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Fault symptom

Order of troubleshooting

Action or item to be replaced

System unhealthy.

If the pulse is below the laser
threshold, clean the cell mirrors.

Clean the mirrors.

Check the laser beam path for
obstructions.

Clear any obstructions from the laser
beam path.

If the system has rejected

consecutive rejects, press the

Reset

alarms

button on LDM.

Press the

Reset

button (see

Status

lamps / errors

If the IN/OUT count does not match,
reset the counters.

Reset the counters.

AIR

warning light illuminated.

Check the blower isolator is in the ON
position and the blower status bulb is
illuminated.

Switch the blower isolator ON.

Check the compressed air supply.

•

Locate and turn off the customer
air supply to the leak detector.

•

Examine the connections at the
leak detector and the customer
supply to ensure they are not
damaged.

•

Check the air line is not pinched or
kinked stopping air flow.

•

Turn back on the customer air
supply.

Troubleshooting and diagnostics

Reference Manual

July 2022

00809-0100-4245

Rosemount CT4215

Summary of Contents for Rosemount CT4215

Page 1: ...Reference Manual 00809 0100 4245 Rev AC July 2022 Rosemount CT4215 Leak Detection System ...

Page 2: ...lication and the products which it describes No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the express prior written permission of the copyright holder If you require further assistance or technical support contact your local Emerson distribution partner or casc...

Page 3: ...ervicing the product If you do not understand the instructions contact cascade support emerson com for additional clarification Follow all warnings cautions and instructions marked on and supplied with the product Inform and educate your personnel in the proper installation operation and maintenance of the product Install your equipment as specified in the installation instructions of the appropri...

Page 4: ...ak detection system must be instructed trained and qualified with the operating company and the manufacturer It is the operating company s responsibility to Train staff Observe safety regulations Follow the safety instructions and procedures in the product manual Operators must Be trained and competent Read and understand all relevant sections of the product manual before commencing work Know the ...

Page 5: ...and NFPA 70 National Fire Protection Association Compliance approvals Important The analyzer is designed for use in Non Hazardous areas ONLY This product is designed and manufactured under an approved quality management system to ISO 9001 2015 Emerson have satisfied the requirements for applying the CE and UKCA marking to this product This equipment meets all requirements of the EMC and Low Voltag...

Page 6: ...e significant damage and or misconfiguration of end users equipment Protect against all intentional or unintentional unauthorized use Physical security is an important part of any security program and fundamental to protecting your system Restrict physical access to protect users assets This is true for all systems used within the facility Safety precautions The precautions in this manual MUST NOT...

Page 7: ...r The compressed air supply operate at pressures that can cause injury WARNING HAZARD BY WRONG SUPPLY VOLTAGE Serious injury or death could occur The rated voltage for the leak detector is fixed during the manufacture and defined on the ratings label fitted to the unit The voltage at the installation site must meet the rated voltage required WARNING MAINTENANCE Serious injury or death could occur ...

Page 8: ...asuring device Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure CAUTION EQUIPMENT DAMAGE Minor or moderate injury will or could occur Always follow the procedures detailed in the manual otherwise damage to the leak detector may result Only authorized personnel can operate the leak detection system Do not operat...

Page 9: ...o the analyzer in the positions shown below Location Label Type Label fitted A Identification label including the Serial No S N Model No and Date of Manufacture DoM or B AC Supply Voltage or C Chassis earth terminal location N A D Laser radiation CAUTION label 9 ...

Page 10: ...tion Label Type Label fitted E Laser module identification label F Fuse and circuit breaker identification label G Isolate before removing cover DANGER Label AC Supply Voltage or Electrical safety label 10 ...

Page 11: ...stalling the leak detector 33 3 4 Electrical signal compressed air in and sample gas connection details 38 Chapter 4 Start up procedure 43 Chapter 5 Shut down procedure 47 Chapter 6 Software interface description 49 6 1 Leak detector manager 49 6 2 Data logging and reporting 59 6 3 Status lamps errors 62 6 4 Status 64 6 5 PLC configuration 64 Chapter 7 Maintaining the leak detector 77 7 1 Schedule...

Page 12: ...Contents Reference Manual July 2022 00809 0100 4245 12 Rosemount CT4215 ...

