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Chapter 13

Preventative maintenance......................................................................................... 163

13.1 Maintaining the analyzer............................................................................................................ 163
13.2 Scheduled maintenance............................................................................................................. 163

Chapter 14

ATEX/IECEX assessment report summary....................................................................165

Appendix A

Engineering drawings................................................................................................ 173

Reference Manual

Contents

00809-0100-4512

October 2019

Reference Manual

xix

Summary of Contents for Rosemount CT5100

Page 1: ...Reference Manual 00809 0100 4512 Rev AA October 2019 Rosemount CT5100 Ex Continuous Gas Analyzer ...

Page 2: ...e 30 This article must not be changed amended or removed Important Users must read understand and comply with the following information before proceeding All users installers operators and maintainers must be familiar with operating the analyzer To install start up operate maintain and service the analyzer in a safe manner it is MANDATORY to read all additional documents shipped with the analyzer ...

Page 3: ... understand any of the instructions contact your Emerson Rosemount representative for 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 appropriate Reference Manual and in ...

Page 4: ...BS EN 61010 1 2010 IEC 61010 1 2010 Safety requirements for electrical equipment for measurements control and laboratory use General requirements IEC 61241 10 2004 06 Electrical apparatus for use in the presence of combustible dust Part 10 Classification of areas where combustible dusts are or may be present BS EN 61326 1 2013 Electrical equipment for measurement control and laboratory use EMC req...

Page 5: ...rdous area protection Emerson has satisfied the requirements of and complies with IEC ATEX and North American regulators for operation of electrical electronic equipment in hazardous locations In accordance with IEC 60079 0 2011 Clause 30 This statement must not be amended or changed Waste disposal Do not dispose of measuring tools into household waste Only for EC countries In accordance with Euro...

Page 6: ...SE DEATH Failure to follow this warning will result in death or serious injury to personnel WARNING DANGER TO PERSONNEL Failure to follow this warning may result in serious injury to personnel CAUTION MAY CAUSE DAMAGE TO EQUIPMENT Failure to follow this warning may result in damage to the equipment NOTICE Important or tip messages will appear in this format 6 ...

Page 7: ...inutes 30 seconds at a minimum flow rate of 280 L m at 1 5 0 5 bar to prevent hazards to personnel during maintenance Purge the sample gas in accordance with the safe working procedures for this site Allow the analyzer and the system for returning the sample gas to run for five minutes to allow any sample gas in the analyzer to be returned to the exhaust Failure to observe this precaution will cau...

Page 8: ...rials or unless all equipment within the protected enclosure is de energized in accordance with NFPA 496 Failure to observe this warning could cause an explosion or potentially hazardous situation which if not avoided may cause death personal injury and or damage to persons and or property WARNING EXPLOSION HAZARD In accordance with IEC 60079 0 2011 Clause 30 Always lock out the gas handling syste...

Page 9: ... handling the equipment Gas handling components within the analyzer contain particulate matter residue from the sample gases Over the life of the analyzer the concentration of particulate matter will become enriched within the gas handling components When performing repairs and maintenance on the analyzer Handle used gas handling components with extreme caution Avoid direct skin contact with used ...

Page 10: ... mW The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040 10 The location of laser safety labels on the analyzer is specified in Safety and system labels and annotation The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure WARNING HAZARDOUS GAS In accordance with IEC 60079 0 2011 ...

Page 11: ...w terminals for electrical connections may require working near live parts Failure to observe this warning and or follow safety instruction could cause an explosion or potentially hazardous situation which if not avoided could result in death or serious injury WARNING HIGH PRESSURE HAZARD In accordance with IEC 60079 0 2011 Clause 30 The maximum inlet purge gas pressure at the inlet valve must not...

Page 12: ...O NOT provide wide range power supplies This type of analyzer is always setup for a specific rated input voltage see nameplate label Ensure the voltage at site of installation meets the rated analyzer input voltage Failure to observe this warning could cause an explosion or potentially hazardous situation which if not avoided may cause death personal injury and or damage to persons and or property...

Page 13: ...mations after performing the overpressure test Failure to observe this warning could cause an explosion or potentially hazardous situation which if not avoided may cause death personal injury and or damage to persons and or property WARNING EXPLOSION HAZARD In accordance with IEC 60079 0 2011 Clause 30 Use only replacement parts and components authorized by Emerson All replacement parts and compon...

Page 14: ...e equipment is tested meets the lifting ratings for the weight of the equipment and is in good operational condition Failure to verify equipment meets the lifting ratings and is in good operational condition may cause injury to personnel or damage the analyzer WARNING PHYSICAL ACCESS Unauthorized personnel may potentially cause significant damage to and or misconfiguration of end users equipment T...

Page 15: ...EMC This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures CAUTION EMC As a general principle if any optical component other than the cell assembly the laser modules and the detectors is unserviceable the analyzer must be repaired by Emerson This is because the repair replacement and alignment o...

Page 16: ...16 ...

Page 17: ...inputs and outputs 34 3 5 Optical description 37 Chapter 4 Specifications 39 4 1 Gas detection 39 4 2 Detailed system specifications 39 4 3 Safety and system labels and annotation 42 Chapter 5 Install 47 5 1 Site selection 47 5 2 Unpacking 48 5 3 Mounting the analyzer 50 5 4 Connecting the electrical electronic inputs and outputs 56 Chapter 6 Controls and display controller 67 6 1 Front panel cont...

Page 18: ... 11 8 Visual examination 122 11 9 Functional failure diagnostics 122 Chapter 12 Repair and replacement 127 12 1 Repair policy 127 12 2 Opening the electrical compartment door 127 12 3 Closing the electrical compartment door 128 12 4 Replacing the fuses 129 12 5 Replacing the TEC board 133 12 6 Replacing the peripheral board 135 12 7 Replacing the motherboard 137 12 8 Replacing the Ethernet in out ...

Page 19: ... assessment report summary 165 14 1 Certification overview 165 14 2 Applicant s name and address 165 14 3 Manufacturer s name and address 165 14 4 Trademark 165 14 5 Product name model number 165 14 6 Rating 165 14 7 Assessment standards 166 14 8 Markings 166 14 9 Conditions of certification special conditions for safe use 169 14 10 Conditions of certification for the replacement of simple devices...

Page 20: ...Contents Reference Manual October 2019 00809 0100 4512 xx Rosemount CT5100 Ex ...

Page 21: ...to include in the documentation any modifications by the manufacturer However this document reflects the supplied analyzer at the revision date on the front cover 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 Fu...

Page 22: ... facility such as an alarm or an automatic shutdown system For correct operation the on site pressurizing air supply must be capable of providing at least 25 L min for leakage compensation When using the analyzer variant fitted with the Elmess gas cell heater certified as BVS 14ATEXE155U and IECEx BVS 14 0106U the equipment top compartment should be cooled with a source of compressed air at a mini...

Page 23: ...intended for use only with air of instrument quality all piping up to and including the shut off valve adjacent to the equipment must be protected against mechanical damage The protective gas supply to the equipment must be marked with the warning as detailed in NFPA496 Clause 4 12 5 When installing conduit for power and data connections the end user must select suitably certified conduit General ...

Page 24: ...perty do not install operate maintain or service this analyzer before reading and understanding this reference manual and receiving appropriate training 1 5 Software version The analyzer includes software that is used to control the operation of the analyzer This manual describes the software version as 5 7 13 1 6 Glossary and abbreviations Table 1 1 Abbreviations Abbreviation Description Copyrigh...

Page 25: ...ternational Electro technical Commission in Inches IP Ingress protection IPxx Ingress protection xx are numbers that define the protection level IS Intrinsically safe ISO International Organization for Standardization k Thousand kg Kilogram kHz Kilo hertz L Liter lb Pound LCD Liquid crystal display LED Light emitting diode L min Liters per minute m Meter m3 Cubic meter mA Milliamp Max Maximum mBar...

