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10.

Turn the

ON/OFF

switches on the front and back panel to the ON position to restart

the analyzer.

7.13

Replacing the fans

The analyzer contains two identical fans. The replacement procedures for both fans are
similar; therefore, the replacement procedure for only one is described.

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 tagged off before removing the top

cover.

The analyzer must be earthed.

Death or personal injury may result if this is not observed.

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 31 kg (68 lb). Emerson

™

recommends that the analyzer is only moved and

lifted by a minimum of two people. Wear suitable protective gloves and protective footwear.

Failure to properly handle the analyzer may cause injury to personnel.

WARNING!

BURNS
Do not touch any part of the analyzer. Assume all parts of the analyzer are hot unless it has
been switched off and allowed to cool down. Some parts of the analyzer may be heated to
190 °C (374 °F). Always wear proper protective equipment when handling the analyzer.

•

Switch off the analyzer and allow it to cool for at least two hours before fitting,
removing, or performing any maintenance.

•

The analysis cell is insulated against heat loss. Allow the analyzer to cool for at least
twelve hours before performing any maintenance on, or in the vicinity of, the analysis
cell.

Failure to allow sufficient cooling may cause serious burn injury to personnel. If burns occur,
seek immediate medical treatment.

Procedure

1.

Power down the analyzer and allow it to cool.

2.

Remove the analyzer from the rack and place it on a stable workbench. This step
requires two people to properly lift and transport it to the workbench.

Troubleshooting and diagnostics

Installation, Operations, and Maintenance Manual

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Summary of Contents for Rosemount CT5400

Page 1: ...Installation Operations and Maintenance Manual D 7010 0045 Rev C January 2018 Rosemount CT5400 Continuous Gas Analyzer ...

Page 2: ...s which it describes Document Number D 7010 0045 Rev C January 2018 Emerson 2017 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the express prior written permission of the copyright holder If you require additional technical assistance request...

Page 3: ...ogram when installing using and maintaining Emerson Rosemount products Failure to follow the proper instructions may cause Loss of life Personal injury Damage to property Damage to this instrument Warranty invalidation Read all instructions prior to installing operating and servicing the product If you do not understand any of the instructions contact your Emerson Rosemount representative for clar...

Page 4: ...0 2011 Clause 30 This section must not be changed amended or removed In depth specialist knowledge is an absolute requirement for working with and on the analyzer Personnel installing operating servicing and maintaining the analyzer must be instructed trained qualified and authorized for hazardous areas with the operating company and the manufacturer It is the operating company s responsibility to...

Page 5: ...2013 Electrical equipment for measurement control and laboratory use EMC requirements General requirements Associated publications Quick Start Guide D 7010 0061 Compliance approvals This product complies with USA 21 CFR 1040 10 It is also designed and manufac tured under an approved quality management system to ISO 9001 2008 Emerson and the Rosemount CT5400 Gas Analyzer have satisfied the require ...

Page 6: ...eath 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 ...

Page 7: ...y result in highly flammable gas being released causing fire or explosion DANGER FAILURE TO VENT SAMPLE GAS MAY CAUSE DEATH The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the analyzer during startup The sample gas in the pipes leading to the analyzer must be purged to prevent hazards to personnel during maintenance Purging the s...

Page 8: ... Avoid direct skin contact with used gas handling components Do not smoke drink or eat in the work area Wear goggles or eye shields Wear a suitable face mask to protect against inhalation of particulate matter Do not wet fingers eyes or any exposed skin Pack used gas handling components for disposal in sealed packaging and label them Contaminated Dispose of contaminated items as hazardous material...

Page 9: ...nutes to allow any sample gas in the system to be returned to the exhaust WARNING EXPLOSION Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type CAUTION EQUIPMENT DAMAGE Always follow the startup procedure Damage to the analyzer may result from a failure to follow this procedure Failure to perform pre system startup checks may cause damage to equipme...

Page 10: ...s physically secure and all electrical and pneumatic connections to the analyzer are in place Before commencing the start up process it is important to ensure that electrical power sample gas handling facilities and any calibration gases that are required are available to the analyzer ...

Page 11: ...osemount CT5400 Continuous Gas Analyzer Serial number CT5400 10008 Model number CT5400 Glendevon House Castle Business Park Stirling FK9 4TZ United Kingdom Tel 44 0 1786 447 721 Emerson com RosemountGasAnalysis Rear panel CAUTION Hot label 1 Cell insulation 2 Both heated lines 3 Rack lid near ventilation holes Laser radiation CAUTION label Baseplate Laser module identification label On each laser ...

