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9

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. Any anomalies found
should be reported to the maintenance department and where in doubt the analyzer
should be switched off until rectified. Variation in customer sites may require these
activities to be performed more or less often than indicated.

Reference Manual

Preventative maintenance

00809-0100-4244

January 2020

Reference Manual

97

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Summary of Contents for Rosemount CT4400

Page 1: ...Reference Manual 00809 0100 4244 Rev AA January 2020 Rosemount CT4400 Continuous Gas Analyzer ...

Page 2: ...ved for future use Contact your local service center or sales office if you are missing documents User information Important All users must read this page before proceeding Rosemount designs manufactures and tests its products to meet many national and international standards The Rosemount CT4400 is a sophisticated technical product and to ensure it continues to operate as designed and within norm...

Page 3: ...t manual Operators must Be trained Read and understand all relevant sections of the product manual before commencing work 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 instruction manual and receiving ...

Page 4: ... result in death or serious injury to personnel WARNING DANGER TO PERSONNEL Failure to follow this warning may result in serious injury to personnel WARNING SAFETY COMPLIANCE Repairs or alterations are not permitted on any flame proof paths features or joints Failure to follow this warning may compromise the product s safety protection method and void the product certification NOTICE Important mes...

Page 5: ...ccessible 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 WARNING HAZARDOUS SUBSTANCES The analyzer may contain hazardous substances Always handle the analyzer assemblies and components with extreme caution Wear personal protective equ...

Page 6: ...ring startup The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance Purging the sample gas must be done in accordance with the safe working procedures for the site Allow the analyzer and the venting system to run for a minimum of five minutes to allow any sample gas in the system to be returned to the exhaust WARNING HEAVY ITEM Handle ...

Page 7: ... which case the user may be required to take adequate measures CAUTION EQUIPMENT DAMAGE Ensure that the local power voltage where the unit is to be installed corresponds to the unit s nominal voltage as given on the name plate label CAUTION EQUIPMENT DAMAGE Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the analyzer are...

Page 8: ... Config No and Date of Manufacture DoM Fitted on the rear panel Identification ratings label for the Half Rack System Fitted on the rear panel of the unit Identification ratings label for the Full Rack System Fitted on the rear panel of the unit Earth identification label Backplate 8 ...

Page 9: ...tion Copyright Percent Degree AC Alternating current BS British Standard C Celsius CE European Conformity CFR Code of Federal Regulations e g For example EC European Community EMC Electromagnetic compatibility EU European Union Hz Hertz H2O Water IEC International Electro technical Commission in Inches IP Internet Protocol ISO International Organization for Standardization k Thousand kg Kilogram L...

Page 10: ...O Nitricoxide N2O Nitrousoxide No Number O2 Oxygen PC Personal computer ppm Parts per million QCL Quantum Cascade Laser SELV Safety Extra Low Voltage SELV circuits Torr Unit of pressure defined as exactly 1 760 of a standard atmosphere USA United States of America USB Universal serial bus V Volt Vac Volt alternating current Vdc Volt direct current W Watt WEEE Waste electrical and electronic equipm...

Page 11: ... Introduction 29 3 2 Preparation for use 29 3 3 Start up procedure 30 Chapter 4 Operating the analyzer 33 4 1 Introduction 33 4 2 Normal operation 33 4 3 Display controller 35 4 4 Gas sensor main screen 36 4 5 Pressure and temperature screen 37 4 6 Help system 38 4 7 Main menu 38 4 8 BACK button 39 Chapter 5 Verifying gas concentrations 41 5 1 Verification 41 Chapter 6 Gas calibration 49 6 1 Requi...

Page 12: ...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 Contents Reference Manual January 2020 00809 0100 4244 xii Rosemount CT4400 ...

Page 13: ...guration required 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 Rosemount recommends that the analyzer is moved by a minimum of two people when lifting and transporting the equipment Fa...

Page 14: ...0 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 Plan Reference Manual January 2020 00809 0100 4244 14 Rosemount CT4400 ...

Page 15: ...om either a 110 Vac 60Hz or a 230 Vac 50Hz supply Gas concentrations are measured using mid infrared optical absorption spectroscopy The light source is provided by a quantum cascade laser or tuned diode laser which produces wavelength sweeps that cover the absorption lines of the gases The light from the laser is routed through an optical path to the analysis cell which provides measurement of lo...

