Emerson Rosemount CT5100 Quick Start Manual
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Emerson Rosemount CT5100 Quick Start Manual

Continuous gas analyzer
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Quick Start Guide
00825-0100-3511, Rev AA
August 2020
™
Rosemount
CT5100 QSG Continuous
Gas Analyzer

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Summary of Contents for Emerson Rosemount CT5100

  • Page 1 Quick Start Guide 00825-0100-3511, Rev AA August 2020 ™ Rosemount CT5100 QSG Continuous Gas Analyzer...
  • Page 2 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 3 Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up the analyzer. Use only replacement parts and components authorized by Emerson. 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.
  • Page 4 WARNING 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 5 August 2020 Quick Start Guide The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. WARNING HIGH PRESSURE GAS AND AIR The calibration gas supply and compressed air supply operate at a pressure that can cause injury, e.g.,...

  • Page 6: Table Of Contents

    As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical components requires the use of special optical test/ calibration equipment and procedures.

  • Page 7: Introduction

    ™ The Rosemount CT5100 Continuous Gas Analyzer, referred to hereafter as the Rosemount CT5100, or analyzer, is an electronic sensor that uses laser spectroscopy to perform analysis of process gas streams. Important The Rosemount CT5100 is designed for use in Non Hazardous areas ONLY.
  • Page 8 Know the safety mechanisms and regulations WARNING To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate, maintain, or service this analyzer before reading and understanding this reference manual and receiving appropriate training. Emerson.com/Rosemount...
  • Page 9 August 2020 Quick Start Guide Software version The analyzer includes software that is used to control the operation of the analyzer. This document describes the software version as: 5.7.13. Quick Start Guide...

  • Page 10: Description

    Figure 2-1, 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 11 August 2020 Quick Start Guide lasers installed depends upon customer requirements. The complete system operates at either 110 or 240 Vac 50/60 Hz supply. Quick Start Guide...

  • Page 12: Specifications

    Figure 3-1 Figure 3-2. Table 3-2 gives the general characteristics of the analyzer. Table 3-1: 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 13 August 2020 Quick Start Guide Table 3-2: General Characteristics (continued) Rosemount CT5100 Value Units Comment Measurement technique Mid infrared (IR) absorption spectroscopy Mid IR source Quantum Cascade Laser Near IR source Interband Cascade Laser Diode Laser Laser classification Class 1 BS EN 60825-1: 2007 safety of laser products.
  • Page 14 Quick Start Guide August 2020 Figure 3-1: Rosemount CT5100 Dimensions - Front View Dimensions are in inches (mm). A. Lifting eyelet B. Ventilation C. User interface Emerson.com/Rosemount...
  • Page 15 August 2020 Quick Start Guide Figure 3-2: Rosemount CT5100 Dimensions - Top View Dimensions are in inches (mm). A. Lifting eyelet B. Sample return C. Sample inlet Quick Start Guide...
  • Page 16 Quick Start Guide August 2020 Figure 3-3: Rosemount CT5100 Dimensions - Bottom View Dimensions are in inches (mm). A. Cable glands B. Earth point Table 3-3: Environmental Characteristics Environmental Value Units Comment characteristic Operating temperature -4 to 131 °F Ambient temperature...
  • Page 17 August 2020 Quick Start Guide Table 3-3: Environmental Characteristics (continued) Environmental Value Units Comment characteristic IP code IP66 (electrical IP to IEC 60529 compartment enclosure) IP20 (optical compartment enclosure) Sensor humidity range 10 to 95 Relative humidity (non- condensing) at 113 °F (45 °C) Quick Start Guide...

  • Page 18: Install

    Quick Start Guide August 2020 Install Site selection The Rosemount CT5100 has a T3 temperature classification which specifies the maximum surface temperature of the analyzer. WARNING FIRE AND EXPLOSION Death, personal injury, and/or damage to persons and/or property may result if this is not observed.
  • Page 19 The analyzer weighs 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. Wear suitable protective gloves and protective footwear.
  • Page 20 Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or other body parts. Emerson recommends that a minimum of two people move and lift the analyzer. Wear suitable protective gloves and protective footwear.
  • Page 21 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.
  • Page 22 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 23 August 2020 Quick Start Guide 4. Use safety approved and tested lifting equipment to lift the analyzer from the stable platform. 5. Ensure that the wall fixing points are capable of supporting a load of 242 lb (110 kg) each; this includes a x 2 factor of safety. Figure 4-2 shows the locations of the mounting points on the analyzer.
  • Page 24 After mounting, do not place any additional load on the analyzer. or leave any loose items on flat surfaces. Connecting the electrical/electronic inputs and outputs 4.4.1 AC power Power is connected to the analyzer instrumentation through the power entry point fitted to the base of the analyzer. Refer to Figure 4-4. Emerson.com/Rosemount...
  • Page 25 August 2020 Quick Start Guide Figure 4-4: 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. Quick Start Guide...
  • Page 26 Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer. Refer to Figure 4-6. The customer supplied power cable for the analyzer instrumentation will be connected to terminals 1 - 3. Emerson.com/Rosemount...
  • Page 27 August 2020 Quick Start Guide Table 4-2: Electrical Power Requirements Electrical supply Power Voltage Fuse consumption Instrumentation 500 W 100 to 230 Vac, 50/60 Hz 3.15 A supply voltage ±10% internal fuses F1 and F2 For the electrical power wiring use 16 AWG stranded, three conductor copper or tin-plated copper power wire, rated for at least 250 Vac, of the required length.
  • Page 28 C as shown in Figure 1). 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. Emerson.com/Rosemount...
  • Page 29 August 2020 Quick Start Guide Figure 4-7: Signal Cable Outputs A. To mains input fuses B. Mains input filter C. To enclosure earth stud D. To digital modules E. To digital modules F. To analog modules G. To status relays H.
  • Page 30 Power input cables and circuit breaker The power input cable circuit breaker can be tested as follows: • Set the main power circuit breaker to ON. • Check that the display controller lights up. The analyzer will then begin to power-up. Emerson.com/Rosemount...
  • Page 31 4.4.10 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. Quick Start Guide...