Page 12: ...ety statement Rear panel AC power supply voltage label On analysis cell insulation AC power supply Danger label 1 Rear panel above mains power input socket 2 On reverse of front panel next to On Off switch AC power supply label Rear panel below power socket ...

Page 13: ...hane CO Carbon monoxide CO2 Carbon dioxide DC Direct current Deg Degree temperature e g For example EC European Community EMC Electromagnetic compatibility EU European Union Hrs Hours Hz Hertz H2O Water ICL Interband Cascade Laser IEC International Electro technical Commission in Inches IP Ingress protection IPxx Ingress protection xx are numbers that define the protection level IS Intrinsically s...

Page 14: ...al Fire Protection Association nm Nanometer NO Nitric oxide NO2 Nitrogen dioxide N2O Nitrous oxide NH3 Ammonia No Number O2 Oxygen PC Personal computer 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 Uni...

Page 15: ...Abbreviation Description WEEE Waste electrical and electronic equipment μm Micro meter ...

Page 16: ......

Page 17: ...tup procedure 21 3 1 Introduction 21 3 2 Preparation for use 21 3 3 Startup procedure 22 Chapter 4 Operating the analyzer 25 4 1 Introduction 25 4 2 Normal operation 25 4 3 Front panel controls and indicators 26 4 4 Rear panel controls 28 4 5 Display controller 28 4 6 Gas Sensor Main screen 30 4 7 Pressure and Temperature screen 31 4 8 Help system 31 4 9 Main menu 32 4 10 BACK button 33 Chapter 5 ...

Page 18: ... 7 17 4 Replacing the Ethernet switch 104 7 17 5 Replacing the laser modules 107 7 18 Replacing the gas temperature sensor 110 7 19 Replacing the pressure sensor 112 7 20 Replacing the thermal cut out 114 7 21 Replacing the gas input line 117 7 22 Replacing the gas output line 119 7 23 Replacing the analysis cell 121 7 24 Cleaning the analysis cell mirrors 124 7 25 Installing the Top Cover 127 7 2...

Page 19: ...Appendix C Engineering Drawings 151 C 1 Engineering drawings 151 Contents Installation Operations and Maintenance Manual iii ...

Page 20: ...Contents iv Rosemount CT5400 ...

Page 21: ...ing maintaining and transporting to prevent crushing of hands feet or other body parts The analyzer weighs 31 kg 68 lb Emerson recommends that the analyzer is only moved and lifted by a minimum of two people Wear suitable protective gloves and protective footwear Failure to properly handle the analyzer may cause injury to personnel This manual is intended for the personnel who install operate and ...

Page 22: ... system the analyzer and the associated interconnecting wiring and gas piping Measurement data from the analyzer can be displayed in the process control center You must provide the gas handling system and interconnecting wiring and gas piping Emerson supplies the CT5400 In Figure 1 2 the items supplied by Emerson are colored orange the items supplied by you are colored blue Table 1 1 lists the mai...

Page 23: ...ptical path to the analysis cell which provides measurement of low concentrations of the subject gases An external sample handling system conditions the sample gas and draws it through the analysis cell The light exits the multi pass analysis cell and is directed to a receiver in the analyzer The variation in the intensity of light in the vicinity of the absorption lines is measured and the concen...

Page 24: ...the CT5400 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 All personnel must read this manual carefully before commencing any work on the analyzer For information regarding installation consult Chapter 2 and the Quick Start Guide D 7010 0052 Emerson is committed to...

Page 25: ...s purpose The fasteners must always be fitted with the washer supplied by the manufacturer The equipment has non conductive surfaces which are a potential electrostatic charging hazard see instructions for guidance The process gas flow rate is limited to a maximum of 6 liters per minute The equipment shall only be used with process gases which are in gas groups B C or D Divisions or IIB H 2 Zones ...

Page 26: ... are familiar with this manual and have been specially trained on the analyzer should install operate switch off and service the analyzer Only qualified and trained persons have the required specific knowledge to correctly interpret the general safety information warnings and procedures given in this manual and apply them to this particular application Emerson or its distribution partners can prov...

Page 27: ...ated aluminum Housing material Powder coated steel Wetted materials PFA coated aluminum 315 stainless steel FKM and FFKM seals CaF2 and BaF2 windows protected gold coated aluminum mirrors Measurement techni que Mid IR absorption spectroscopy Mid IR source Quantum Cascade Laser Laser classification Class 1 BS EN 60825 1 2007 safety of laser products Equipment classification and requirements identic...