Page 16: ...e cable MUST be earthed 10 Cable from analyzer to control center Customer Customer choice 1 N A 11 482 6 mm 19 in rack system Customer Customer choice 1 Holds the Rosemount CT4400 1 4 Customer information This manual contains all the important information that must be followed to ensure the correct operation and safety of personnel when operating the analyzer For information regarding installation...

Page 17: ... 1 6 Qualified personnel This manual provides installation operation and maintenance personnel with the level of knowledge required to safely start operate and switch off the analyzer Only technically qualified personnel in the field of analysis and control who are familiar with this manual and have been specially trained on the analyzer should install operate switch off and service the analyzer O...

Page 18: ...istics Rosemount CT4400 Value Units Comment Supply voltage 110 230 10 Vac N A Supply Frequency 60 50 5 Hz N A Peak power consumption 50 W Max consumption Frame and structure material N A N A Anodized and powder coated aluminum Housing material N A N A Powder coated steel Wetted materials N A N A PF Acoated aluminum 316 stainless steel FKM and FFKM seals CaF2 and BaF2 windows protected gold coated ...

Page 19: ... atm abs Typically 1 atm abs Sample gas flow rate 1 5 L min N A Sample gas moisture content 2 Ensure the dew point of the gas is at minimum 18 10 below the ambient temperature to avoid condensate in the gas lines Sample gas particulate density 5 mg m3 Maximum Sample gas particulate size 10 µm Maximum Maximum operating altitude 2000 m N A Maximum relative humidity 80 31 Decreasing linearly to 50 re...

Page 20: ...t all times Sudden fluctuations in pressure will affect the analysis being performed In the event of a power failure any residual sample gas should be purged from the analyzer to ensure any corrosive gas elements are not left to contaminate degrade the internal components Failure to do so could result in irreparable damage to the analyzer Sample filtration may be required to ensure the gas sample ...

Page 21: ...es and protective footwear Procedure 1 Visually inspect the packaging to ensure there has been no damage in transit or storage 2 Open the packaging and visually inspect the exterior of the analyzer for signs of damage corrosion gas leaks or signs of previous overheating if returning from storage 3 Report anything found to the maintenance organization 4 Carefully lift the analyzer from the shipping...

Page 22: ...et G Sample gas inlet H Analog output 4 20 mA I Mains power inlet 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 Plan Reference Manual January 2020 00809 0100 4244 22 Rosemount CT4400 ...

Page 23: ...ormance 2 Site selection for analyzer installation MUST account for the handles on the front face of the full rack system and rear entry for the cable and tube connections see Figure 2 1 and Figure 2 2 3 Screw in rubber feet have been fitted to the base of the analyzer if required these can be removed to aid assembly into the rack system being provided 4 The full rack system has additional slotted...

Page 24: ...out of the rack on the slides 8 Install the analyzer in a standard 19 in 482 6 mm rack system Note Supply of the rack telescopic slide rails fitting and securing the analyzer into the rack is the responsibility of the Customer Typical requirement 2 off telescopic slides 24 in 610 mm long 121 3 lb 55 kg maximum load 2 in 50 8 mm over travel 4 in 9 6 mm slide thickness Lock out Front disconnect 9 In...

Page 25: ...omer must provide gas at a constant temperature to the sample gas input port on the analyzer to prevent condensation forming at any point in the sample supply line within the analyzer which could reduce the accuracy of the gas analysis 2 The gas sample enters the analyzer through the sample gas input port C Figure 2 4 3 Once the gas sample passes through the measurement cell and it is expelled fro...

Page 26: ... 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 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 Install Reference Man...

Page 27: ...utput from the analyzer through the Analog Output connection Figure 2 5 C and sent to your process control center Table 2 1 Analog Outputs Half Rack System 25 Way Socket Pins Function Measurement point of display 1 14 Analog channel 0 set in config file 4 20 mA SELV Sample gas measurement 1 2 15 Analog channel 1 set in config file 4 20 mA SELV Sample gas measurement 2 3 16 Analog channel 2 set in ...

