) retained in Step 13. Torque tighten the screws to 0.6 Nm. Emerson.com/Rosemount...

  • Page 127: Replace The Ethernet In/Out Relay Modules

    The number of Ethernet in/out relay modules may vary depending upon the application of the analyzer. To replace the Ethernet in/out relay modules, refer to Figure 12-7 complete the following steps. Figure 12-7: Lower DIN Rail – Right Side A. Ethernet in/out relay module B. Lever Rosemount CT5100...

  • Page 128: Lower (Main) Din Rail Electronic Components

    DIN rail. Replace the fuses to replace a fuse. The terminal blocks (I and J) and low-power status relays (A) should not require replacement during the expected life of the equipment. Emerson.com/Rosemount...

  • Page 129: Replace A Dc Power Supply

    DC power supply. The two DC power supplies are identical; therefore, the replacement procedure for only one is described. To replace a DC power supply from the DIN rail, refer to Figure 12-9 complete the following steps. Rosemount CT5100...
  • Page 130 8. Place the replacement DC power supply (A) in its correct location on the DIN rail. 9. While pressing the small lever (D) on the underside of the DC power supply to the down position, push the DC power supply onto the DIN rail. Emerson.com/Rosemount...

  • Page 131: Replace The 10 Amp Solid State Relay

    6. Clip the replacement Ethernet connector into its correct location on the DIN rail. Check that the DC power supply is secure. 7. Connect the wiring harnesses to the Ethernet connector. 8. Close the door of the electrical compartment and restart the analyzer as described Start-up procedure. Rosemount CT5100...

  • Page 132: Replace The Laser Module

    C. Laser module D. Captive screw E. Ribbon cable F. Captive screw Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. 2. Open the door of the electrical compartment. Refer to Figure 12-10. 3. Disconnect the ribbon cable (E). Emerson.com/Rosemount...
  • Page 133 The laser module must mate with the two locating pins (B) on the base plate. 8. Secure the laser module by tightening the two captive screws (D and F). 9. Connect the ribbon cable (E) to the laser module. 10. Close the door of the electrical compartment and restart the analyzer. Rosemount CT5100...

  • Page 134: Replace The Detector Module

    F. M3 spring washer G. M3 nut H. Wiring harness Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. 2. Open the door of the electrical compartment. 3. Disconnect the trigger OUT harness (A). Refer to Figure 12-11. Emerson.com/Rosemount...

  • Page 135: Replacing The O Detector

    1 or 2. Replace the O detector identified using the following steps. 12.15.1 Replace O detector (type 1) Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. 2. Open the door of the electrical compartment. Rosemount CT5100...
  • Page 136 9. Connect the BNC cable to the O detector. 10. Close the door of the electrical compartment and restart the analyzer. 12.15.2 Replace O detector (type 2) Procedure 1. Shut down the analyzer. Refer to Shutdown procedure. 2. Open the door of the electrical compartment. Emerson.com/Rosemount...
  • Page 137 (I) to the base. 10. Connect the power cable by screwing it onto the mating connector on the O detector. 11. Connect the BNC cable to the O detector. 12. Close the door of the electrical compartment and restart the analyzer. Rosemount CT5100...

  • Page 138: Replace The Main Terminal Board

    9. Secure the main terminal board by fitting the two self-sealing screws (C and D). Use new self-sealing screws. 10. Connect the wiring harnesses to the main terminal board. 11. Close the door of the electrical compartment and restart the analyzer. Emerson.com/Rosemount...

  • Page 139: Replace The Mains Power Filter

    6. Inspect the replacement mains power filter for damage. 7. Fit the mains power filter to the main terminal board and secure with the two nuts retained in Step 8. Connect the wiring harnesses to the mains power filter. 9. Fit the main terminal board. Rosemount CT5100...

  • Page 140: Remove The Top Cover

    7. Re-engage the right-angled notches (C) on the top cover from the mating lugs on the chassis beneath. 8. Rotate the two locking mechanisms (A) clockwise to lock the front of the top cover (B) in position. Refer to Figure 12-12. Emerson.com/Rosemount...

  • Page 141: Replace The Pressure Sensor

    (1¼) turns with a spanner. 8. Reconnect the wiring harness and fit with cable ties. Rosemount CT5100...