Page 13: ...roduct range and a where required a reject mechanism to remove the defective goods from the production line This document is intended for the personnel who install operate and maintain the leak detector 1 1 System overview The leak detector can be installed along side existing production lines and comprises an all metal stainless steel enclosure containing the analyzer PLC control system compresse...

Page 14: ...Product line direction F Input gate G Rejector H Sample head I Reject chute Collection bin customer supplied J Circuit breakers K AC supply L Customer connections M Compressed air line connections Leak detection overview Reference Manual July 2022 00809 0100 4245 14 Rosemount CT4215 ...

Page 15: ...uttons C Upper enclosure fitted with the analysis cell and cell purge D 1st compartment fitted with the electrical back plate and electronics panel E 2nd compartment fitted with the air preparation panel F 3rd compartment fitted with the sample air motor and electrical shut off Reference Manual Equipment and accessories 00809 0100 4245 July 2022 Reference Manual 15 ...

Page 16: ...ing controls and displays A USB port 2 B USB port 1 C Air fault indicator D Reset button E Main HMI display screen F PLC screen Equipment and accessories Reference Manual July 2022 00809 0100 4245 16 Rosemount CT4215 ...

Page 17: ...t connected to the blower motor E Cell output mirrors directing the laser beam from the cell into the detector F Detector G One of two purge connections for the output mirrors inside the cell H Sample gas analysis cell I Laser module J Cell input mirrors directing the laser beam into the cell Reference Manual Equipment and accessories 00809 0100 4245 July 2022 Reference Manual 17 ...

Page 18: ...n is mounted in the 1st compartment of the lower enclosure A Electronics panel B Electrical back plate upper DIN rail C Electrical back plate lower DIN rail Equipment and accessories Reference Manual July 2022 00809 0100 4245 18 Rosemount CT4215 ...

Page 19: ...24V power supply F 12V power supply G PLC Figure 2 2 Lower DIN rail components A Earth terminal block B Earth terminal block C Fuse terminals D Double terminals E Terminals F Relays G 24V opto relay H 12V opto relay Reference Manual Equipment and accessories 00809 0100 4245 July 2022 Reference Manual 19 ...

Page 20: ...be filtered dried and pressure regulated before being used to purge the analysis cell when needed or the reject system if attached The assembly shown is A Ethernet hub B Factory compressed air in C Shut off valve D Pressure regulator with 40 µm filter E 0 1 µm filter F Membrane dryer G Pressure switch MPa H Filtered air out I Reject solenoid Equipment and accessories Reference Manual July 2022 008...

Page 21: ...ment of the lower enclosure A Sample gas blower motor B Cooling fans C Electrical shut off and isolation D Sample gas out vented to the factory E Sample gas in drawn from the analysis cell outlet Reference Manual Equipment and accessories 00809 0100 4245 July 2022 Reference Manual 21 ...

Page 22: ...s a fault C Green beacon indicates the leak detector system is working normally D Sample gas inlet connection to the cell E Sample gas outlet from the cell to the blower motor inlet F In line cartridge filter G Ø19mm inside diameter sample line connected to the sample head Maximum tube length 5 metres Equipment and accessories Reference Manual July 2022 00809 0100 4245 22 Rosemount CT4215 ...

Page 23: ...supplying an air reject system H M6 Chassis earth connection I Signal connection from the sample head input gate Mating connector will be supplied with the unit J Signal connection from the sample head reject gate Mating connector will be supplied with the unit K Status connection for customer telemetry output connection Mating connector will be supplied with the unit L Ethernet connection M Loose...

Page 24: ...ther sampling or bespoke options can be discussed with your local Emerson distribution partners Typical Beverage Production System Typical Food Production System A Conveyor new or fitted to an existing product line B Sample head examples for illustration purposes C Product being sampled D Light gates for product count in and out E Reject system to eject faulty product from the line Equipment and a...

Page 25: ... to encourage Modified Atmosphere Packages MAP gas to leak through defect points The sample head height can be height adjusted on the production line to support multiple product pack sizes A Sample bar B Roller C Height adjustment The passive roller head consists of three semi flexible rollers with sample bars fitted at the entry and exit of the sample head As product packs pass through the passiv...