Page 26: ...puter PM Preventative maintenance ppm Parts per million psi Pounds per square inch QCL Quantum Cascade Laser TDL Tunable Diode Laser Torr Unit of pressure defined as exactly 1 760 of a standard atmosphere UKAS United Kingdom Accreditation Service USA United States of America USB Universal serial bus V Volt VA Volt ampere Vac Volt alternating current Vdc Volt direct current W Watt WEEE Waste electr...

Page 27: ...conductor layers giving access to high power lasers covering the mid infrared spectral region The lasers have no need for cryogenic cooling have excellent spectral quality in chirped mode and have good tuneability 2 3 Gas concentration measurements In the Rosemount CT5100 Ex gas concentrations are measured using optical absorption spectroscopy The laser light sources are operated to produce wavele...

Page 28: ...Theory of operation Reference Manual October 2019 00809 0100 4512 28 Rosemount CT5100 Ex ...

Page 29: ...zer The analyzer can be configured to detect and measure up to 10 different gases depending on the combination of laser modules fitted 3 2 System overview A complete Rosemount CT5100 Ex system consists of a gas handling system the analyzer and the associated interconnecting wiring and gas piping Reference Manual Description 00809 0100 4512 October 2019 Reference Manual 29 ...

Page 30: ... Sample supply line D Sample return exhaust line E Rosemount CT5100 Ex F Electrical power G Two pole main isolator H Purge power I Control center J Measurement data The analyzer contains an optical system with multiple lasers and a series of optical components that provide an optical path a heated multi pass analysis cell and sample and outlet ports that can be connected to a gas handling system a...

Page 31: ...m Name or description Supplied by Part number Quantity Notes 1 Rosemount CT5100 Ex Emerson Rosemount CT5100 Ex 1 2 Rosemount CT5100 Ex software package version 5 7 13 Emerson N A Software is embedded in the system 1 Version described in manual 3 Gas handling system Customer optionally by Emerson Customer Choice or Emerson 1 4 Heated gas sample line hose Customer Customer choice 1 5 Exhaust line ho...

Page 32: ...er the electrical compartment is held at a positive pressure above the surrounding air pressure 3 3 Gas flow through analyzer The analyzer has two gas inputs and one gas output See Figure 3 3 Figure 3 3 Gas Inlet and Outlet Connectors A Sample gas return port B Sample gas input port C Top cover of Rosemount CT5100 Ex cell compartment D Purge air supply E Laser electrical compartment Description Re...

Page 33: ...nalyzer through the sample gas return port A 3 A compressed air supply enters the analyzer through a port D on the underside of the unit The sample supply line must be heated all the way to the sample gas input port on the analyzer to prevent condensation forming at any point in the sample supply line WARNING AIR SUPPLY The air supply must be clean filtered and free from moisture Reference Manual ...

Page 34: ... A Purge power and alarm entry point B Power entry point C Analog digital entry point Electrical electronic signal connections to the analyzer are made through three electrical entry points located on the underside of the analyzer as shown in Figure 3 4 Use the wiring diagram to make the electrical connections as shown in Engineering drawings and Figure 3 5 Description Reference Manual October 201...

Page 35: ... B 1 A purge electrical supply that is used to power the overpressure facility in the electrical compartment of the analyzer entry point A 2 An instrumentation electrical supply that is used to power all other functions of the analyzer entry point C Both power supplies are 110 to 230 Vac 50 60 Hz 10 AC to DC power converters inside the analyzer automatically adjust in response to the input voltage...

Page 36: ...rge controller have been followed during installation The complete wiring diagram used during the manufacture of the Rosemount CT5100 Ex is included for reference in Engineering drawings Figure 3 6 Pepperl Fuchs Wiring Diagram External Mount Figure 3 7 Pepperl Fuchs Wiring Diagram Internal Mount Figure 3 8 Pepperl Fuchs Wiring Diagram Terminal Block Connections General wiring instructions for the ...

Page 37: ...late onto an optical steering assembly which directs the laser beam through the sample cell The sample cell contains a set of mirrors to create a path through the sample gas that is between 0 7 ft 0 2 m and 49 2 ft 15 m through multiple reflections along the length of the cell The laser beams exit the cell at the opposite end from where they entered and are directed using a second optical block to...

Page 38: ...ent contains a PC and numerous electrical electronic components that are not certified for use in hazardous atmospheres To prevent explosive gases from entering the electrical compartment it is sealed and held at a positive air pressure above the surrounding air pressure when the analyzer is switched on Description Reference Manual October 2019 00809 0100 4512 38 Rosemount CT5100 Ex ...

Page 39: ... 110 or 230 Vac 50 60 HZ 10 Purge supply voltage 110 or 230 Vac 50 60 Hz 10 Peak power consumption 500 W Max consumption per gas analyzer Continuous steady state power consumption 300 W Once the gas analyzer has stabilized and the analysis cell has reached the temperature set point Electrical compartment enclosure N A N A Stainless steel Optical compartment enclosure N A N A Stainless steel Measur...

Page 40: ...Purge inlet certified system only Purge air pressure 2 Barg Measurement result signals 4 to 20 mA 4 or 8 channel outputs specify on order Communication 10 100 Mbps Ethernet Warm up time 90 minutes Figure 4 1 Rosemount CT5100 Ex Dimensions Front View A Ventilation B Lifting eyelet C User interface D Purge control panel Specifications Reference Manual October 2019 00809 0100 4512 40 Rosemount CT5100...

Page 41: ...let C Sample return D Sample inlet Figure 4 3 Rosemount CT5100 Ex Dimensions Bottom View A Atmospheric pressure refer plug B Earth point C Purge pressure Set D Air supply E Cable glands F Purge vent Reference Manual Specifications 00809 0100 4512 October 2019 Reference Manual 41 ...

Page 42: ...moisture content 20 Maximum Sample gas particulate density 5 mg m3 Maximum Sample gas particulate size 10 µm Maximum IP code 66 N A IP to IEC 60529 Sensor humidity range 10 to 95 Relative humidity non condensing at 113 F 45 C 4 3 Safety and system labels and annotation The labels and annotation applied to the analyzer are specified in the table below Label type Example Location Identification labe...

Page 43: ...type Example Location IECEx and ATEX ratings label Enclosure side panel North America Canada ratings label Enclosure side panel Reference Manual Specifications 00809 0100 4512 October 2019 Reference Manual 43 ...

Page 44: ...side panel Laser radiation CAUTION label Baseplate Laser module identification label On each laser module housing Intrinsically safe label 1 HMI 2 Intrinsically safe sensor barrier Specifications Reference Manual October 2019 00809 0100 4512 44 Rosemount CT5100 Ex ...

Page 45: ...te Manufacturer s label On analysis cell heater block Electrical safety label On inside of electrical compartment door AC Power Supply Danger label 1 On outside of electrical compartment door 2 On manifold block of air overpressure system Reference Manual Specifications 00809 0100 4512 October 2019 Reference Manual 45 ...

Page 46: ...Specifications Reference Manual October 2019 00809 0100 4512 46 Rosemount CT5100 Ex ...

Page 47: ...rdance with NFPA496 Death personal injury and or damage to persons and or property may result if this is not observed DANGER ELECTRIC SHOCK The analyzer operates using mains voltage which may cause death or serious injury to personnel Ensure that the circuit breakers are set to Off and locked out and tagged out off before removing the top cover or opening the front cover Failure to observe this pr...

Page 48: ...tion during unpacking installation maintenance and transport to prevent crushing of hands feet or other body parts The analyzer weighs 121 lb 55 kg and should always be lifted and moved using suitable lifting moving equipment Emerson recommends that a minimum of two people using suitable tools for transportation and lifting are employed Wear suitable protective gloves and protective footwear Insta...

