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Emerson Rosemount CT4400 Reference Manual

Continuous gas analyzer
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Reference Manual
00809-0100-4244, Rev AA
January 2020
™
Rosemount
CT4400
Continuous Gas Analyzer

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  • Page 1 Reference Manual 00809-0100-4244, Rev AA January 2020 ™ Rosemount CT4400 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 • To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except when maintenance is being performed by qualified personnel. • The information contained in this document is subject to change without notice. General safety notice residual risk Installation, operation, and maintenance of the analyzer must be in accordance with these instructions.
  • Page 4 This product complies with USA 21 CFR 1040.10. It is also designed and manufactured under an approved quality management system to ISO 9001:2015. Emerson and the Rosemount CT4400 Gas Analyzer have satisfied the requirements for applying the CE marking to the Rosemount CT4400 Gas Analyzer.
  • Page 5 WARNING LASER OPTICAL RADIATION EXPOSURE HAZARD The Rosemount CT4400 is a Class 1 laser product. The lasers are fully enclosed so that no hazardous radiation is accessible under normal operating conditions. Opening the analyzer and attempting to perform adjustments or procedures other than those specified in this manual may result in hazardous optical radiation exposure to personnel.
  • Page 6 WARNING HAZARDOUS GAS The product stream that the analyzer is examining may be hazardous even at low concentrations. Therefore, take special care to ensure that the sample gas return port either returns the sample gas to the product stream or discharges the sample gas to a location that will not cause a hazard.
  • Page 7 CAUTION EQUIPMENT DAMAGE Always follow the start-up procedure. Damage to the analyzer may result from a failure to follow this procedure. CAUTION EQUIPMENT DAMAGE Always follow the shutdown procedure. Damage to the analyzer may result from a failure to follow this procedure. CAUTION UNSERVICEABLE EQUIPMENT If the pressure and temperature measurements are out of tolerance, refer to...
  • Page 8 Label type Example Location Identification label (including Fitted on the rear panel the Serial No. (S/N) Model, Config No. and Date of Manufacture (DoM). Identification ratings label for Fitted on the rear panel of the the Half Rack System. unit Identification ratings label Fitted on the rear panel of the unit...
  • Page 9 Label type Example Location CAUTION Laser Radiation Rear panel safety statement AC power supply voltage label Fitted on inside rear panel next to power input socket. Abbreviations The following symbols and abbreviations are used in this manual. Abbreviation Description © Copyright Percent °...
  • Page 10 Abbreviation Description Maximum Milligram mg/m Milligram/cubicmeter Mid IR Mid Infrared Minimum Millimeter National Electrical Code NFPA National Fire Protection Association Ammonia Nanometer Nitricoxide Nitrousoxide Number Oxygen Personal computer Parts per million Quantum Cascade Laser SELV Safety Extra Low Voltage (SELV) circuits. Torr Unit of pressure defined as exactly 1/760 of a standard atmosphere United States of America...

  • Page 11: Table Of Contents

    Reference Manual Contents 00809-0100-4244 January 2020 Contents Chapter 1 Plan..........................13 1.1 Description.............................13 1.2 Equipment purpose and role......................13 1.3 System overview..........................15 1.4 Customer information........................16 1.5 Safety precautions and conditions for safe use................17 1.6 Qualified personnel........................17 1.7 Software version..........................17 1.8 Detailed system specifications......................18 1.9 Unpacking the analyzer........................
  • Page 12 7.4 Visual examination......................... 78 7.5 Failure diagnostics..........................78 7.6 Replacing the power socket fuses....................83 7.7 Cleaning the analysis cell mirrors....................85 Chapter 8 Shutdown procedure....................91 Chapter 9 Preventative maintenance................... 97 Chapter 10 Recommended spare parts...................99 Appendix A Engineering drawings....................101 Rosemount CT4400...

  • Page 13: Chapter 1 Plan

    Plan 00809-0100-4244 January 2020 Plan Description The Rosemount CT4400 Continuous Gas Analyzer, referred to hereafter as Rosemount ™ CT4400 is a multi-component Quantum Cascade Laser (QCL)/Tuned Diode Laser (TDL) analyzer designed for applications where processing gas streams is required. Optimized for cold/dry applications running at ambient pressure with low maintenance,...
  • Page 14 Plan Reference Manual January 2020 00809-0100-4244 Figure 1-1: Rosemount CT4400 Half Rack System Figure 1-2: Rosemount CT4400 Full Rack System The analyzer can be configured to detect and measure up to six different gases simultaneously. Rosemount CT4400...