Page 26: ... be drawn into the sample bars and through the leak detector triggering the counter and product reject systems 2 9 2 Keg barrel The keg barrel sample head consists of a simple support frame and sample bar that can be mounted easily onto an existing conveyor line A Support frame B Sample bar The sample bar MUST be installed 25 mm 1 inch above the height of the keg barrel being tested allowing the p...

Page 27: ...s to be opened to complete the installation and for any future maintenance The leak detector MUST be positioned within 2 m 6 6 feet of the sample head being used to ensure the sample tube connection is kept to a minimum The total sample tube length must be less than 5 m 16 4 feet Note Longer lengths will result in additional sample delay and additional time between the sampling and rejection point...

Page 28: ...iew showing floor area required for installation of the leak detector B Plan view showing floor area required for the leak detector with transportation wheels fitted Installation Reference Manual July 2022 00809 0100 4245 28 Rosemount CT4215 ...

Page 29: ...l and ShockDot labels fitted to the outside of the shipping container Tip N Tell White arrow becomes blue when tilted 80 from vertical Shock Dot indicator turns red when a potentially damaging impact has occurred The labels will alert the customer to any mishandling of the analyzer when in transit Where possible transport the leak detector in the shipping crate to the site selected for install Car...

Page 30: ... leather gloves and safety shoes as a minimum The ramp can now be located at the front of the shipping container Visually inspect the exterior of the analyzer for signs of damage and verify that all items shipped were received Report anything found to the maintenance organization Installation Reference Manual July 2022 00809 0100 4245 30 Rosemount CT4215 ...

Page 31: ...o the floor of the shipping container Remove the threaded rod from the container floor Finally remove any straps used to secure the leak detector upper sections from vibration during transit Reference Manual Installation 00809 0100 4245 July 2022 Reference Manual 31 ...

Page 32: ...ing it moving as the leak detector is removed Removing the Leak Detector from the shipping container Option 2 Remove the ramp from the front of the container to allow fork lift access 4 x Fork lift pockets are provided as part of the transportation trolleys Care must be taken if a fork lift is used as there is limited head clearance between the shipping container and the top off the leak detector ...

Page 33: ...The leak detection system weighs 119 kg 263 lb and should only be moved by a minimum of two people using suitably rated lifting moving equipment To prevent crushing of hands feet or other body parts always wear suitable protective gloves and footwear when handling The selected installation site must be suitable to support the weight of the leak detection system cabling and gas sample lines when in...

Page 34: ...n the floor 636mm 25in apart to suit M8 anchor bolts This will secure the leak detector when installed A Securing anchor bolt hole dimensions B Leveling feet pads C M8 Anchor bolt D Additional oversized washer Installation Reference Manual July 2022 00809 0100 4245 34 Rosemount CT4215 ...

Page 35: ...the leak detector enclosure while the transportation wheels are slid out from under the unit Remove the two press fit covers to access the bolting position Fit the securing bolts loosely to locate the leak detector in place DO NOT TIGHTEN at this time Remove the 4 off press fit covers to access the adjustable feet Using a 14mm AF socket adjust the feet to suit giving a horizontal stable platform f...

Page 36: ...has been fitted to the enclosure upside down for transportation Using an 8mm AF hex allan key give a quarter turn to open the top enclosure door lock Note Cables are connected to the inside of the door Installation Reference Manual July 2022 00809 0100 4245 36 Rosemount CT4215 ...

Page 37: ...ure door when complete The hose from sample head can now be connected to the inlet filter fitted to the rear of the leak detector Installation of the leak detector is now complete Please refer to separate instructions for installation of the sampling head required Reference Manual Installation 00809 0100 4245 July 2022 Reference Manual 37 ...

Page 38: ...WRONG SUPPLY VOLTAGE Serious injury or death could occur The rated voltage for the leak detector is fixed during the manufacture and defined on the ratings label fitted to the unit The voltage at the installation site must meet the rated voltage required Procedure 1 All electrical connections are fitted to the rear panel of the leak detector 2 Power to the leak detector is connected through the Ma...