Page 49: ...orking at the open unit This is permitted only when both the analyzer and connected external circuitry are de energized Depending on the local regulation this may require a competent hot work supervisor to issue a hot work permit WARNING HEAVY ITEM In accordance with IEC 60079 0 2011 Clause 30 Failure to propery handle the analyzer may cause injury to personnel Ensure the wall the analyzer is moun...

Page 50: ...nance organization 4 Attach suitably rated and tested lifting slings to the safety engineered lifting eye bolts mounted on top of the analyzer 5 One person should carefully guide the equipment from the horizontal to vertical position while the other person lifts the equipment 6 Use safety approved and tested lifting equipment to remove the analyzer from the shipping container and place it on a sol...

Page 51: ...unpacking installing maintaining and transporting to prevent crushing of hands feet or other body parts The analyzer weighs 121 lb 55 kg Emerson recommends that a minimum of two people move and lift the analyzer Wear suitable protective gloves and protective footwear 2 Attach suitably rated and tested lifting slings to the safety engineered lifting eye bolts see Figure 5 2 items A and D mounted on...

Page 52: ...m diameter mounting points F Purge compressed air supply port 3 One person should carefully guide the equipment while the other person operates the lifting equipment 4 Use safety approved and tested lifting equipment to lift the analyzer from the stable platform Install Reference Manual October 2019 00809 0100 4512 52 Rosemount CT5100 Ex ...

Page 53: ...mounting points on the analyzer All mounting points are 0 413 in 10 5 mm diameter holes Confirm the bolts are secure Do not over tighten the fasteners The analyzer must be mounted using the four off factory fitted and pre drilled holes on the brace bars Refer to Figure 5 2 6 Remove the lifting eyes and retain them for future use Threads must be protected with a suitable grease and plastic grommets...

Page 54: ...and the O ring E Install the vent cap locking it in position with the grub screws Refer to Figure 5 2 An Allen key is provided for the grub screws The protector cap C must be retained as it will need to be refitted whenever the analyzer is being shutdown for a prolonged period to seal the purge vent from fluid ingress Install Reference Manual October 2019 00809 0100 4512 54 Rosemount CT5100 Ex ...

Page 55: ...Figure 5 4 Mounting Details A Mounting points Reference Manual Install 00809 0100 4512 October 2019 Reference Manual 55 ...

Page 56: ... inputs and outputs 5 4 1 AC power Power is connected to the analyzer instrumentation through the power entry point B and the purge controller through the purge power and alarm entry point A fitted to the base of the analyzer Refer to Figure 5 6 Install Reference Manual October 2019 00809 0100 4512 56 Rosemount CT5100 Ex ...

Page 57: ...umentation electrical supply that is used to power all other functions of the analyzer See Figure 5 6 Item B The customer supplied circuit breakers must be in accordance with ATEX IECEx North American protection concepts The main power isolator controls the application of electrical power to the purge controller with the secondary power isolator controlling the application of electrical power to t...

Page 58: ...mains input fuses B Mains input filter C To enclosure earth stud Table 5 1 Mains Input Terminal Terminal Function 1 Sensor system supply L 2 Sensor system supply N 3 Earth Install Reference Manual October 2019 00809 0100 4512 58 Rosemount CT5100 Ex ...

Page 59: ...the analyzer for entry into the analyzer enclosure and the purge control unit Terminal Function L Purge control supply live N Purge control supply neutral K1 normally open Alarm contract K2 normally closed Alarm contract Electrical protection for the instrumentation circuitry of the analyzer is provided by fuses F1 and F2 located inside the analyzer Refer to Figure 5 9 The customer supplied power ...

Page 60: ...rated for at least 250 Vac of the required length Cables must be terminated in the power entry points in accordance with local electrical codes The full electrical wiring diagram is provided in Engineering drawings 5 4 2 Fuses Figure 5 9 shows the location of the fuses Figure 5 9 Fuses A Fuse F4 24 Vdc supply B Fuse F3 12 Vdc supply C Fuse F1 mains supply live D Fuse F2 mains supply neutral Table ...

Page 61: ...ube fittings To avoid the risk of gas leaks confirm that these connections are made correctly and tightly Both the sample gas supply pipe and the sample return pipe should be thermal insulated The maximum sample gas supply pressure is 2 BarG 5 4 4 Connecting the signal cables The signal cables are connected to the system through an entry point outlet C as shown in Figure 3 4 All signal cables are ...

Page 62: ...tput terminals Table 5 4 User Connections Terminal Function 11 Digital output 1 12 Digital output 2 13 Digital output 3 14 Digital output 4 15 Digital output 5 16 Digital output 6 17 Digital output 7 18 Digital output 8 19 Digital output 9 20 Digital output 10 21 Digital output 11 Install Reference Manual October 2019 00809 0100 4512 62 Rosemount CT5100 Ex ...

Page 63: ...ich if not avoided may cause death personal injury and or damage to persons and or property The power input cable purge power cable circuit breakers can be tested as follows Set the Purge circuit breaker to ON The purge pressurization process will start ONLY when the K1 LED on the purge control panel comes on indicating the purge process is complete can you proceed to the next step Refer to Figure...

Page 64: ...ll temperature and pressure are within the required test range It is not essential to flow sample gas through the system nitrogen or atmospheric air will be adequate for this test With the analyzer at operating temperature and pressure ensure that a current between 4 mA and 20 mA is generated on each 4 20 mA output This can either be measured as a current with a multimeter or as a gas concentratio...

Page 65: ...ons once acceptance tests have been made on the system to ensure that the analyzer does not need to be removed 5 4 11 Commissioning Once the sensor is fully installed as described above it should be commissioned in accordance with the commissioning plan agreed between Emerson and the customer Reference Manual Install 00809 0100 4512 October 2019 Reference Manual 65 ...

Page 66: ...Install Reference Manual October 2019 00809 0100 4512 66 Rosemount CT5100 Ex ...

Page 67: ...5100 Ex is configured from the two control displays located on the front panel Refer to Figure 6 1 Figure 6 1 Front Panel A Display controller B Purge control panel C Protector cap D Purge vent Reference Manual Controls and display controller 00809 0100 4512 October 2019 Reference Manual 67 ...

Page 68: ... Off switches on the analyzer The application of electrical power to the analyzer is controlled through two external circuit breakers Both external circuit breakers are simple two pole on off circuit breakers Both must be set to On to permit the safe operation of the analyzer Operation of the analyzer is controlled primarily through the display controller Refer to Figure 6 3 Controls and display c...

Page 69: ...ntenance personnel Five LEDs identified as K1 K2 PSV Bypass and PT100 are located on the upper part of the purge control panel These five LEDs indicate the status of the overpressure air system Figure 6 4 Purge Control Panel 6 2 Display controller Operation of the Rosemount CT5100 Ex is controlled through the six buttons on the display controller Figure 6 5 The LCD display A can be used to display...

Page 70: ...r buttons B D E and G are configured to perform different functions according to which software screen is shown on the LCD display 6 3 Gas Sensor Main screen When the analyzer is switched on at the end of the start up procedure the Gas Sensor Main screen Figure 6 6 appears appears The Gas Sensor Main screen is the screen that is normally displayed NOTICE The gas concentrations shown in the followi...

Page 71: ...n dioxide NO2 At the end of the start up procedure the gas measurements initially appear as 0 00 ppm until the first readings are taken After a few seconds the initial gas concentrations are displayed The Gas Sensor Main screen also shows the status of the analyzer In the example shown in Figure 6 7 the analyzer is Running and OK i e no faults have been identified This area of the display shows an...