Page 28: ...nel 4 set in config file 4 20 mA SELV Sample gas measurement 5 6 19 Analog channel 5 set in config file 4 20 mA SELV Sample gas measurement 6 7 20 Analog channel 6 set in config file 4 20 mA SELV Sample gas measurement 7 8 21 Analog channel 7 set in config file dry contacts 1A 30 Vdc Sample gas measurement 8 9 22 Status output 1 check function optional dry contacts 1A 30 Vdc N A 10 23 Status outpu...

Page 29: ...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 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 CAUTION EQUIPMENT DAMAGE D...

Page 30: ...r of the analyzer for signs of damage corrosion gas leaks or overheating Report anything found to the maintenance organization 2 Ensure that the analyzer has been correctly installed See Install 3 Ensure that the On Off switch at the rear of the analyzer is set to I ON Figure 3 1 Rear Panel ON OFF Switch A Rear panel B On Off switch 4 The start up sequence commences automatically under software co...

Page 31: ...analyzer 7 Start the gas handling system that conditions the sample gas before it is fed into the analyzer 8 Allow the analyzer sufficient time to stabilize in accordance with Table 1 3 before steady state measurements are taken Reference Manual Start up procedure 00809 0100 4244 January 2020 Reference Manual 31 ...

Page 32: ...Start up procedure Reference Manual January 2020 00809 0100 4244 32 Rosemount CT4400 ...

Page 33: ...refore its normal state is to be switched on and performing gas measurements The analyzer is usually only switched off for maintenance The shutdown procedure used to switch off the analyzer is described in Shutdown procedure Provided that the Start up procedure has been followed the analyzer does not require any human intervention during normal operation other than occasional calibration checks as...

Page 34: ...ture screen Figure 4 2 has no function when the analyzer is operating correctly If however the software detects a fault and an error message is displayed press to get further information on the error 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 and to scroll up and down the list Operating the anal...

Page 35: ...are configured to perform different functions according to which software screen is shown on the LCD display Table 4 1 Display Controller Navigation Button Functions Button Description Normally used to scroll up Referred to as UP Normally used to scroll down Referred to as DOWN Normally used to select Also accesses the Main Menu from the Home screen Referred to as RIGHT Used to go back to the prev...

Page 36: ...ification signal out of the specified range Indicates the analyzer is performing a calibration or validation or that the software has been deliberately stopped Failure non valid output signal 4 4 Gas sensor main screen When the analyzer is switched on at the end of the startup procedure the Gas Sensor Main screen Figure 4 4 appears The Gas Sensor Main screen is the screen that is normally displaye...

Page 37: ...screen Figure 4 5 Press to toggle between the two screens is a link to the Home Screen Press to go to a Help screen described in Help system On the Gas Sensor Main screen has no function when the analyzer is operating correctly If however the software detects a fault an error message is displayed Press to get further information on the error 4 5 Pressure and temperature screen The Pressure and Tem...

Page 38: ... the internal calculations and compares desired and actual parameters for example the analysis cell pressure and temperature The diagnostics routines and screens are used to perform fault diagnosis FAULTS Navigates to a screen that lists any faults affecting the analyzer This option is used as part of the failure diagnosis procedures GAS SERVICE Allows you to check the sensor readings against a kn...

Page 39: ...hese options are not available on older analyzers Figure 4 7 Main Menu 4 8 BACK button On most of the software screens is configured as a BACK button Press to return to the previous screen Reference Manual Operating the analyzer 00809 0100 4244 January 2020 Reference Manual 39 ...

Page 40: ...Operating the analyzer Reference Manual January 2020 00809 0100 4244 40 Rosemount CT4400 ...

Page 41: ...g the following procedure Procedure 1 Use nitrogen gas of instrument gas purity as the zero verification gas 2 Ensure that a pressure regulator is connected to the nitrogen gas bottle 3 Connect a hose from the nitrogen gas bottle through a T piece to the sample supply port on the rear of the analyzer 4 Connect an excess flow line to the unused port on the T piece and route the excess flow line to ...

Page 42: ...r Gas 9 Scroll or and select from the list the gas to be tested Press Figure 5 3 Select Gas Screen 10 Scroll or and select RUN ZERO Press Figure 5 4 For NH3 Verifying gas concentrations Reference Manual January 2020 00809 0100 4244 42 Rosemount CT4400 ...