  • Page 142: Replace The Pt100 Cell Temperature Sensor

    2. Remove the top cover. 3. Tag or otherwise identify all wiring harnesses connected to the PT100 cell temperature sensor disconnecting. 4. Note the routing of the PT100 cell temperature sensor wiring and the location of any cable ties used. Emerson.com/Rosemount...
  • Page 143 5. Open the insulation around the analysis cell and remove the top section of insulation. 6. Carefully cut and remove any cable ties and release any cable clips used to secure the PT100 cell temperature sensor wiring. 7. Disconnect the PT100 cell temperature sensor wiring. Rosemount CT5100...
  • Page 144 9. Taking hold of the wires next to the insulation, gently pull the PT100 cell temperature through the insulation until it is free. Note The hole diameter in the insulation is slightly smaller than the diameter of the PT100. Emerson.com/Rosemount...

  • Page 145: Cleaning The Cell Mirrors

    Equipment materials The following equipment and materials are required when cleaning the cell mirrors: • Spectroscopic grade methanol or ethanol • Optical grade lens tissue • Invertible air duster • Hex head keys, sizes 1.5 mm to 4 mm Rosemount CT5100...
  • Page 146 12.21.3 Clean the cell mirrors with air duster Emerson recommends initially cleaning the cell mirrors with an invertible air duster to remove any particulates or dust that may have contaminated the surface. Following cleaning with the air duster, check the pulses to see if any improvement has been made.
  • Page 147 Procedure 1. Fold a piece of lens tissue several times to produce a soft loop of tissue. 2. Apply a small amount (one or two drops) of spectroscopic grade methanol to the front of the tissue loop. Rosemount CT5100...
  • Page 148 4. Clean the mirrors using the lens tissue in the direction shown in Figure 12-14. CAUTION Be careful to wipe across the mirror surface to prevent any residue marks appearing on the mirror surface where the solvent has evaporated. Figure 12-14: Cleaning the Mirrors 5. Reassemble the analysis cell. Emerson.com/Rosemount...
  • Page 149 If the pulses have returned to a usable signal size proceed to operate the analyzer. Note If pulses have not returned to a usable signal size, contact Emerson for assistance. 12.21.5 Assemble the analysis cell Figure 12-15: Assembling Analysis Cell A.

  • Page 150: Spare Parts List

    72 W switch mode DIN rail panel mount power Power supply 24 V P-6001-00018 90 W switch mode DIN rail panel mount power Mirror M-1000-3420 Mirror, general steering, 0.8 x 0.8 in. (20 x 20 mm) Main cell window M-1000-0178 Window, cell main Emerson.com/Rosemount...
  • Page 151 1.5 mm) Viton , cell window Inner cell window BS029V75 O-ring BS029 - 1.49 x 0.07 in. (37.82 x 1.78 mm) Viton, cell window inner Cell lid P-6000-00245 O-ring 4.74 x 0.07 in. (120.37 x 1.78 mm) Viton, cell lid Rosemount CT5100...
  • Page 152 Repair and replacement Reference Manual May 2020 00809-0100-4511 Emerson.com/Rosemount...

  • Page 153: Chapter 13 Preventative Maintenance

    CAUTION EQUIPMENT DAMAGE Under no circumstances can da damp cloth be used to clean components inside the analyzer (the only exception being when cleaning the cell mirrors). Procedure 1. Shut down the analyzer as described in Shutdown procedure. Rosemount CT5100...

  • Page 154: Maintaining The Analyzer

    3. Check the X-Shift calibration of the lasers. Contact your local service representative for guidance. Annually 1. Perform the three-monthly check detailed in the previous row. 2. Perform a laser wavelength calibration. Contact your local service representative for guidance. Emerson.com/Rosemount...

  • Page 155: Appendix A Engineering Drawings

    00809-0100-4511 May 2020 Engineering drawings Use the wiring diagrams for the Rosemount CT5100 analyzer to assist with troubleshooting faults. You can use these diagrams to locate the position of a wiring connector should it become disconnected. Table A-1: List of Engineering Drawings...
  • Page 162 2020 Emerson. All rights reserved. twitter.com/rosemount_news The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a Facebook.com/Rosemount mark of one of the Emerson family of companies. All other marks are the property of their youtube.com/RosemountMeasurement respective owners.

Table of Contents