Page 72: ...d in Help system MENU B is a link to the Main Menu of the software Press the MENU button A to go to the MAIN MENU screen described in Main menu On the Gas Sensor Main screen STATUS has no function when the analyzer is operating correctly If however the software detects a fault an error message is displayed Press STATUS to get further information on the error 6 4 Pressure and Temperature screen The...

Page 73: ...er software includes a context sensitive help system Press which is available on most of the software screens to open the help system The help system contains a number of different Help screens each conveying a different message As the help system is context sensitive the Help screen that appears is the one that is most appropriate to the software function engaged when was pressed Figure 6 9 shows...

Page 74: ...alibration diagnostics fault finding downloading data and shutting down the analyzer Figure 6 10 Main Menu 6 7 BACK button On most of the software screens the top left hand button Figure 6 11 is configured as a BACK button Press BACK A to return to the previous screen Figure 6 11 BACK Button A BACK button Controls and display controller Reference Manual October 2019 00809 0100 4512 74 Rosemount CT...

Page 75: ... a plant shutdown or maintenance 7 2 Preparation for use The Rosemount CT5100 Ex must be installed and fully commissioned prior to start up 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 in place Before commencing the start up process ensure that electrical power sample gas hand...

Page 76: ...nality of the software which is the same regardless of the gases being measured Note To stop the start up procedure at any time set the main circuit breaker to Off To start up the analyzer Procedure 1 Visually inspect the exterior of the analyzer for signs of damage corrosion gas leaks or overheating Report anything found to the maintenance organization 2 Verify that the analyzer has been correctl...

Page 77: ...rical compartment F Analog digital power entry point G Power entry point H Purge power and alarm entry point 8 Visually check that the electrical connections have been made to the three power entry points Figure 7 1 at the base of the analyzer 9 Visually check that the vent cap is fitted to the purge vent Figure 5 3 Reference Manual Start up procedure 00809 0100 4512 October 2019 Reference Manual ...

Page 78: ...at 1 5 0 5 bar to prevent hazards to personnel during the startup process Only after the purge pressurization cycle has been completed can electrical power be applied to the rest of the analyzer 10 Turn on the compressed air supply to the analyzer 11 Set the main circuit breaker to On The air pressurization will begin its automatic start up and begin to purge the air inside the analyzer Figure 7 2...

Page 79: ...artment The analyzer must be purged for a minimum of 2 minutes 30 seconds at a minimum flow rate of 280 L m at 1 5 0 5 bar to prevent hazards to personnel during the startup process Only after the purge pressurization cycle has been completed can electrical power be applied to the rest of the analyzer 14 Wait until the purge cycle is performed Do not switch on the secondary circuit breaker until t...

Page 80: ...re the gas measurements initially appear as 0 00 ppm until the first readings are taken After a few seconds the initial gas concentrations are displayed The start up procedure is now complete 7 4 Front panel controls and indicators The Rosemount CT5100 Ex is configured from the control display located on the front panel Figure 7 4 Start up procedure Reference Manual October 2019 00809 0100 4512 80...

Page 81: ... analyzer is controlled through a customer provided external circuit breaker The circuit breaker is a simple two pole on off circuit breaker that must be set to On to permit the safe operation of the analyzer Operation of the analyzer is controlled primarily through the display controller Figure 7 5 Reference Manual Start up procedure 00809 0100 4512 October 2019 Reference Manual 81 ...

Page 82: ...ing the shutdown and restart process It is essential that only trained qualified personnel operate the controls on the analyzer Failure to follow these instructions may cause warranty invalidation property damage and or personal injury or death Figure 7 6 Default Program Screen The purge control panel Figure 7 7 is used to program the operation of the overpressure air system that prevents flammabl...

Page 83: ...are located on the upper part of the purge control panel These five LEDs indicate the status of the overpressure air system Figure 7 7 Purge Control Panel if Applicable Reference Manual Start up procedure 00809 0100 4512 October 2019 Reference Manual 83 ...

Page 84: ...Start up procedure Reference Manual October 2019 00809 0100 4512 84 Rosemount CT5100 Ex ...

Page 85: ...y maintenance on or in the vicinity of the analysis cell allow the analyzer to cool for at least twelve hours as the analysis cell is insulated against heat loss When handling the analyzer always use suitable protective gloves Personal injury and or damage to property may result if these safety precautions are not observed These precautions are especially important when working at heights If you r...

Page 86: ...Figure 8 1 Gas Sensor Main Screen Figure 8 2 Pressure and Temperature Screen Operating the analyzer Reference Manual October 2019 00809 0100 4512 86 Rosemount CT5100 Ex ...

Page 87: ...tionality of the software which is the same regardless of the gases or gas concentrations being measured WARNING BURN HAZARD Some parts of the analyzer may be heated up to 320 F 160 C To prevent burns do not touch any of the hot parts All parts of the analyzer are hot unless it has been switched off and allowed to cool down Before fitting removing or performing any maintenance on the analyzer ensu...

Page 88: ...ng to the analyzer to prevent hazards to personnel during maintenance Purge the sample gas in accordance with safe working procedures for the site Allow the analyzer and system for returning the sample gas to run for five minutes to allow any sample gas in the analyzer to be returned to the exhaust 2 Purge any sample gas in the pipe hose from the gas handling system to the analyzer using factory a...

Page 89: ...Main screen Figure 9 1 or the Pressure and Temperature screen Figure 9 2 Figure 9 1 Gas Sensor Main Screen Figure 9 2 Pressure and Temperature Screen The Main menu Figure 9 3 opens Reference Manual Shutdown procedure 00809 0100 4512 October 2019 Reference Manual 89 ...

Page 90: ...lect B The System screen opens Refer to Figure 9 4 Figure 9 4 System Screen A BACK button B SELECT button C Scroll up button D HELP button E Scroll down button 8 Use scroll up C and scroll down E to select SHUTDOWN as shown in Figure 9 4 B Then press SEL select B The Shutdown screen Figure 9 5 opens Shutdown procedure Reference Manual October 2019 00809 0100 4512 90 Rosemount CT5100 Ex ...

Page 91: ...1 Set the external main circuit breaker to Off Lock out and tag out the main circuit breaker 12 Remove the vent cap and O ring fitted to the purge vent see Figure 5 3 and fit the protector cap that was supplied with the analyzer to prevent moisture ingress during a prolonged shutdown Reference Manual Shutdown procedure 00809 0100 4512 October 2019 Reference Manual 91 ...

Page 92: ...Shutdown procedure Reference Manual October 2019 00809 0100 4512 92 Rosemount CT5100 Ex ...

Page 93: ...calibrate the water measurement directly If you need to calibrate e g for legal requirements you can use a water vapor generator to supply a known concentration of water vapor The validation procedure is essentially the same as the calibration procedure except that it does not adjust the analyzer measurements to match the calibration standard CAUTION EQUIPMENT DAMAGE DO NOT under any circumstances...

Page 94: ...nctions are accessed through the Main menu Figure 10 4 Procedure 1 To get the Main menu press the MENU button on the Gas Sensor Main screen Figure 10 2 or Pressure and Temperature screen Figure 10 3 NOTICE Pressing the BACK button cancels the procedure and returns you to the previous screen Figure 10 2 Gas Sensor Main Screen Gas calibration Reference Manual October 2019 00809 0100 4512 94 Rosemoun...

Page 95: ... to access the software routines and screens that are used throughout the process Figure 10 4 Main Menu 3 Use the middle buttons and to scroll up or down to select GAS SERVICE 4 Press the SEL button Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 95 ...

Page 96: ...SEL button Figure 10 6 Select Gas NO 7 Use the middle buttons and to scroll up or down to select the desired gas e g NO 8 Press the SEL button 9 To check or change the current offset value select ZERO OFFSET and press CAL to view Gas calibration Reference Manual October 2019 00809 0100 4512 96 Rosemount CT5100 Ex ...