Page 43: ...has detected a concentration of 0 866 ppm If the reading is within tolerance no further action is required 12 Press to end the zero verification process 13 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 Reference Manual Verifying gas c...

Page 44: ...that a pressure regulator is connected to the reference gas bottle 3 Connect a hose from the reference gas bottle through a T piece to the sample supply port on the rear panel of the analyzer 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 or select GAS SERVICE Press F...

Page 45: ...ER GAS Press Figure 5 8 Gas Service 8 Scroll or and select from the list the gas to be tested Press Figure 5 9 Select Gas Selection Reference Manual Verifying gas concentrations 00809 0100 4244 January 2020 Reference Manual 45 ...

Page 46: ...ayed matches the cylinder you are using Once the concentration has been set Press to accept 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 Verifying gas concentrations Reference Manual January 2020 00809 01...

Page 47: ...ed is NH3 and the analyzer has detected a concentration of 0 510 ppm Figure 5 13 Result Screen If the reading is within tolerance no further action is required If the reading is outside tolerance follow the zero calibration procedure in Zero calibration 13 Press to end the span verification process Reference Manual Verifying gas concentrations 00809 0100 4244 January 2020 Reference Manual 47 ...

Page 48: ...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 Verifying gas concentrations Reference Manual January 2020 00809 0100 4244 48 Rosemount CT4400 ...

Page 49: ... calibration must be carried out e g for legal requirements it can be calibrated by using a water vapor generator to supply a known concentration of water vapor 6 2 Gas service menu definitions The GAS SERVICE menu screen can be accessed from the Main Menu screen This gives the operator access to a number of software routines and screens that are used for calibration and maintenance of the analyze...

Page 50: ...nce 2 At regular intervals such as once a month 6 3 1 Zero calibration The zero calibration procedure adjusts for any zero offset in the measurement Zero calibration is done by calibrating the analyzer measurements against a known sample gas using the following procedure Prerequisites Run the analyzer at a stable temperature for at least thirty minutes prior to commencing this procedure Procedure ...

Page 51: ...6 Using and select GAS SERVICE Press Figure 6 1 Main Menu 7 Using and select PER GAS Press Figure 6 2 Per Gas Reference Manual Gas calibration 00809 0100 4244 January 2020 Reference Manual 51 ...

Page 52: ... the gas to be tested Press Figure 6 3 Select Gas Screen Manually adjust the ZERO OFFSET Procedure 1 Use or select ZERO OFFSET Press Figure 6 4 Zero Offset Gas calibration Reference Manual January 2020 00809 0100 4244 52 Rosemount CT4400 ...

Page 53: ...ue 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 Gas calibration 00809 0100 4244 January 2020 Reference Manual 53 ...

Page 54: ...and the analyzer has detected a concentration of 0 510 ppm vol 3 To abort the calibration process press or otherwise the analyzer will perform the ZERO CALIBRATION either after waiting for the purge time or when or is 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 Ser...

Page 55: ... for at least thirty minutes prior to commencing this procedure Procedure 1 Use a certified reference gas cylinder as the source of the span calibration gas 2 Ensure that a suitably rated pressure regulator is connected to the reference gas bottle 3 Connect a hose from the reference gas bottle through a T piece to the sample supply port on the rear panel of the analyzer 4 Connect an excess flow li...

Page 56: ... Use or and select GAS SERVICE Press Figure 6 10 Select Gas Service 7 Use or and select PER GAS Press Figure 6 11 Per Gas Gas calibration Reference Manual January 2020 00809 0100 4244 56 Rosemount CT4400 ...

Page 57: ...ist the gas to be tested Press Figure 6 12 Select Gas 9 To manually adjust the SPAN FACTOR use and to select SPAN FACTOR Press Figure 6 13 Span Factor Reference Manual Gas calibration 00809 0100 4244 January 2020 Reference Manual 57 ...

Page 58: ...uired 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 Gas calibration Reference Manual January 2020 00809 0100 4244 58 Rosemount CT4400 ...

Page 59: ...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 Gas calibration 00809 0100 4244 January 2020 Reference Manual 59 ...

Page 60: ...result of the calibration will then be displayed as below Figure 6 18 Span Calibration Result 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 Gas calibration Reference Manual January 2020 00809 0100 4244 60 Rosemount CT4400 ...