Page 39: ...upply IEC 60309 industrial right angle connector 2P E Yellow 110 130 V Blue 200 250 V Fitted to the rear of the leak detector B AC supply IEC 60309 industrial cable mount connector 2P E Yellow 110 130 V Blue 200 250 V Supplied loose for customer connection Pin 1 Live Pin 2 Neutral Pin 3 Earth C Power cable Mains 3 core 1 5mm2 power cable sheathed 16A 300 500V minimum Customer supplied power cable ...

Page 40: ...Procedure 1 Use the information provided in this section to make the required electrical connections 2 The Ethernet connector is used by either the service technicians for downloading data for failure diagnosis purposes or for a customer control center Item Designation Type Max rating Description A Ethernet RJ45 Ethernet N A Communication with sensor B Status Bulgin 3P male 30Vdc 1A Relay contacts...

Page 41: ... count incoming packs Input current 10mA maximum Signal connection from the sample head input gate Mating connector will be supplied with the unit E Earth connection N A N A M6 threaded stud for customer chassis earthing point Pin orientation shown when looking at the rear panel connections Pin Status B Reject C Input D 1 Relay normally closed 24V 24V 2 Relay common Switched 0V 0V 3 Relay normally...

Page 42: ...low 2 Compressed air connections for purge and reject option A Sample gas connection point B Sample gas inlet to the analysis cell C Sample gas outlet from the analysis cell to the blower motor inlet D Connection from the factory compressed air supply using 8mm outside diameter push fit plastic tubing Factory compressed air in connected to the inlet on the air preparation plate E Optional compress...

Page 43: ...osure doors are closed and locked If you cannot close and lock the doors report it to the maintenance organization and do not proceed until the door has been repaired 4 Visually inspect the leak detector s exterior for signs of damage reporting anything found to the maintenance organization 5 Confirm that all connections to the leak detector and the sample handling system fitted to the production ...

Page 44: ...10 Switch on the factory compressed air supply 11 Switch on the blower motor at the blower isolator switch mounted on the lower right panel the blower status lamp should be on if not report the fault to the maintenance organization Start up procedure Reference Manual July 2022 00809 0100 4245 44 Rosemount CT4215 ...

Page 45: ...ress the Reset button and ensure there is a green light on the beacon to confirm the leak detector is now operational A Beacon buzzer line unhealthy line stop B Beacon red LED line unhealthy line stop C Beacon green LED line healthy D Reset button E Air fault indicator Reference Manual Start up procedure 00809 0100 4245 July 2022 Reference Manual 45 ...

Page 46: ...Start up procedure Reference Manual July 2022 00809 0100 4245 46 Rosemount CT4215 ...

Page 47: ...egulated clean filtered and moisture free supply source NOTICE Failure to follow the correct shutdown procedure may damage the on board systems for the leak detector In an emergency the leak detector can be turned off at the unit isolator Procedure 1 Turn off the compressed air supply connected to the leak detector 2 On the main display screen select the PowerDown option indicated Reference Manual...

Page 48: ...itch off 5 Switch off the unit and blower isolators mounted on the side panel 6 Mains voltage is still being applied to the leak detector Turn off the mains power at the customer supplied circuit breaker or remove the plug Shut down procedure Reference Manual July 2022 00809 0100 4245 48 Rosemount CT4215 ...

Page 49: ...eak detector manager The leak detector manager software is designed to provide clear information of the production through put of the line being monitored A Control options B Outputs Explained in Status lamps errors C Counters showing product throughput D Screen option selections Toggle between the three tabs to change which visual information is displayed The Pulse display shows the laser pulse a...

Page 50: ...lower threshold is typically set at 80 of the upper threshold to capture any packs with marginal leaks Allowing the operator to investigate where required The Unit display continually shows the readings being taken for each product pack tested on the production line The plot shows all data points between the input and output gate and records the size of any rejection spike detected 6 1 1 Setup Fac...

Page 51: ...aser system 6 1 3 Monitoring start stop The leak detector automatically starts monitoring after startup has been completed Pressing the stop monitoring button will pause the system software Note It will not stop the leak detector packages will continue to be detected and rejected Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 51 ...

Page 52: ... 6 1 4 Configure The configure button allows access for specialists during setup and password protected is not required to be accessed by the operator Operator access is not required select cancel to return to the main screen Software interface description Reference Manual July 2022 00809 0100 4245 52 Rosemount CT4215 ...