Page 97: ...ult offset is zero and under normal circumstances the offset should never be a positive number If it is shown as positive press LEFT until the space to the left of the number is highlighted then select INCR to change it to a minus sign 12 To check or change the current span value select SPAN FACTOR and press CAL to view Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual...

Page 98: ...nder normal circumstances the offset should be between 0 8 and 1 2 10 2 1 Zero calibrate an individual gas Procedure 1 To get the Main menu press the MENU button on the Gas Sensor Main screen Figure 10 2 or Pressure and Temperature screen Figure 10 3 NOTICE Pressing the BACK button will cancel the procedure and return the user to the previous screen Gas calibration Reference Manual October 2019 00...

Page 99: ...VICE Press the SEL button Figure 10 11 Main Menu GAS SERVICE 3 Use the middle buttons and to scroll up or down to select PER GAS Press the SEL button Figure 10 12 Gas Service Menu PER GAS Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 99 ...

Page 100: ...ct Gas NO 5 Use the middle buttons and to scroll up or down to select RUN ZERO Figure 10 14 Action Screen for NO RUN ZERO 6 Press the CAL button to calibrate or the VER button to verify Figure 10 15 displays as the calibration progresses Gas calibration Reference Manual October 2019 00809 0100 4512 100 Rosemount CT5100 Ex ...

Page 101: ...e complete the program will automatically open the Result screen Figure 10 16 Figure 10 16 Result Screen 7 Press OK The Verify next screen displays Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 101 ...

Page 102: ...ibrate an individual gas Procedure 1 To get to the Main menu press the MENU button on the Gas Sensor Main screen Figure 10 2 or Pressure and Temperature screen Figure 10 3 NOTICE Pressing the BACK button will cancel the procedure and return the user to the previous screen 2 Use the middle buttons and to scroll up or down to select GAS SERVICE Press the SEL button Gas calibration Reference Manual O...

Page 103: ...ll up or down to select PER GAS Press the SEL button Figure 10 19 Gas Service PER GAS 4 Use the middle buttons and to scroll up or down to select the desired gas e g NO Press the SEL button Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 103 ...

Page 104: ... the middle buttons and to scroll up or down Select RUN SPAN Press the CAL button to calibrate or the VER button to verify Figure 10 21 Action SPAN Gas calibration Reference Manual October 2019 00809 0100 4512 104 Rosemount CT5100 Ex ...

Page 105: ...he program will automatically open Span Factor For NO Figure 10 23 Figure 10 23 Span Input Note that if an excessively high or low span factor is calculated 0 7 or 1 3 for example and if the calibration gas is a different concentration from that set above it will be rejected and the previous span factor will be displayed and will continue to be used Reference Manual Gas calibration 00809 0100 4512...

Page 106: ...ble to run a calibration on all gases The valves will sequentially switch through each of the span and zero gases This option is not practical to use on systems which require manual valve switching In order to set the cylinder concentration when a new span gas cylinder is to be used it is necessary to perform a single gas calibration as described earlier This concentration will then be stored for ...

Page 107: ...he procedure and return the user to the previous screen 2 Use the middle buttons and to scroll up or down to select GAS SERVICE Press the SEL button Figure 10 26 Main Menu GAS SERVICE 3 Use the middle buttons and to scroll up or down to select CALIBR ALL Press the SEL button Figure 10 27 Gas Service CALIBR ALL Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 107 ...

Page 108: ...when the Zero and Span calibrations process completes Figure 10 29 Calibration Finished 5 Press BACK This completes the process and the display returns to the Main menu 10 2 4 Change the automatic calibration settings Procedure 1 To get to the Main menu press the MENU button on the Gas Sensor Main screen Figure 10 2 or the Pressure and Temperature screen Figure 10 3 Gas calibration Reference Manua...

Page 109: ... up or down to select CALIBR PARAMS or VERIFY PARAMS for validation settings Press the SEL button Figure 10 31 Gas Service CALIBR PARAMS 4 This section applies to systems configured to perform automatic calibration at timed intervals only 5 To adjust the frequency of automatic calibration Use the middle buttons and to scroll up or down 6 Select AUTO PERIOD 7 Press the SEL button Reference Manual G...

Page 110: ...ys hours min and sec between calibrations Use the LEFT RIGHT INCR increase and DECR decrease buttons to set the number and time interval Figure 10 33 Calibration Period 9 Press the OK button Gas calibration Reference Manual October 2019 00809 0100 4512 110 Rosemount CT5100 Ex ...

Page 111: ...ibr param PURGE TIME 11 Press the SEL button 12 To change the time between opening the valve and performing the calibration Figure 10 35 Purge Time 13 Use the LEFT RIGHT INCR increase and DECR decrease buttons to set the number and time interval 14 Press the OK button Reference Manual Gas calibration 00809 0100 4512 October 2019 Reference Manual 111 ...

Page 112: ...Gas calibration Reference Manual October 2019 00809 0100 4512 112 Rosemount CT5100 Ex ...

Page 113: ...BIST detects a fault the STATUS display in the bottom left hand corner of the Gas Sensor Main screen Figure 11 1 Item A will change from OK to flashing the word FAILURE Figure 11 1 Gas Sensor Main Screen A FAILURE message B FAILURE button 2 Similarly if a fault is detected and the Pressure and Temperature screen Figure 11 2 is being displayed the STATUS display in the bottom left hand corner of th...

Page 114: ...message B FAILURE button 4 The FAULTS menu can also be accessed through the Main Menu Figure 11 4 as follows 5 In the Gas Sensor Main screen Figure 11 1 press the MENU button 6 Alternatively press the MENU button on the Pressure and Temperature screen Figure 11 2 The Main Menu screen Figure 11 3 opens Troubleshooting and diagnostics Reference Manual October 2019 00809 0100 4512 114 Rosemount CT510...

Page 115: ...F Scroll Down arrow G Scroll Down button 7 Using the Scroll Up button D and Scroll Down button G select FAULTS Refer to Figure 11 3 8 Press the SEL button C The Faults menu will then open Figure 11 4 Faults Menu No Faults Indicated Reference Manual Troubleshooting and diagnostics 00809 0100 4512 October 2019 Reference Manual 115 ...

Page 116: ...roll Down G buttons to highlight a fault for further investigation by the BIT system 3 Once the fault that you wish to diagnose has been highlighted press the SEL button to select that fault The Fault Display screen for the component that is reporting an error will then open The Fault Display screen will display the parameters of the suspect component Figure 11 7 shows an example of a Fault Displa...

Page 117: ... have the necessary information to determine if the suspect component is faulty contact Cascade Technologies Ltd for advice and assistance If there are more parameters than can be displayed on the available screen space a PAGE message will appear in the top right hand corner of the screen and the top right hand button will become the associated PAGE button Pressing the PAGE button will display the...

Page 118: ...rcuit breaker that controls the application of electrical power to the analyzer Power cables and interconnecting wiring that connect to the analyzer Pneumatic pipes hoses and associated T pieces pneumatic connectors and fittings etc that route the gas sample to and from the analyzer Any gas conditioning equipment necessary to condition the gas sample before it is routed to the analyzer 11 4 Repair...

Page 119: ...this section fail to return the analyzer to normal operation or do not identify a fault notify your service agent for further assistance 11 7 Diagnostics menu Selecting DIAGNOSTICS on the Main Menu will open the Diagnostics Menu Figure 11 8 The Diagnostics Menu lists those main components of the Rosemount CT5100 Ex where problems can be diagnosed using the BIST system The Diagnostics Menu also ena...