Page 61: ... the gas service calibration settings The gas purge time can be adjusted as follows Procedure 1 Use or and select GAS SERVICE Press Figure 6 20 Select Gas Service Reference Manual Gas calibration 00809 0100 4244 January 2020 Reference Manual 61 ...

Page 62: ... or to select PURGE TIME Press Note AUTO PERIOD is not available on the Rosemount CT4400 Figure 6 22 Calibrate Parameters 4 Use the or to select the number or duration to be changed seconds minutes hours days 5 Use the or to change the number or duration value Gas calibration Reference Manual January 2020 00809 0100 4244 62 Rosemount CT4400 ...

Page 63: ...es 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 Gas calibration 00809 0100 4244 January 2020 Reference Manual 63 ...

Page 64: ...Gas calibration Reference Manual January 2020 00809 0100 4244 64 Rosemount CT4400 ...

Page 65: ...ing and failure diagnosis procedures described in this chapter assume that any host equipment provided by you is fully functional Always make sure that the host equipment is fully serviceable before performing failure diagnosis on the analyzer Failure diagnosis repair and maintenance must only be performed by Maintenance engineers who have the necessary skills and who have been authorized to perfo...

Page 66: ...lf rack system and 66 lb 30 kg for the full rack system Rosemount recommends that the analyzer is moved by a minimum of two people when lifting and transporting the equipment Failure to properly handle the analyzer may cause injury to personnel wear suitable protective gloves and protective footwear WARNING FIRE AND EXPLOSION Always lock out tag out the gas handling system when shutting down the a...

Page 67: ...g the Built In Self Test BIST fault diagnostics The analyzer has a Built In Self Test BIST function that can be used to perform failure diagnosis of some functions other than a complete failure of the equipment The BIST is accessed and controlled through the display controller mounted on the front panel of the analyzer The BIST runs in the background when the analyzer is operating and continuously...

Page 68: ...the operator Pressing the Back key will return to the previous screen Pressing the Home key at any time will return to the Main Menu screen 3 You can see the STATUS information from either the Gas Sensor Main screen Figure 4 4 or the Pressure and Temperature screen Figure 4 5 When the analyzer is running correctly the STATUS displays Running and OK If a fault is detected the STATUS display in the ...

Page 69: ... 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 Troubleshooting and diagnostics 00809 0100 4244 January 2020 Reference Manual 69 ...

Page 70: ...status and where appropriate the values of any of the listed components The Diagnostics menu screen can be accessed from the Main Menu screen This gives the operator access to a number of options when checking the overall health of the analyzer Procedure 1 Where more options are available than can be displayed on the screen use the or keys to scroll up or down onto the next page The screen will co...

Page 71: ...in specification BEKA RS232 NOT AN OPERATOR REQUIRED OPTION CELL HEATER provides the operator with information on the CELL HEATER XSTREAM NOT AN OPERATOR REQUIRED OPTION 3 Pressing the Back key will return to the previous screen Pressing the Home key at any time will return to the Main Menu screen 4 Scroll or and select DIAGNOSTICS Press Figure 7 5 Main Menu Example 1 Use or to view all the option...

Page 72: ...analyzer has been selected and the current Status is OK Figure 7 7 Config Status Example 2 Use or to view all the options available Select the Item required to obtain further details on the next screen Press Troubleshooting and diagnostics Reference Manual January 2020 00809 0100 4244 72 Rosemount CT4400 ...

Page 73: ...ser 1 Status Note Additional operating information has been provided for this option 7 3 Configuring the 4 20mA outputs The DATA SERVICE menu screen can be accessed from the Main Menu screen This gives the operator access to set the 4 20 mA output ranges for the gas being analyzed Reference Manual Troubleshooting and diagnostics 00809 0100 4244 January 2020 Reference Manual 73 ...

Page 74: ...creen if required by the operator 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 4 Pressing the Back key will return to the previous screen 5 Pressing the Home key at any time will return to the Main M...

Page 75: ... 8 Scroll or 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 Troubleshooting and diagnostics 00809 0100 4244 January 2020 Reference Manual 75 ...

Page 76: ...mber to be changed 11 Use the or 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 Troubleshooting and diagnostics Reference Manual January 2020 00809 0100 4244 76 Rosemount CT4400 ...