  • Page 32: Controls And Display Controller

    Quick Start Guide August 2020 Controls and display controller Front panel controls and indicators ™ The Rosemount CT5100 is configured from the control display located on the front panel. A. Display controller Emerson.com/Rosemount...
  • Page 33 August 2020 Quick Start Guide NOTICE ON/OFF circuit breaker There is no ON/OFF switch on the analyzer. The external circuit breaker controls the application of electrical power to the analyzer. The external circuit breaker is a simple two-pole ON/OFF circuit breaker that must to set to ON to permit the safe operation of the analyzer.
  • Page 34 0.00 ppm until the first readings are taken. After a few seconds, the initial gas concentrations are displayed. The Gas Sensor Main screen also shows the status of the analyzer. In the example shown the analyzer is Running and OK (e.g. no faults have been identified). Emerson.com/Rosemount...
  • Page 35 August 2020 Quick Start Guide 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. A. MENU button B. MENU text C. PAGE text D.
  • Page 36 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 5-1 shows an example of a Help screen. Emerson.com/Rosemount...
  • Page 37 August 2020 Quick Start Guide Figure 5-1: Example of a Help Screen Quick Start Guide...
  • Page 38 Main menu is used for calibration, diagnostics, fault finding, downloading data, and shutting down the analyzer. BACK button On most of the software screens, the top left hand button is configured as a BACK button. Press BACK to return to the previous screen. A. BACK button Emerson.com/Rosemount...

  • Page 39: Start-Up Procedure

    August 2020 Quick Start Guide Start-up procedure Introduction CAUTION EQUIPMENT DAMAGE Damage to the analyzer may result from a failure to follow this procedure. Always follow the start-up procedure. The analyzer normally operates continuously. It should only be necessary to start up the analyzer under the following circumstances: •...
  • Page 40 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.
  • Page 41 August 2020 Quick Start Guide A. Sample gas input port B. Sample gas return port C. Top cover (cell compartment) D. Laser/electrical compartment E. Analog/digital power entry point F. Power entry point 8. Ensure that the electrical connection has been made to the power entry point at the base of the analyzer.
  • Page 42 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 43 August 2020 Quick Start Guide Front panel controls and indicators Configure the analyzer from the control display located on the front panel. A. Display controller NOTICE ON/OFF circuit breaker There are no ON/OFF switches on the analyzer. A customer-provided external circuit breaker controls the application of electrical power to the analyzer.
  • Page 44 This will lock the software controlling the analyzer requiring the analyzer to shut down externally and restarted 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. Emerson.com/Rosemount...

  • Page 45: Operating The Analyzer

    August 2020 Quick Start Guide Operating the analyzer Introduction This section describes the normal operation of the analyzer. NOTICE The gas concentrations shown in the following screenshots may be different from those shown in your particular analyzer. The screenshots indicate the functionality of the software, which is the same regardless of the gases or gas concentrations being measured.
  • Page 46 Quick Start Guide August 2020 Figure 7-1: Gas Sensor Main Screen Figure 7-2: Pressure and Temperature Screen Emerson.com/Rosemount...

  • Page 47: Shutdown Procedure

    August 2020 Quick Start Guide Shutdown procedure Safety precautions CAUTION EQUIPMENT DAMAGE Damage to the analyzer may result from a failure to follow this procedure. Always follow the shutdown procedure. The analyzer normally operates continuously. It should only be necessary to shut down the analyzer in the following circumstances: •...
  • Page 48 2. Purge any sample gas in the pipe/hose from the gas handling system to the analyzer using factory air or nitrogen supply. Emerson.com/Rosemount...
  • Page 49 August 2020 Quick Start Guide 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).
  • Page 50 D. HELP button E. Scroll down button 5. On the display controller, select System. 6. Press SEL (select). The System screen opens. A. BACK button B. SELECT button C. Scroll up button D. HELP button E. Scroll down button Emerson.com/Rosemount...
  • Page 51 August 2020 Quick Start Guide 7. Use scroll up and scroll down to select SHUTDOWN . Then press SEL (select). The Shutdown screen opens. 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.

  • Page 52: Engineering Drawings

    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 Drawing number Description W-2000-0035 (Sheets 1-5) Rosemount CT5100 heated Emerson.com/Rosemount...
  • Page 53 August 2020 Quick Start Guide Wiring diagram W-2000-0035 (page 1) Quick Start Guide...
  • Page 54 Quick Start Guide August 2020 Wiring diagram W-2000-0035 (page 2) Emerson.com/Rosemount...
  • Page 55 August 2020 Quick Start Guide Wiring diagram W-2000-0035 (Page 3) Quick Start Guide...
  • Page 56 Quick Start Guide August 2020 Wiring diagram W-2000-0035 (Page 4) Emerson.com/Rosemount...
  • Page 57 August 2020 Quick Start Guide Wiring diagram W-2000-0035 (Page 5) Quick Start Guide...
  • Page 58 Quick Start Guide August 2020 Emerson.com/Rosemount...
  • Page 59 August 2020 Quick Start Guide Quick Start Guide...
  • Page 60 Linkedin.com/company/Emerson- Automation-Solutions The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a twitter.com/rosemount_news mark of one of the Emerson family of companies. Facebook.com/Rosemount All other marks are the property of their youtube.com/RosemountMeasurement respective owners.

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