Page 120: ...R button G Scroll down button In the example shown in Figure 11 8 LASER 1 has been highlighted Pressing the SEL button B to select the LASER 1 component will open up the Laser 1 diagnostics menu shown in Figure 11 9 Troubleshooting and diagnostics Reference Manual October 2019 00809 0100 4512 120 Rosemount CT5100 Ex ...

Page 121: ... parameters If you do not have the necessary information to determine if the suspect component is faulty contact Emerson for advice and assistance If there are more parameters than can be displayed on the available screen space a PAGE message will appear in the top right hand corner of the screen as shown in Figure 11 9 and the top right hand button will become the associated PAGE button Pressing ...

Page 122: ...ctrical compartment door 11 9 Functional failure diagnostics If the Built in Self Test and the visual examination fail to identify the fault perform the failure diagnostics and recommended actions 11 9 1 No illuminated LEDs on Power supply unit PSU when analyzer switched ON Recommended actions 1 Check mains power is available 2 If OK replace PSUs 11 9 2 Nothing powers up when connected to mains Re...

Page 123: ...e OK replace BEKA display panel 11 9 6 NAMUR relay LED is OFF and no FAILURE reported on BEKA Recommended actions 1 Check power connections from peripheral board to relay 2 If the interconnecting cable is replace NAMUR relay 11 9 7 BEKA shows low noisy gas readings with FAILURE status Condition Faults page may display MISALIGNMENT on Gas Sensor 3 weak or no pulses from the affected laser with Misa...

Page 124: ...gnment of laser under Paths in the monitoring tab and possibly Pulse too noisy message Recommended actions 1 Ensure laser modules are working properly check laser current voltage and TEC readings on Gas Sensor 3 replace if necessary 2 Check the cable between motherboard and detector TEC PCB 14 way ribbon cable replace if necessary 3 Check 10 way cable from detector TEC PCB to VIGO replace if neces...

Page 125: ...icable 2 If interconnecting cable OK replace pressure sensor 11 9 12 BEKA display shows FAILURE status Condition The faults page shows CELL HEATER fault due to temperature being out of range with cell temperature reading either a constant value short circuit or a high value of 21000 and above Recommended actions 1 Check connection cable between cell temperature PT100 sensor and peripheral board 2 ...

Page 126: ...o peripheral board 2 Check 20 way ribbon cable from motherboard to peripheral board 3 Check connections to sensors and relays 4 If all are OK replace peripheral board 11 9 16 BEKA display won t show any information or only displays start up screen Recommended actions 1 Check SD Card is connected if SD card is not working replace it 2 Ensure the 12 V PSU and 12 Vdc fuse are OK if 12 Vdc fuse is not...

Page 127: ...n only be repaired by Emerson Where an item is unserviceable and no replacement procedure is given in this manual then the fault must be repaired by Emerson 12 2 Opening the electrical compartment door To gain access to the electrical compartment and the components mounted on the inside of the door open the door on the front of the Rosemount CT5100 Ex as follows Procedure Using an 8 mm Allen key l...

Page 128: ...ssion latch C 2 off cam latches 12 3 Closing the electrical compartment door The procedure for closing and locking the door to the electrical compartment is the reverse of the opening procedure Repair and replacement Reference Manual October 2019 00809 0100 4512 128 Rosemount CT5100 Ex ...

Page 129: ...art up procedure Damage to the analyzer may result from a failure to follow the start up procedure Procedure 1 Close the electrical compartment door 2 Using an 8 mm Allen key tighten the compression screw B and cam latch screws C to lock the door A See Figure 12 1 3 Restart the analyzer Refer to Start up procedure for the start up procedure 12 4 Replacing the fuses The analyzer contains internal f...

Page 130: ...ows one of the fuse holders which is shown in both the closed and partially open positions 3 No tools are required to remove the fuse Place a finger on the catch on the upper part of the fuse holder and lift up the upper part of the fuse holder as shown in Figure 12 3 Repair and replacement Reference Manual October 2019 00809 0100 4512 130 Rosemount CT5100 Ex ...

Page 131: ...ay result in personal injury or death and or damage to persons and or property 5 Fit the replacement fuse into the fuse holder Refer to Table 12 1 and verify that the fuse is of the correct type and rating When lowering the upper part of the fuse holder ensure that it clicks into place when fully lowered 6 Close the door of the electrical compartment and restart the analyzer Reference Manual Repai...

Page 132: ...eramic 0001 1011 2 Neutral line 110 230 Vac following mains filter 3 15 A 250 V fast acting ceramic 0001 1011 3 Analyzer 12 Vdc supply rail 5 A 250 V fast acting ceramic 0001 1011 4 Analyzer 24 Vdc supply rail 3 15 A 250 V fast acting ceramic 0001 1011 Repair and replacement Reference Manual October 2019 00809 0100 4512 132 Rosemount CT5100 Ex ...

Page 133: ... mm socket head cap screw E Ribbon cable to motherboard F Wiring harness to detector module G Backplate H Connector for ribbon cable Procedure 1 Shut down the analyzer Refer to Shutdown procedure 2 Open the door of the electrical compartment 3 Tag or otherwise identify all wiring harnesses before disconnecting Reference Manual Repair and replacement 00809 0100 4512 October 2019 Reference Manual 13...

Page 134: ... in the same orientation Using the packaging from the replacement TEC board send the unserviceable TEC board to Emerson for evaluation 11 Secure the TEC board by fitting the four screws D and associated spring washers C and flat washers B that were retained during the removal procedure 12 Apply Loctite 222 to the four off M3 screws and torque tighten the screws to 0 75 Nm 13 Connect the wiring har...

Page 135: ...e D TEC board ribbon cable E 12 V power wiring harness F M3 flat washer G M3 spring washer H M3 x 6 mm socket head cap screw I Relay wiring harness J Gas cell temperature monitoring harness K Gas cell temperature monitoring harness L Gas cell temperature monitoring harness Procedure 1 Shut down the analyzer Refer to Shutdown procedure Reference Manual Repair and replacement 00809 0100 4512 October...

Page 136: ...cell temperature monitoring harness from the peripheral board 9 Remove and retain the four screws H and associated spring washers G and flat washers F 10 Remove and discard the peripheral board 11 Place the peripheral board A in position on the backplate 12 Secure the peripheral board by fitting the four screws H and the associated spring washers G and flat washers F retained during the removal pr...

Page 137: ...A M3 flat washer B Ribbon cable connector J12 C M3 spring washer D M3 x 6 mm socket head cap screw E TEC board ribbon cable F Signal Out connector J32 G Signal Out connector J31 H Signal Out wiring harness I Signal Out wiring harness J Ribbon cable connector J7 Reference Manual Repair and replacement 00809 0100 4512 October 2019 Reference Manual 137 ...

Page 138: ...32 F 7 Disconnect the Laser Module ribbon cables P from the motherboard The number of Laser Module ribbon cables to be disconnected will vary depending upon the application that the analyzer has been configured for 8 Disconnect the 12 V power output wiring harness O from connector J17 L 9 Disconnect the 12 V power input wiring harness N from connector J16 M 10 Disconnect the peripheral PCB ribbon ...

Page 139: ...ing harness I to connector J31 G 24 If applicable connect the Detector Module 2 Signal Out wiring harness H to connector J32 F 25 Connect the TEC board ribbon cable E to connector J12 B 26 Close the door of the electrical compartment and restart the analyzer 12 8 Replacing the Ethernet in out relay modules The Ethernet in out relay modules to match section title are located on the right hand side ...

Page 140: ...placement Ethernet in out relay module A in its correct location on the DIN rail 8 Press the small lever B on the underside of the Ethernet in out relay module and push the module onto the DIN rail 9 Release the small lever and check that the Ethernet in out relay module is secure 10 Connect the wiring harnesses to the Ethernet in out relay module 11 Close the door of the electrical compartment an...