  • Page 15: System Overview

    00809-0100-4244 January 2020 System overview A complete Rosemount CT4400 system consists of the analyzer, and the associated interconnecting wiring and gas piping. Measurement data from the analyzer can be displayed in the process control center. You must provide a stable gas handling system and interconnecting wiring and gas piping;...

  • Page 16: Customer Information

    Should you require further information, or should particular problems arise that are not covered in this manual, you can request additional help from Cascade Technical Support (cascade.support@emerson.com) or Emerson distribution partners. Further contact details for Emerson can be found on the back page of this manual. Rosemount CT4400...

  • Page 17: Safety Precautions And Conditions For Safe Use

    Only qualified and trained persons have the required specific knowledge to correctly interpret the general safety information, warnings, and procedures given in this manual and apply them to this particular application. Emerson or its distribution partners can provide this training on request.

  • Page 18: Detailed System Specifications

    658 x 483 x 172 Length x width x height (Full Rack) 25.9 x 19 x 6.8 Nominal dimensions Weight (Full Rack) Approximate weight Table 1-3: General Characteristics Rosemount CT4400 Value Units Comment Supply voltage 110/230 ± 10% Supply Frequency 60/50 ± 5% Peak power consumption Max.
  • Page 19 Reference Manual Plan 00809-0100-4244 January 2020 Figure 1-4: Half Rack Dimensions Figure 1-5: Full Rack Dimensions Table 1-4: Environmental Characteristics Value Units Comment Environmental characteristic 5 ℃ to 50 ℃ ℃ Operating temperature range Ambient temperature 41 ℉ to 122 ℉ ℉...
  • Page 20 Note The Rosemount CT4400 Continuous Gas Analyzer is suitable for indoor use only. 1.8.1 Sample gas conditioning requirements The sample gas temperature in Table 1-4 indicates the temperature range that the analyzer can operate within.

  • Page 21: Unpacking The Analyzer

    Reference Manual Plan 00809-0100-4244 January 2020 Unpacking the analyzer WARNING HEAVY ITEM Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or other body parts. The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack system.
  • Page 22 Figure 1-7: Full Rack Front and Rear Views A. Front panel B. Display screen C. User interface D. Rear panel E. Ethernet connection F. Sample gas outlet G. Sample gas inlet H. Analog output (4-20 mA) I. Mains power inlet Rosemount CT4400...

  • Page 23: Chapter 2 Install

    Reference Manual Install 00809-0100-4244 January 2020 Install Site selection and rack mounting WARNING HEAVY ITEM Handle the analyzer with caution during unpacking, installing, maintaining, and transporting to prevent crushing of hands, feet, or other body parts. The analyzer weighs 33 lb (15 kg) for the half rack system and 66 lb (30 kg) for the full rack system.
  • Page 24 4 in. (9.6 mm) slide thickness Lock-out Front disconnect.). 9. Installation of telescopic slides on the analyzer will be in accordance with the manufacturer’s procedure the locations for the slide fixing points are provided in Figure 2-1 Figure 2-2. Rosemount CT4400...

  • Page 25: Gas Inputs And Outputs

    Reference Manual Install 00809-0100-4244 January 2020 Figure 2-3: Analyzer With Telescopic Slides 10. Due to the weight, care MUST be taken when installing the analyzer in the rack. Gas inputs and outputs The analyzer has provision for gas input and gas output, both of which are located on the rear panel of the analyzer (Figure 2-4).

  • Page 26: Connecting The Electrical/Electronic Inputs And Outputs

    ON/OFF switch at the rear of the panel is set to OFF and the power cable plug is removed. The analyzer MUST be earthed using a grounded three core cable suitable for the rating defined in the General Characteristics (Table 1-3). Death or personal injury may result if this is not observed. Rosemount CT4400...
  • Page 27 Reference Manual Install 00809-0100-4244 January 2020 Figure 2-5: Electrical/Electronic Inputs and Outputs A. Rear panel B. Ethernet connection C. D sub connector type - 25 way D. Mains power inlet Procedure 1. Make electrical/electronic signal connections to the analyzer through connectors located on the analyzer's rear panel (see Figure 2-5).
  • Page 28 Status output 2 (maintenance required), optional (dry contacts: 1A, 30 Vdc) 11 & 24 Status output 3 (out of specification), optional (dry contacts: 1A, 30 Vdc) 12 & 25 Status output 4 (failed), optional (dry contacts: 1A, 30 Vdc) Rosemount CT4400...