Page 77: ...to select the number to be changed 15 Use the or to change the number value Figure 7 16 Maximum Limit 16 Press to accept the change Home key to cancel Reference Manual Troubleshooting and diagnostics 00809 0100 4244 January 2020 Reference Manual 77 ...

Page 78: ...he analyzer and allow it to cool 2 Visually examine the exterior of the analyzer for signs of damage 3 Perform a visual inspection of the electrical and gas connections on the rear panel of the analyzer 4 If any loose connections are found tighten as required 7 5 Failure diagnostics If the BIST and the visual examination fail to identify the fault perform the failure diagnostics and recommended ac...

Page 79: ... 5 2 Calibration validation drift Potential cause Sensor reading invalid Recommended action 1 Check measurement validity flag 2 Reading is invalid 3 refer to Measurement invalid flag Potential cause Sensor required calibration Recommended action 1 Check measurement validity flag 2 Reading is valid 3 Perform a new Zero and Span calibration to ensure calibration factors are correct 4 Readings return...

Page 80: ...y 7 Replace calibration cylinder 8 Readings do not return to normal 9 Check the calibration pipework 10 Pipework damaged 11 Replace pipework 12 Readings return to normal 13 Pipework was damaged Potential cause Pipework damaged empty Recommended action 1 Check measurement validity flag 2 Reading is valid 3 Perform a new Zero and Span calibration to ensure calibration factors are correct 4 Readings ...

Page 81: ...e support emerson com Potential cause Pressure or temperature is out of range Recommended action 1 Check display controller to assess which measurements are invalid 2 All gas readouts are invalid 3 Use the display controller to check pressure and cell temperature 4 Pressure is out of range 5 Refer to Analysis cell pressure out of range Potential cause Pressure or temperature is out of range Recomm...

Page 82: ...ayed 4 Contact cascade support emerson com 7 5 5 Analysis cell pressure out of range Potential cause Pressure was out of range Recommended action 1 Adjust inlet valve to change pressure 2 Pressure returns to normal 3 No further action required Potential cause Pressure was out of range Recommended action 1 Adjust inlet valve to change pressure 2 If pressure is unstable or impossible to adjust 3 Con...

Page 83: ...rnal fuses located in the power socket attached to the rear panel 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 The analyzer MUST be earthed using a grounded three core cable suitable for the rating defined in the General Characteristics Tabl...

Page 84: ...e 5 Remove the fuse C from the holder B 6 Fit a new fuse C of the same type and rating into the fuse holder B 6 3A 250 VAC ceramic cartridge fuse 5x20 mm Speed F IEC 60127 compliant 7 Repeat for the second fuse 8 Fully push the fuse holder B back into position in the power socket A 9 Reconnect the external power supply to the power socket on the back panel 10 Start up the analyzer by turning the O...

Page 85: ...he cell mirrors must be cleaned the analysis cell must only be opened in a CLEAN DRY DUST FREE area to prevent further contamination Observe all safety precautions before starting this procedure 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 T...

Page 86: ...zer is moved by a minimum of two people when lifting and transporting the equipment Failure to properly handle the analyzer may cause injury to personnel wear suitable protective gloves and protective footwear Procedure 1 Turn the ON OFF switch on the back panel to OFF 2 Disconnect the external power supply from the power socket 3 VERIFY the sample gas handling system has been shut down and locked...

Page 87: ...d to secure the top cover s 11 Lift the top cover s clear of the chassis assembly 12 Examine the cover for signs of physical damage inside and out 13 Locate the two cam lock screws securing the hinged PCB tray rotate a turn to release Figure 7 19 Releasing the PCB Tray Reference Manual Troubleshooting and diagnostics 00809 0100 4244 January 2020 Reference Manual 87 ...

Page 88: ...ing an Allen key remove and retain the six socket head cap screws and washers 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 Troubleshooting and diagnostics Reference Manual January 2020 ...

Page 89: ...ue Care MUST be taken not to apply pressure to the lens during this operation to prevent scratching the reflective surface Scratches to the mirror surface WILL affect the ability for the analyzer to operate and WILL NOT be covered by the warranty for the analyzer If reagent grade methanol is unavailable then reagent grade IPA may be used instead Reference Manual Troubleshooting and diagnostics 008...

Page 90: ... Cleaning the mirrors with methanol may not visibly improve the mirror surface but should improve reflectivity in the mid infrared band used by the lasers 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 reins...