Page 53: ...the alarm button to cancel the alarm Select Yes to reset the alarm Provided the fault has been cleared the main display screen will return showing a green healthy display If the system is still detecting a fault refer to Troubleshooting and diagnostics Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 53 ...

Page 54: ...e counters button to zero the product count being monitored on the production line Confirm counters have to be reset Counters reset Software interface description Reference Manual July 2022 00809 0100 4245 54 Rosemount CT4215 ...

Page 55: ...If checked software will start monitoring on startup Display scale If checked software will display scaling options for graphs on bottom right of screen 6 1 8 Recipe The recipe screen allows the user to change the system leak detection thresholds for different product packs Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 55 ...

Page 56: ...quired from the list Press Download Select Yes On the following pop ups select Yes After a few seconds delay press Restart Sensor and the recipe window will disappear Software interface description Reference Manual July 2022 00809 0100 4245 56 Rosemount CT4215 ...

Page 57: ...thresholds can be manually adjusted by selecting Set Thresholds The upper and lower thresholds required can be entered Pressing Send Values will update the system immediately No software reboot is required Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 57 ...

Page 58: ...n Select the power down button when shutting down the leak detector before switching off the main power supply Note Switching off the mains power without powering down the software can cause data loss and or corruption Confirm computer shutdown is required Software interface description Reference Manual July 2022 00809 0100 4245 58 Rosemount CT4215 ...

Page 59: ...s elsewhere A USB port 2 B USB port 1 C Air fault indicator D Reset button E Main HMI display screen F PLC display screen Select Reports to start the reporting process The reporting screen is password protected the password will be supplied during installation Follow the on screen instructions to generate the report required Reference Manual Software interface description 00809 0100 4245 July 2022...

Page 60: ...tion E Copy Report File Move a file from one location to another F Create Service Report Creates a service report Note The file must be saved as filename txt You can export the txt report file to a USB stick and process it elsewhere If you open the file using a spreadsheet application it will look like the example below Software interface description Reference Manual July 2022 00809 0100 4245 60 R...

Page 61: ... the concentration exceeds this value the package is rejected LT The lower threshold If two consecutive concentration points exceed this value the package is rejected Noiselevel The noise value at the time when the package is logged Reject Packages which do not breach thresholds are reject 0 and those which breach thresholds are reject 1 Note If you want to view only rejected packages then filter ...

Page 62: ...y trigger the red beacon bulb black buzzer and line stop if applicable A Alarm beacon Green for healthy red for unhealthy line stop black audible buzzer for unhealthy line stop B Reset button to clear latched alarms C AIR status bulb Illuminates when blower or compressed air is off D Blower status The bulb is on when power is supplied to the blower motor If the power is interrupted the bulb doesn ...

Page 63: ...his error automatically clears when the pulse amplitude is above the threshold Maintenance The yellow warning triangle appears if the laser pulse amplitude is below the warning threshold value System performance is not affected but you should consider activating the mirror purge or cleaning the cell mirrors soon This error automatically clears when the pulse amplitude is above the warning threshol...

Page 64: ...ners The PLC screen has password protection in order to prevent unauthorized Only trained personnel should change the settings for the PLC access The credentials are provided to the relevant department during installation Following any change to line speed pack size or pack spacing qualified personnel should verify the system setup to ensure test packs are being detected correctly The system is de...

Page 65: ...t E Reject delay F Reject duration G Single product pack One Shot H Product pack length I Sample head J Input gate location K Leak detection control system L Reject mechanism location Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 65 ...

Page 66: ... inspected Range 0 10000 msecs End time time taken for the gas sample to reach the leak detector pack travel time between first and second sample bars Reject Delay This is the delay between measurement end and the rejection point Range 0 60000 msecs 1 minute Reject Duration The time the rejector will remain on for This should be set long enough to ensure the pack is rejected but not long enough th...

Page 67: ...ld take for the pack to pass through the input gate in msecs milliseconds One second 1000 msecs A Minimum pack length B Maximum pack length 3 Alternatively using a stopwatch or video determine the time taken for a pack to fully pass by the input gate For fast moving product lines take the measurement over a larger number of packs and divide the time recorded by the number of packs Reference Manual...