  • Page 29: Start-Up Procedure

    Reference Manual Start-up procedure 00809-0100-4244 January 2020 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 30: Start-Up Procedure

    B. On/Off switch 4. The start-up sequence commences automatically under software control. 5. After a few minutes, the Gas Sensor Main screen (Figure 3-2) appears on the display controller. If it does not, report the fault to maintenance. Rosemount CT4400...
  • Page 31 Reference Manual Start-up procedure 00809-0100-4244 January 2020 Figure 3-2: Gas Sensor Main Screen 6. Start/open the return system installed for the sample gas handling for the analyzer. 7. Start the gas handling system that conditions the sample gas before it is fed into the analyzer.
  • Page 32 Start-up procedure Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 33: Operating The Analyzer

    January 2020 Operating the analyzer Introduction This chapter describes the controls, displays, and indicators on the Rosemount CT4400 and how to use the display controller located on the front panel of the analyzer. NOTICE The gases shown in the screenshots and the measurements may be different from those shown in your particular analyzer.
  • Page 34 On both the Gas Sensor Main screen and the Pressure and Temperature screen, if the analyzer makes more measurements than can fit on the display, use to scroll up and down the list. Rosemount CT4400...

  • Page 35: Display Controller

    Reference Manual Operating the analyzer 00809-0100-4244 January 2020 Display controller Operation of the analyzer is controlled primarily through the display controller (Figure 4-3, Figure 4-3: Front Panel Display Controller A. LCD display B. Navigation buttons The LCD display (A) can be used to display: •...

  • Page 36: Gas Sensor Main Screen

    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. Figure 4-4: Gas Sensor Main Screen Rosemount CT4400...

  • Page 37: Pressure And Temperature Screen

    Reference Manual Operating the analyzer 00809-0100-4244 January 2020 The Gas Sensor Main screen displays the gas concentration measurements obtained by the analyzer. In the example shown in Figure 4-4, the gases Nitric Oxide (NO), Nitrous Oxide (N O), Carbon Monoxide (CO) and Ammonia (NH ) are being measured and, for each gas, the concentration detected is in parts per million (ppm).

  • Page 38: Help System

    DATA SERVICE: Navigates to a screen that allows data to be downloaded from the analyzer. The downloaded data is used to diagnose faults. SYSTEM: Navigates to a screen that allows you to shut down the analyzer or access system information, such as software versions or IP addresses. Rosemount CT4400...

  • Page 39: Back Button

    Reference Manual Operating the analyzer 00809-0100-4244 January 2020 The main motherboard IP address can also be changed from this menu. Some of these options are not available on older analyzers. Figure 4-7: Main Menu BACK button On most of the software screens, is configured as a BACK button.
  • Page 40 Operating the analyzer Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 41: Verifying Gas Concentrations