Page 91: ... 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 Death or personal injury may result if this is not observed DANGER FAILURE TO VENT SAMPLE GAS The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the analyzer d...

Page 92: ...ple gas and feeds it to the analyzer Lock out the gas handling system to prevent its unauthorized operation during maintenance which could cause an escape of gas WARNING HIGH PRESSURE GAS AND AIR The gas supply operates at a pressure that can cause injury e g damage to eyes and skin punctures from debris blown by high pressure gas or compressed air 2 Purge any sample gas in the pipe tube from the ...

Page 93: ... Shutdown example below Pressing the screen Refresh key at any time will refresh the current display screen if required by the operator SAVE CONFIG NOT AN OPERATOR OPTION saves the current configuration to the SD card SHUTDOWN allows the OPERATOR to shutdown the software in a controlled manner SHOW VERSIONS displays the software version installed on the analyzer NETWORK INFO NOT AN OPERATOR OPTION...

Page 94: ...13 Press or and select SHUTDOWN Press Figure 8 2 System 14 Press to accept Press to reject Figure 8 3 Shutdown Shutdown procedure Reference Manual January 2020 00809 0100 4244 94 Rosemount CT4400 ...

Page 95: ...k 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 Shutdown procedure 00809 0100 4244 January 2020 Reference Manual 95 ...

Page 96: ...Shutdown procedure Reference Manual January 2020 00809 0100 4244 96 Rosemount CT4400 ...

Page 97: ...for the analyzer MUST be run monthly to confirm the continued accuracy of the analysis being performed Any anomalies found should be reported to the maintenance department and where in doubt the analyzer should be switched off until rectified Variation in customer sites may require these activities to be performed more or less often than indicated Reference Manual Preventative maintenance 00809 01...

Page 98: ...Preventative maintenance Reference Manual January 2020 00809 0100 4244 98 Rosemount CT4400 ...

Page 99: ...rson com The only authorized spare parts that are available are listed in Table 10 1 below Table 10 1 Spare Parts List Part Numbers Description P 6000 01332 6 mm Ferrule Nut for sample gas connection P 6000 01272 6 mm back front ferrules for sample gas connection P 6000 00657 AC power cable UK version P 6000 00951 AC power cable US version P 6000 00952 AC power cable Euro version P 6000 01441 AC p...

Page 100: ...Recommended spare parts Reference Manual January 2020 00809 0100 4244 100 Rosemount CT4400 ...

Page 101: ... 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 Engineering drawings 00809 0100 4244 January 2020 Reference Manual 101 ...

Page 102: ...alogue Channel 1 Set In Config File Analogue Channel 0 Set In Config File 2 15 3 16 4 17 9 22 Status Output 1 Check Function Optional 10 23 11 24 12 25 Status Output 2 Maintenance required Optional Status Output 3 Out of Specification Optional Status Output 4 Failed Optional PMC L N E V V 12V DC PSU DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 DIG O P RELA...

Page 103: ...TER EARTH STUD EARTH STUD TO ELECTRONICS TRAY GRD 1 2 E E 66 65 E 2 1 J22 J6 J3 J4 J8 J9 J7 J23 1 2 3 L N E 6 3A 6 3A 65 66 36 38 40 42 35 37 39 41 57 58 56 55 54 53 52 51 68 1 2 Pin 1 Pin 14 PMC L N E V V 12V DC PSU DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 70 72 74 69 71 73 75 51 53 55 57 52 54 56 58 ETHERNET PORT E ALL ET...

Page 104: ... DRAWING AND DATA CONTAINED WITHIN IT ARE THE SOLE PROPERTY OF CASCADE TECHNOLOGIES LTD PART OF EMERSON PROCESS MANAGEMENT AND CANNOT BE COPIED COMMUNICATED OR REPLICATED PARTIALLY OR IN ITS ENTIRETY WITHOUT EXPRESSED WRITTEN CONSENT BY CASCADE TECHNOLOGIES LTD GENERAL DRAWING PRACTICE TO ISO14617 PNEUMATIC SYMBOLS DRAWN TO ISO1219 1 PIPING AND INSTRUMENTATION DIAGRAMS P ID DRAWN TO ISO 10628 WIRI...

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