Page 141: ...nnector I Terminal blocks J Terminal blocks 12 10 Replacing a DC power supply Use this procedure and the wiring diagrams in Engineering drawings to replace a DC power supply The two DC power supplies are 12V and 24V To replace a DC power supply from the DIN rail refer to Figure 12 9 and complete the following steps Reference Manual Repair and replacement 00809 0100 4512 October 2019 Reference Manu...

Page 142: ...connect the wiring harness connector C from the bottom of the DC power supply 5 Press the small lever D on the underside of the DC power supply to release it from the DIN rail While continuing to press the lever remove the DC power supply from the DIN rail 6 Discard the unserviceable DC power supply 7 Inspect the replacement DC power supply for damage 8 Place the replacement DC power supply A in i...

Page 143: ...ve and discard the unserviceable 10 Amp relay 5 Inspect the replacement relay for damage 6 Place the replacement 10 Amp relay E in its correct location on the DIN rail 7 Make the wiring connections E to the relay 8 Close the door of the electrical compartment and restart the analyzer as described in Start up procedure 12 12 Replacing the Ethernet connector The Ethernet connector is clipped onto th...

Page 144: ...zer The laser modules are located on the underside of the optical compartment base plate Figure 12 10 Replacing the Laser Module A Base plate B Pin C Laser module D Captive screw E Ribbon cable F Captive screw Procedure 1 Shut down the analyzer Refer to Shutdown procedure 2 Open the door of the electrical compartment Repair and replacement Reference Manual October 2019 00809 0100 4512 144 Rosemoun...

Page 145: ... new laser module in position on the base plate A The laser module must mate with the two locating pins B on the base plate 8 Secure the laser module by tightening the two captive screws D and F 9 Connect the ribbon cable E to the laser module 10 Close the door of the electrical compartment and restart the analyzer Reference Manual Repair and replacement 00809 0100 4512 October 2019 Reference Manu...

Page 146: ...x 35 mm socket head cap screw C Detector module D M3 plain washer E Detector bracket F M3 spring washer G M3 nut H Wiring harness Procedure 1 Shut down the analyzer Refer to Shutdown procedure 2 Open the door of the electrical compartment 3 Disconnect the trigger OUT harness A Refer to Figure 12 11 Repair and replacement Reference Manual October 2019 00809 0100 4512 146 Rosemount CT5100 Ex ...

Page 147: ... the detector module C 11 Close the door of the electrical compartment and restart the analyzer 12 15 Replacing the O2 detector The O2 detector is located on the underside of the optical compartment base plate First determine which detector type is fitted 1 or 2 Replace the O2 detector identified using the following steps 12 15 1 Replacing O2 detector type 1 Procedure 1 Shut down the analyzer Refe...

Page 148: ...d plain washer C removed previously secure the O2 detector to the base 8 Connect the power cable by screwing it onto the mating connector on the O2 detector 9 Connect the BNC cable to the O2 detector 10 Close the door of the electrical compartment and restart the analyzer 12 15 2 Replacing O2 detector type 2 Procedure 1 Shut down the analyzer Refer to Shutdown procedure 2 Open the door of the elec...

Page 149: ... O2 detector 7 Inspect the replacement O2 detector for damage 8 Fit the replacement O2 detector D in position Using the M4 socket head cap screw A spring washer B plain washer C and the M4 counter sunk screw E secure the O2 detector to the bracket 9 Use the two M3 socket head cap screws F spring washers G and plain washers H to connect the O2 detector and bracket I to the base 10 Connect the power...

Page 150: ... mm self sealing cross pan head screw D M5 x 12 mm self sealing cross pan head screw 5 Remove and discard the two self sealing screws C and D 6 Remove the main terminal board 7 Inspect the replacement main terminal board for damage 8 Fit the main terminal board A in position at the front of the carcass B 9 Secure the main terminal board by fitting the two self sealing screws C and D New self seali...

Page 151: ...inal board 5 Remove and discard the mains power filter 6 Inspect the replacement mains power filter for damage 7 Fit the mains power filter to the main terminal board and secure with the two nuts retained in Replacing the mains power filter 8 Connect the wiring harnesses to the mains power filter 9 Fit the main terminal board 12 18 Removing the top cover To gain access to the pneumatic compartment...

Page 152: ...ies if required 6 Carefully lift the top cover into position 7 Re engage the right angled notches C on the top cover from the mating lugs on the chassis beneath 8 Refer to Figure 12 15 Rotate the two locking mechanisms A clockwise to lock the front of the top cover B in position 12 19 Replacing the PT100 gas temperature sensor Note Approval for the PT100 temperature sensor as a simple device To pe...

Page 153: ... the two conditions below are given The total Li of the external circuit excluding the cable is 1 percent of the Lo value or The total Ci of the external circuit excluding the cable is 1 percent of the Co value Note The reduced capacitance of the external circuit including cable shall not be greater than 600 nF for Group IIC Procedure 1 Shut down the analyzer Refer to Shutdown procedure 2 Remove t...

Page 154: ...t turning while using the second spanner to loosen cap G Remove the PT100 gas temperature sensor assembly B E F and G 10 Discard the faulty PT100 gas temperature sensor B retaining the cap G follower F and seal E 11 Inspect the replacement PT100 gas temperature sensor B for damage If damaged contact your local customer care representative 12 In this order slide the cap G follower F and seal E onto...

Page 155: ...2 Remove the analyzer top cover Refer to Removing the top cover 3 Disconnect the pressure sensor electrical connector D 4 While holding the bulkhead adaptor A steady unscrew the pressure sensor C 5 Discard the unserviceable pressure sensor 6 Inspect the new pressure sensor for damage 7 Install the replacement pressure sensor C and dowty washer B onto the bulkhead adaptor A Hold the bulkhead adapto...

Page 156: ... the form of a static dissipative mat and anti static wrist strap must be used at all times when handling electronic components and assemblies 12 21 1 Equipment materials The following equipment and materials are required when cleaning the cell mirrors Spectroscopic grade methanol or ethanol Optical grade lens tissue Invertible air duster Hex head keys sizes 1 5 mm to 4 mm Repair and replacement R...

Page 157: ...identify all wiring harnesses before disconnecting 4 The cell Insulation is closed using Velcro flaps Open the flaps and lift the cell lid insulation C to access the cell lid 5 Disconnect the tube fitting nut D 6 Remove and retain the bracket fastener G to disconnect the bracket E and pressure sensor F from the cell lid A Place to one side 7 Remove and retain the six cell lid fasteners B 8 Remove ...

Page 158: ... temperature to stabilize and check the pulses in the gas sensor software If pulses have returned to a usable signal size proceed to operate the analyzer Otherwise take a note of the signal sizes and go to next step Cleaning the mirrors with lens tissue and spectroscopic grade methanol 12 21 4 Cleaning the mirrors with lens tissue and spectroscopic grade methanol If cleaning with an invertible air...

Page 159: ...essure to the mirrors Figure 12 20 Figure 12 20 Correct Cleaning Technique A Correct B Incorrect 4 Clean the mirrors using the lens tissue in the direction shown in Figure 12 21 Be careful to wipe across the mirror surface to prevent any residue marks appearing on the mirror surface where the solvent has evaporated Reference Manual Repair and replacement 00809 0100 4512 October 2019 Reference Manu...

Page 160: ... 7 Allow the cell temperature to stabilize and check the pulses in the gas sensor software If the pulses have returned to a usable signal size proceed to operate the analyzer Note If pulses have not returned to a usable signal size contact Emerson for assistance Repair and replacement Reference Manual October 2019 00809 0100 4512 160 Rosemount CT5100 Ex ...