    Reference Manual Verifying gas concentrations 00809-0100-4244 January 2020 Verifying gas concentrations Verification Verification flows the known gas concentration through the analyzer and gives you a display of the measurement, the cylinder value, and the difference between the two. You can use verification to confirm that the analyzer is within tolerance. If it is out of tolerance, perform a calibration (see Calibration).
  • Page 42 PER GAS. Press Figure 5-2: Per Gas 9. Scroll and select from the list the gas to be tested. Press Figure 5-3: Select Gas Screen 10. Scroll and select RUN ZERO. Press Figure 5-4: For NH3 Rosemount CT4400...
  • Page 43 Reference Manual Verifying gas concentrations 00809-0100-4244 January 2020 11. Allow the concentration readings to stabilize. Figure 5-5: Result This screen gives a reading of the concentration of the selected gas that is present as an impurity in the nitrogen calibration gas. In the example the gas being measured is NH , and the analyzer has detected a concentration of 0.866 ppm.
  • Page 44 4. Connect an excess flow line to the unused port on the T-piece and route the excess flow line to a suitable extractor. 5. On the display controller, browse to the Main menu. 6. Press , select GAS SERVICE. Press Figure 5-7: Main Menu Rosemount CT4400...
  • Page 45 Reference Manual Verifying gas concentrations 00809-0100-4244 January 2020 7. Scroll and select PER GAS. Press Figure 5-8: Gas Service 8. Scroll and select from the list the gas to be tested. Press Figure 5-9: Select Gas Selection Reference Manual...
  • Page 46 Figure 5-11: Verify Input 11. The VERIFY SPAN screen will be visible while the analyzer makes the verification measurement. Allow the concentration readings to stabilize. After the purge time set has elapsed, the RESULT screen will then be shown. Rosemount CT4400...
  • Page 47 Reference Manual Verifying gas concentrations 00809-0100-4244 January 2020 Figure 5-12: Verify Span 12. This RESULT screen gives a reading of the concentration for the selected gas that is present as an impurity in the calibration gas. In the example the gas being measured is NH , and the analyzer has detected a concentration of 0.510 ppm.
  • Page 48 To return to the Gas Service Screen. To select the next gas from the Select Gas screen. To return to the Main Menu. To return to the Gas Sensor Main screen (Figure 4-4). Figure 5-14: Next Gas Service Rosemount CT4400...

  • Page 49: Chapter 6 Gas Calibration

    PER GAS allows for gas calibration or verification on a gas by gas basis. CALIBR ALL not an option available for the Rosemount CT4400 analyzer. VERIFY ALL not an option available for the Rosemount CT4400 analyzer. Reference Manual...

  • Page 50: Calibration

    VERIFY PARAMS allows configuration of the purge time for Gas Verification. STREAM SWITCH not an option available for the Rosemount CT4400 analyzer. Pressing the Back key will return to the previous screen. Pressing the Home key any time will return to the Main Menu screen.
  • Page 51 Reference Manual Gas calibration 00809-0100-4244 January 2020 6. Using , select GAS SERVICE. Press Figure 6-1: Main Menu 7. Using , select PER GAS. Press Figure 6-2: Per Gas Reference Manual...
  • Page 52 January 2020 00809-0100-4244 8. Scroll and select from the list the gas to be tested. Press Figure 6-3: Select Gas Screen Manually adjust the ZERO OFFSET Procedure 1. Use , select ZERO OFFSET. Press Figure 6-4: Zero Offset Rosemount CT4400...
  • Page 53 Reference Manual Gas calibration 00809-0100-4244 January 2020 2. Use as required to set required value, Press to confrim. Figure 6-5: Gas Compensation - Zero Offset ZERO CALIBRATE Procedure 1. Press to start the ZERO CALIBRATION process. Figure 6-6: Run Zero Calibration Reference Manual...
  • Page 54 ZERO CALIBRATION, either after waiting for the purge time, or when ► or pressed, whichever is sooner. The result of the calibration will then be displayed, as below. Figure 6-8: Result 4. Press the appropriate button Option Description To return to the Gas Service Screen. Rosemount CT4400...
  • Page 55 Reference Manual Gas calibration 00809-0100-4244 January 2020 Option Description To select the next gas from the Select Gas screen. To return to the Main Menu. To return to the Gas Sensor Main screen (Figure 4-4). Figure 6-9: Next Gas Service 6.3.2 Span calibration The span gas concentrations measured by the analyzer when reference gas is flowing can...
  • Page 56 Gas calibration Reference Manual January 2020 00809-0100-4244 6. Use and select GAS SERVICE. Press Figure 6-10: Select Gas Service 7. Use and select PER GAS. Press Figure 6-11: Per Gas Rosemount CT4400...
  • Page 57 Reference Manual Gas calibration 00809-0100-4244 January 2020 8. Use and select from the list the gas to be tested. Press Figure 6-12: Select Gas 9. To manually adjust the SPAN FACTOR, use to select SPAN FACTOR. Press Figure 6-13: Span Factor Reference Manual...
  • Page 58 Reference Manual January 2020 00809-0100-4244 10. Use as required to set the required value. Press to confirm. Figure 6-14: Gas Compensation Span Factor Span calibrate Procedure 1. Use to start the SPAN CALIBRATION process. Figure 6-15: Run Span Rosemount CT4400...
  • Page 59 Reference Manual Gas calibration 00809-0100-4244 January 2020 2. Use as required to set the calibration value for the test cylinder. Press to confirm. Figure 6-16: Verify Input Figure 6-17: Calibrate Span Finish Reference Manual...
  • Page 60 4. Press the appropriate button. Option Description To return to the Gas Service Screen. To select the Next Gas from the Select Gas screen. To return to the Main Menu. To return to the Gas Sensor Main screen (Figure 4-4). Rosemount CT4400...
  • Page 61 Reference Manual Gas calibration 00809-0100-4244 January 2020 Figure 6-19: Next Gas Service Finish Change the gas service calibration settings The gas purge time can be adjusted as follows: Procedure 1. Use and select GAS SERVICE. Press Figure 6-20: Select Gas Service Reference Manual...
  • Page 62 3. To adjust the length of time for the calibration gas to flush the cell use select PURGE TIME. Press Note AUTO PERIOD is not available on the Rosemount CT4400. Figure 6-22: Calibrate Parameters 4. Use the to select the number or duration to be changed. (seconds/ minutes/hours/days).