Page 68: ...onfirm the setup has been calculated entered correctly Adjust if required 6 5 2 Setting the measurement start and end The measurement start and end require more detailed configuration Sufficient time MUST be taken to ensure that all steps in the procedure below have been completed Procedure 1 The production line MUST be running steadily at the required production rate to ensure accurate measuremen...

Page 69: ...Using a stopwatch or video determine the time taken for a pack to pass between the input gate and the first sample measurement bar For fast moving product lines take the measurement over a larger sample number of packs and divide the time recorded by the number of packs Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 69 ...

Page 70: ...e required measurement start time 6 Repeat this process to measure the time taken for the pack to pass between the input gate and the second sample measurement bar Add a further 500 msecs to the time taken and enter it as the initial measurement end time 7 A test pack with a known leak situated at the far end of the pack will be sent along the product line to confirm the setup 8 Leak detection is ...

Page 71: ...checking the unit tab A Measurement start B Far end leak detected C Measurement end 10 Retest a minimum of 10 times to confirm that the spikes are being detected for packs with a far end leak Spikes will be detected consistently in the same region of the graph Always confirm the presence of a spike on the concentration screen before checking the unit tab 11 Change the test pack being tested to a n...

Page 72: ...sistently in the same region of the graph Always confirm the presence of a spike on the concentration screen before checking the unit tab 15 The measurement window measurement start measurement end is now set for this package type and product line speed 16 If other package types and line speeds are used commonly then these should be configured separately Record the settings for each pack and produ...

Page 73: ...ST be running steadily at the required production rate to ensure accurate measurements If the line speed is changed the measurement will need to be repeated and reset 2 Sample packs with a known leak will be required to trigger the reject mechanism 3 Once the pack length and measurement start stop settings have been configured set the initial reject delay to 10 msecs milliseconds 4 Set the reject ...

Page 74: ...e tape mark For fast moving product lines take the measurement over a larger sample number of packs and divide the time recorded by the number of packs 8 Repeat the measurement a number of times to enure consistent results 9 Convert the time taken to msecs milliseconds One second 10000 msecs 10 Reset the reject delay time to the time taken in msecs to reach the tape mark 11 Install the reject mech...

Page 75: ...e pack has been rejected Reduce the reject duration 10 msecs at a time 14 Retest a minimum of 10 times to confirm that the packs are still being rejected cleanly Reference Manual Software interface description 00809 0100 4245 July 2022 Reference Manual 75 ...

Page 76: ...Software interface description Reference Manual July 2022 00809 0100 4245 76 Rosemount CT4215 ...

Page 77: ...aning materials or methods on the outside of the unit Visually inspect the sample gas inlet filter only if required clean or replace As Required Cleaning the cell mirrors Purging the analysis cell 7 2 Purging the analysis cell WARNING HIGH PRESSURE AIR Serious injury or death could occur The compressed air supply operate at pressures that can cause injury Cell mirrors are a precision optical devic...

Page 78: ... Note If this does not solve the issue Follow all the steps in Cleaning the cell mirrors 7 3 Cleaning the cell mirrors CAUTION LASER OPTICAL PATH Serious injury or death could occur Operators do not have access to the internal laser or electrics during normal operation Maintenance personnel must only access the internal laser or electrics after the analyzer has been turned off Opening the leak det...

Page 79: ... listed below Optical grade lens cleaning tissues Spectroscopic grade methanol or ethanol Preparation Switch off the blower isolator Note Leave the Unit Isolator switched on Using a 8mm AF hex allan key give a quarter turn to open the top enclosure door lock Under no circumstance should the lower enclosure door be opened at this time Note Cables are connected to the inside of the door Care must be...

Page 80: ...as shown The cell mirror is recessed back into the ends of the analysis cell making it difficult to see when cleaning Note The cell mirror coating is delicate and highly reflective Excessive force WILL permanently damage the mirror coating putting the leak detector out of operation ONLY trained operators should perform this task Maintaining the leak detector Reference Manual July 2022 00809 0100 4...

Page 81: ...direct pressure compressing the tissue this will scratch the mirrors Wipe the wet tissue across the mirror in one continuous motion in the direction shown DO NOT apply pressure or repeat the process The tissue should pass lightly over the mirror surface picking up any debris Note Use 1 lens tissue for each mirror cleaned Mirror Cleaning Complete Carefully refit the o ring and cell lid to the analy...