Page 161: ...he cell lid A 2 Fit the cell lid A to the analysis cell using the cell lid fasteners B 3 Pass the cell lid insulation C over the bracket before attaching the bracket E to the cell lid using the bracket fastener G 4 Reattach the tube fitting nut D to the pipe adaptor 5 Fit the cell lid Insulation into position and secure using the Velcro flaps Reference Manual Repair and replacement 00809 0100 4512...

Page 162: ... 00025 Remote Ethernet I O Digital output module P 5000 1034 Remote Ethernet I O Screen display BEKA BA488C certified P 6001 00011 Panel mount IS display module Heater 230 V certified P 6001 00014 Ex cart heater Heater 120 V certified P 6001 00015 SL Blocktherm DKA 80 W heater block Power supply 12 V P 6001 00017 72 W switch mode DIN rail panel mount power Power supply 24 V P 6001 00018 90 W switc...

Page 163: ...performed are contained in Table 13 1 Table 13 1 Scheduled Checks Frequency Action Monthly 1 Check the zero and span calibration Perform the calibration more or less frequently if necessary to meet quality control or plant operation requirements 2 Clean outside of system Ensure all vents are clean and unobstructed Every three months quarterly 1 Perform the monthly check detailed in the previous ro...

Page 164: ...RATING STATE On completion of any maintenance ensure that the Rosemount CT5100 Ex is in a safe and correct operating state Preventative maintenance Reference Manual October 2019 00809 0100 4512 164 Rosemount CT5100 Ex ...

Page 165: ...ent standards in order to support the issue of prime ATEX and IECEx certification 14 2 Applicant s name and address Cascade Technologies Ltd Glendevon House Castle Business Park Stirling FK9 4TZ UK 14 3 Manufacturer s name and address As applicant 14 4 Trademark 14 5 Product name model number Rosemount CT5100 Ex Continuous Gas Analyzer 14 6 Rating 110 V to 120 V 60 Hz 220 V to 240 V 50 Hz 1100 W R...

Page 166: ...editation Sira s flexible scope is available on request 14 8 Markings Table 14 2 IECEx and ATEX Markings Detail IECEx ATEX Certificate number IECEx SIR 16 0050X Sira 16ATEX1158X Certification code EX ia d ia Ga op is pzc IIC T3 Gc Tamb 20 to 55 EX ia d ia Ga op is pzc IIC T3 Gc Tamb 20 to 55 Other marking N A II 3 1 G Table 14 3 North American Markings Detail CSA North American Marking Certificate...

Page 167: ...ame Cascade Technologies Ltd Manufacturer s address Glendevon House Castle Business Park Stirling FK9 4TZ UK Ambient range 4 to 131 F 20 to 55 C Serial number As applicable Year of manufacture As applicable Reference Manual ATEX IECEX assessment report summary 00809 0100 4512 October 2019 Reference Manual 167 ...

Page 168: ...gaz inerte et peut constituer un danger d asphyxie WARNING Batteries are located inside this enclosure Do not open when an explosive atmosphere is present AVERTISSEMENT Présence de batteries à l intérieur de cette enveloppe Ne pas ouvrir si une atmosphère explosive est présente WARNING This pressurized enclosure contains a battery which remains connected after the external power has been isolated ...

Page 169: ...n pollution degree 2 as defined in IEC 60664 1 The cable glands used in the equipment are only suitable for use in areas with a low risk of mechanical damage and must be suitably protected Rosemount CT5100 Ex purge controller automatically monitors the internal pressure of the enclosure and will output any fault conditions onto contact K2 It is the responsibility of the end user to connect this co...

Page 170: ...ssment does not cover reliable function performance or other properties of the equipment not related to safety The equipment is to be installed using wire no larger than the protective earth wire Equipment is only to be installed by manufacturer trained personnel If at anytime there is a conflict between the system safety provisions and any relevant local national or regional requirements the loca...

Page 171: ...meters apply when one of the two conditions below is given The total Li of the external circuit excluding the cable is 1 percent of the Lo value or The total Ci of the external circuit excluding the cable is 1 percent of the Co value The above parameters are reduced to 50 when both of the two conditions below are given The total Li of the external circuit excluding the cable is 1 percent of the Lo...

Page 172: ...ATEX IECEX assessment report summary Reference Manual October 2019 00809 0100 4512 172 Rosemount CT5100 Ex ...

Page 173: ...g faults These diagrams may be used to locate the position of a wiring connector should it become disconnected Table A 1 List of Engineering Drawings Drawing number Description W 2000 0034 Sheets 1 5 Rosemount CT5100 Ex heated Reference Manual Engineering drawings 00809 0100 4512 October 2019 Reference Manual 173 ...

Page 174: ...6 47 48 49 50 DGITAL OUTPUT 7 DGITAL OUTPUT 8 DGITAL OUTPUT 9 DGITAL OUTPUT 10 DGITAL OUTPUT 11 DGITAL OUTPUT 12 ANALOGUE OUTPUT 5 ANALOGUE OUTPUT 6 ANALOGUE OUTPUT 7 ANALOGUE OUTPUT 8 STATUS OUTPUT 1 Check Function C C C C C C C C C C C C NO NO NO NO NO NO NO NO NO NO NO NO NO B A 2 1 3 4 5 6 7 8 C D E B A C D E A3 CASCADE TECHNOLOGIES LTD GLENDEVON HOUSE CASTLE BUSINESS PARK STIRLING FK9 4TZ UK ...

Page 175: ...SER MODULE DETECTOR MODULE 1 DETECTOR MODULE 2 optional 8 2 2B TO M BOARD 10 2 2E METAL BARRIER MUST BE IN PLACE DURING OPERATION TO M BOARD 12 2 4A TO TEC BOARD 114 113 65 64 63 62 E E EARTH STUD E E E 3 4 64 65 66 65 67 62 67 63 67 67 63 63 63 E F1 F2 F3 F4 11 2 2B TO M BOARD 1 X1 2 3 61 60 E 61 60 E 1 2 3 61 60 E 61 60 E X1 16 4 6D 17 4 6D TO CELL HEATERS 61 59 INTERNAL PT100 THERM No CONNECTOR...

Page 176: ... SEPARATELY FROM OTHER CABLES LOOMS BLUE TRI RATED WIRING TO BE USED FOR I S CIRCUIT BA 488C DISPLAY PURGE CONTROL UNIT 90 89 E V V 3 4 Tx Rx A2 A1 A3 A4 S1 S2 S3 S4 S5 S6 S7 E VIEW ON REAR OF FRONT COVER 1 2 5 6 Vsi I S CIRCUIT METAL BARRIER MUST BE IN PLACE DURING OPERATION B A 2 1 3 4 5 6 7 8 C D E B A C D E A3 CASCADE TECHNOLOGIES LTD GLENDEVON HOUSE CASTLE BUSINESS PARK STIRLING FK9 4TZ UK TH...

Page 177: ...ASTLE BUSINESS PARK STIRLING FK9 4TZ UK THIS 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 INSTRUMEN...

Page 178: ... 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 WIRING DRAWN TO IEC61346 ICS 19 2002 WHERE APPLICABLE CUSTOM SYMBOLS LISTED ON KEY PROVIDED BLOCK DIAGRAMS CAN BE INSERTED TO CLARIFY FUNCTIONALITY DO NOT SCALE DO NOT ALTER MANUALLY DRAWING No DESCRIPTION REV DRAWN BY CHECKED BY...

Page 179: ...rt emerson com MIDDLE EAST AND AFRICA REGIONAL OFFICE Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai United Arab Emirates P O Box 17033 971 4 811 8100 971 4 886 5465 cascade support emerson com ASIA PACIFIC REGIONAL OFFICE Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Republic of Singapore 65 6 777 8211 65 6 777 0947 cascade support emerson com Linkedin com co...

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