  • Page 63: Reference Gas - Suggested Concentration Ranges

    Reference gas - suggested concentration ranges Calibration gas ranges are recommended to be between 80 percent and 100 percent of the full range of the analyzer. Please contact your Rosemount Customer Care Representative if you require further assistance at (cascade.support@emerson.com). Reference Manual...
  • Page 64 Gas calibration Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 65: Troubleshooting And Diagnostics

    In all the cases described in this chapter, maintenance personnel must perform the repairs by directly replacing the faulty item with a known serviceable spare part supplied by Emerson. All other items must be repaired or replaced by the manufacturer. CAUTION...
  • Page 66 Unauthorized operation of the gas handling system when maintenance is being performed on the analyzer or its associated pipes/hoses may result in highly flammable gas being released, causing fire or explosion. Failure to observe this precaution will cause death, personal injury, and/or damage to persons. Rosemount CT4400...

  • Page 67: Using The Built-In-Self Test (Bist) Fault Diagnostics

    Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 WARNING HAZARDOUS SUBSTANCES The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution. Gas handling components within the analyzer will contain particulate matter residue from the sample gases. Over the life of the analyzer, the concentration of the particulate matter will become enriched within the gas handling components.
  • Page 68 If a fault is detected the STATUS display in the bottom left-hand corner of the screen changes from OK to a flashing . 4. Pressing the Forward key will move to the Main menu screen. Figure 7-1: Faults Screen Selection Rosemount CT4400...
  • Page 69 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 5. Scroll and select Faults. Press Figure 7-2: Main Menu - Faults Screen 6. Scroll and select the component to obtain details on the next screen. Press to obtain details about the fault Figure 7-3: Faults Selection Screen Reference Manual...
  • Page 70 8. Examine the data shown on the corresponding Faults screen to determine if a component has failed or if it is operating outside of its correct parameters. 9. Contact your Emerson Customer Care Representative (cascade.support@emerson.com) if you need further assistance with a component's Fault Status. 7.2.2...
  • Page 71 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 LASER XXX provides the operator with additional information on each LASER that the analyzer has been set up to monitor. PATH XXX provides the operator with information on the laser PATH for each gas being monitored by the analyzer.
  • Page 72 The example screen below shows the CONFIG option for the analyzer has been selected and the current Status is OK . Figure 7-7: Config Status Example 2: Use to view all the options available. Select the Item required to obtain further details on the next screen. Press Rosemount CT4400...

  • Page 73: Configuring The 4-20Ma Outputs

    Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Figure 7-8: Diagnostics - Component Selection Screen The example screen above shows the Laser 1 option for the analyzer has been selected and the current Status is OK . Figure 7-9: Laser 1 Status Note Additional operating information has been provided for this option.
  • Page 74 ANALOG RANGES allows the operator to set the upper and lower limits for the 4-20 mA measurement output. USB DATA DUMP NOT an option available for the Rosemount CT4400 analyzer. TFTP TRANSFER NOT an option available on the Rosemount CT4400 analyzer.
  • Page 75 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Figure 7-11: Data Service - Analog Ranges 8. Scroll and select from the list of gases being tested. Press Figure 7-12: Analog Range Gas Selection Screen 9. Select the MIN option. Press Reference Manual...
  • Page 76 10. Use the to select the number to be changed. 11. Use the to change the number value. Figure 7-14: Minimum Limit 12. Press to accept the change Home key to cancel. 13. Select the MAX option. Press Rosemount CT4400...
  • Page 77 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Figure 7-15: MAX Option Selected 14. Use the to select the number to be changed. 15. Use the to change the number value. Figure 7-16: Maximum Limit 16. Press to accept the change Home key to cancel.