Page 82: ...s 0 4 V Note Contact cascade support emerson com if there are any issues 7 4 Replace the sample gas inlet filter The sample gas filter is essential as it prevents dust and debris from reaching the analysis cell Switch of the blower isolator to stop the sample gas being drawn from the production line sample head Locate the sample gas inlet filter connected to the rear panel A Circlip retaining wash...

Page 83: ...t compromised 7 5 Replacing a fuse Fuses are located on the electrical backplate located in the lower enclosure Due to the risk only a competent person can perform this task DANGER ELECTRIC SHOCK Serious injury or death will occur The leak detection system operates using mains voltage and must be switched off and the power cable removed before opening the analyzer Turn off the compressed air suppl...

Page 84: ...key give a quarter turn to open the lower enclosure door locks Note Cables are connected to the inside of the door Care must be taken when opening and closing the door to prevent damage The fuses are located on the lower DIN rail fitted to the electrical back plate Locate the fuse required to be changed Maintaining the leak detector Reference Manual July 2022 00809 0100 4245 84 Rosemount CT4215 ...

Page 85: ...test using an ohmmeter If blown replace the fuse If okay refit and go to the Troubleshooting and diagnostics section Note Only an approved fuse as specified below MUST be used F1 4 A Eaton GMA 4 R F2 5 A Eaton GMA 5 R F3 1 A Eaton GMA 1 R Reference Manual Maintaining the leak detector 00809 0100 4245 July 2022 Reference Manual 85 ...

Page 86: ...Maintaining the leak detector Reference Manual July 2022 00809 0100 4245 86 Rosemount CT4215 ...

Page 87: ... On the isolator Check the mains power plug is fully connected on the unit rear panel If loose or disconnected Switch off the unit isolator Fit the plug correctly and lock in place using the locking ring fitted Switch back on the unit isolator Check the mains power cable connection to the customer circuit breaker or wall socket If Off switch On Check the mains power cable connection to the custome...

Page 88: ...hed on at the Blower isolator fitted on the lower side panel If Off switch On the isolator Check the MCB fitted to the isolator distribution box has not tripped Open the lower enclosure door If the circuit breaker has tripped Switch off the blower isolator and contact maintenance to investigate why it has tripped Troubleshooting and diagnostics Reference Manual July 2022 00809 0100 4245 88 Rosemou...

Page 89: ...n Reconnect the cable connections if loose Trace the cables back to confirm the second end is also connected fully Restart the leak detector Maintenance alarm on LDM If the pulse is below the LASER warning threshold consider purging the cell with compressed air Note The system will still be healthy Purge the cell Consider cleaning the cell mirrors soon when pulse is below threshold Clean the mirro...

Page 90: ... OUT count does not match reset the counters Reset the counters AIR warning light illuminated Check the blower isolator is in the ON position and the blower status bulb is illuminated Switch the blower isolator ON Check the compressed air supply Locate and turn off the customer air supply to the leak detector Examine the connections at the leak detector and the customer supply to ensure they are n...

Page 91: ... unhealthy and System unhealthy above Check if the AIR warning light is illuminated Repeat the row AIR warning light illuminated above System is not counting packs Check the INPUT gate cable is attached at both ends control system and light gate Attach the cable do not hot plug if loose Check that the orange LED is flashing on the light gate when a pack enters the system Gate sensitivity can be ad...

Page 92: ...Troubleshooting and diagnostics Reference Manual July 2022 00809 0100 4245 92 Rosemount CT4215 ...

Page 93: ...lled operating temperature Storage temperature range 20 to 50 C 4 to 122 F Ambient temperature when in storage shipping Altitude 2000 m 6562 ft N A Humidity range 10 to 95 Relative humidity non condensing at 35 C 95 F Ambient pollution degree 2 N A Laser Type Product laser classification Class 1 BS EN 60825 1 2014 safety of laser products Equipment classification and requirements IEC 60825 1 2014 ...

Page 94: ...ll rights reserved Emerson Terms and Conditions of Sale are available upon request The Emerson logo is a trademark and service mark of Emerson Electric Co Rosemount is a mark of one of the Emerson family of companies All other marks are the property of their respective owners ...

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