  • Page 78: Visual Examination

    Gas reading abnormal Potential cause Gas reading abnormal Recommended action 1. Check measurement validity flag. 2. Reading invalid. 3. refer to Measurement invalid flag. Potential cause Gas reading abnormal Recommended action 1. Check measurement validity flag. 2. Reading valid. Rosemount CT4400...
  • Page 79 1. Check measurement validity flag. 2. Reading valid. 3. Perform a new Zero and Span calibration to ensure calibration factors are correct. 4. Abnormal readings persist. 5. Cause Unknown. 6. Contact (cascade.support@emerson.com). Related information Measurement invalid flag. 7.5.2 Calibration/validation drift Potential cause Sensor reading invalid.
  • Page 80 5. Check calibration cylinder. 6. Calibration cylinder near empty. 7. Replace calibration cylinder. 8. Readings do not return to normal. 9. Check the calibration pipework. 10. Pipework damaged. 11. Replace pipework. 12. Readings do not return to normal. Rosemount CT4400...
  • Page 81 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 13. Cause Unknown. 14. Contact (cascade.support@emerson.com). Related information Measurement invalid flag 7.5.3 Measurement invalid flag Potential cause Pressure or temperature is out of range. Recommended actions 1. Check display controller to assess which measurements are invalid.
  • Page 82 Recommended actions 1. Check which gas. 2. Check fault readings. 3. Fault reading active. 4. Use Fault to access further diagnostic information 5. Contact (cascade.support@emerson.com). Potential cause Gas reading invalid Recommended action 1. Check which gas. 2. Check fault readings.

  • Page 83: Replacing The Power Socket Fuses

    3. Contact (cascade.support@emerson.com). Potential cause PC or HMI failure. Recommended actions 1. Attempt a reboot. 2. System does not reboot. 3. Contact Cascade (cascade.support@emerson.com). 7.5.7 Other error not covered in other sections Potential cause Unknown Recommended actions Contact Cascade (cascade.support@emerson.com).
  • Page 84 9. Reconnect the external power supply to the power socket on the back panel. 10. Start up the analyzer by turning the ON/OFF switch on the back panel to the ON position. 11. The analyzer will automatically begin the startup process. Rosemount CT4400...

  • Page 85: Cleaning The Analysis Cell Mirrors

    Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Cleaning the analysis cell mirrors Cleaning the analysis cell mirrors will only be required if the sample gas is not conditioned in accordance with gas requirements defined in the General characteristics Table 1-3 the Environmental characteristics Table 1-4.
  • Page 86 8. Remove the analyzer from the rack and place on a flat, stable surface that can accommodate the weight of 33 lb (15kg) for the half rack and 66 lb (30 kg) for the full rack system. This step requires two people to lift and transport the analyzer. Rosemount CT4400...
  • Page 87 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Figure 7-18: Removing the Top Cover 9. The area selected MUST be clean and dust free. 10. Remove and retain the 12 off (24 off) M3 button head screws and plain washers used to secure the top cover(s).
  • Page 88 (D) used to secure the cell cover (C) on the analysis cell (B). Care MUST be taken to ensure the O-Ring (A) does not get damaged. 16. It may be necessary to use a small flat blade screwdriver to lever the cell cover off. With the cover removed, the mirrors are now exposed. Rosemount CT4400...
  • Page 89 Reference Manual Troubleshooting and diagnostics 00809-0100-4244 January 2020 Figure 7-21: Opening the Analysis Cell A. Analysis cell B. O-ring C. Cell cover D. Fasteners 17. Clean the mirrors by applying a small quantity of reagent grade methanol to a clean, dry, lens tissue and then gently wiping the mirrors with the lens tissue. Care MUST be taken not to apply pressure to the lens during this operation to prevent scratching the reflective surface.
  • Page 90 18. Refit the cell cover (C) onto the analysis cell (B) and secure with the six socket head cap screws and washers (D) removed previously. 19. Close the hinged PCB tray and secure in position using the two cam lock screws. 20. Refit the top cover and reinstall the analyzer in the rack. Rosemount CT4400...

  • Page 91: Chapter 8 Shutdown Procedure

    Reference Manual Shutdown procedure 00809-0100-4244 January 2020 Shutdown procedure This chapter describes the procedure to be followed when shutting down the analyzer. DANGER ELECTRIC SHOCK The analyzer operates using mains voltage that is dangerous to life. Make sure that the power ON/OFF switch at the rear of the panel is set to OFF and the power cable plug is removed.
  • Page 92 6. Turn off the purge gas supply to the analyzer. Lock-out the purge to prevent its unauthorized operation. 7. The Shutdown procedure can be started as follows. The SYSTEM menu screen can be accessed from the Main Menu screen. Rosemount CT4400...
  • Page 93 Reference Manual Shutdown procedure 00809-0100-4244 January 2020 This gives the operator access to the Shutdown option for the analyzer which will close the software. The other options are factory menus that the operator WILL NOT need to access but are available for a Rosemount service technician during any planned future maintenance.
  • Page 94 Shutdown procedure Reference Manual January 2020 00809-0100-4244 13. Press and select SHUTDOWN. Press Figure 8-2: System 14. Press to accept. Press to reject. Figure 8-3: Shutdown Rosemount CT4400...
  • Page 95 Reference Manual Shutdown procedure 00809-0100-4244 January 2020 15. The screen WILL NOT go blank when the Shutdown has completed. Wait for the heartbeat to stop flashing (Typically 10 -15 seconds) before turning off the power. Figure 8-4: Shutdown Reference Manual...
  • Page 96 Shutdown procedure Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 97: Chapter 9 Preventative Maintenance

    Reference Manual Preventative maintenance 00809-0100-4244 January 2020 Preventative maintenance As a minimum the analyzer MUST be visually inspected for signs of damage or corrosion at the connections weekly to confirm the continued safe operation of the analyzer. As a minimum the Zero and Span calibration for the analyzer MUST be run monthly to confirm the continued accuracy of the analysis being performed.
  • Page 98 Preventative maintenance Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 99: Recommended Spare Parts

    Preventative maintenance to be conducted by unauthorized personnel. Should the need arise to have the analyzer examined you MUST contact customer support (cascade.support@emerson.com) or Emerson distribution partners for technical assistance. General inquiries should be sent to (cascade.support@emerson.com). The only authorized spare parts that are available are listed in Table 10-1 below.
  • Page 100 Recommended spare parts Reference Manual January 2020 00809-0100-4244 Rosemount CT4400...

  • Page 101: Appendix A Engineering Drawings

    January 2020 Engineering drawings These diagrams may be used to locate the position of a connector should it become disconnected. Table A-1: Engineering Drawings Drawing Numbers Description W-2000-0068 Rosemount CT4400 Half Rack System W-2000-0069 Rosemount CT4400 Full Rack System Reference Manual...
  • Page 102 09/JAN/2018 SHEET THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE CASCADE TECHNOLOGIES LTD DESCRIPTION: PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON DO NOT SCALE GLENDEVON HOUSE-CASTLE BUSINESS PARK BALLOON I.D. NO. PROCESS MANAGEMENT AND CANNOT BE COPIED,...
  • Page 103 09/JAN/2018 SHEET THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE CASCADE TECHNOLOGIES LTD DESCRIPTION: PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON DO NOT SCALE GLENDEVON HOUSE-CASTLE BUSINESS PARK BALLOON I.D. NO. PROCESS MANAGEMENT AND CANNOT BE COPIED,...
  • Page 104 THIS DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE SHEET DESCRIPTION: CASCADE TECHNOLOGIES LTD DO NOT SCALE PROPERTY OF CASCADE TECHNOLOGIES LTD, PART OF EMERSON GLENDEVON HOUSE-CASTLE BUSINESS PARK PROCESS MANAGEMENT AND CANNOT BE COPIED, COMMUNICATED BALLOON I.D. NO.
  • Page 106 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 respective owners. youtube.com/RosemountMeasurement...

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