Page 28: ...system locking holes D Ventilation Do not obstruct Dimensions Side View Figure 1 4 A Handle swings out 63 mm 2 5 in B 2 off telescopic slide 610 mm 24 in long 55 kg 121 3 lb max load 50 8 mm 2 in over travel 9 6 mm 4 in slide thickness Lock out Front disconnect Plan 8 Rosemount CT5400 ...

Page 29: ... F Ambient temperature Sample gas temperature range 50 to 195 122 to 383 C F Factory set specify on order Sample gas particulate density 5 mg m3 Maximum Sample gas particulate size 10 μm Maximum Sensor humidity range 10 to 95 Relative humidity non condens ing at 45 C 113 F Note The CT5400 Continuous Gas Analyzer is suitable for indoor use only Plan Installation Operations and Maintenance Manual 9 ...

Page 30: ...m of two people to safely remove the equipment from the shipping container 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 31 kg 68 lb Emerson recommends that the analyzer is only moved and lifted by a minimum of two people Wear suitable protective gloves and prote...

Page 31: ...anel left side handle B Front panel right side handle Rear View Showing Lifting Handle Figure 1 7 A Rear panel handle 5 Place the analyzer on a solid level surface and prepare to rack mount the analyzer Plan Installation Operations and Maintenance Manual 11 ...

Page 32: ...Plan 12 Rosemount CT5400 ...

Page 33: ...ICE Fitting the analyzer into the rack and securing it are your responsibilities 2 Install the analyzer in a suitable shelter to protect it from environmental elements and water The Ingress Protection rating IP for the analyzer is IP 44 per the IEC 60529 standard DANGER FLAMMABLE SUBSTANCES Some parts of the analyzer may reach temperatures of 190 C 374 F and may present an ignition source Exercise...

Page 34: ...le protective gloves and protective footwear Failure to properly handle the analyzer may cause injury to personnel Note You must supply the rack Procedure 1 One person aligns the analyzer s telescoping slide rails on the unit as the other person carefully guides the analyzer into the rack using the front panel and rear handles see Figure 2 1 Left Side View Lifting Handles and Telescopic Slide Rail...

Page 35: ...3 A Rear ventilation holes B Rear panel handle 3 Inspect the analyzer and ensure the unit is correctly mounted in the rack and glides easily on the telescoping slide rails The analyzer must slide in and out of the rack to make the power analog digital Ethernet and gas connections Install Installation Operations and Maintenance Manual 15 ...

Page 36: ...B Gas Inlet and Outlet Connectors Figure 2 4 A Sample gas input port B Sample gas return port 3 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 HAZARDOUS GAS The product stream that the analyzer is examining may be hazardous even at low concentrations Therefore take special...

Page 37: ...connector Electrical electronic signal connections to the analyzer are made through electrical connectors located on the rear panel of the instrument as shown in Figure 2 5 Use the wiring diagram to make the electrical connections as shown in Appendix C Status outputs 10 way socket H Table 2 1 Pins Function 1 6 Status output 1 check function optional 2 7 Status output 2 maintenance required option...

Page 38: ... 0 set in config file 2 10 Analog channel 1 set in config file 3 11 Analog channel 2 set in config file 4 12 Analog channel 3 set in config file 5 13 Analog channel 4 set in config file 6 14 Analog channel 5 set in config file 7 15 Analog channel 6 set in config file 8 16 Analog channel 7 set in config file CAUTION EQUIPMENT DAMAGE Make sure that the mains supply cable used is of a suitable rating...

Page 39: ...sent on the digital output terminals External circuits should be installed in accordance with national wiring regulations Failure to obey the wiring regulations may result in serious injury to personnel WARNING ELECTRIC SHOCK The analyzer passed electromagnetic compatibility EMC tests based on all electrical cables and harnesses attached to the instrument having a length of 3 m 9 8 ft Attaching ca...

Page 40: ...Install 20 Rosemount CT5400 ...

Page 41: ...lace Before commencing the start up process it is important to ensure that electrical power sample gas handling facilities and any calibration gases that are required are available to the analyzer WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some parts of the analyzer may be heated to 190 C 374...

Page 42: ... leaks or overheating Report anything found to the maintenance organization 2 Make sure that the analyzer has been correctly installed see Chapter 2 3 Make sure that the rack lid is fitted to the analyzer If it is not report it to the maintenance organization and do not proceed further until the rack lid has been fitted 4 Make sure that the On Off switch at the rear of the analyzer is set to I ON ...

Page 43: ...n Gas Sensor Main screen Figure 3 2 6 Start up the system for returning the sample gas 7 Start up the gas handling system that conditions the sample gas before it is fed into the analyzer Allow the analyzer to warm up in accordance with Table 1 3 before the sample gas supply is turned on Startup procedure Installation Operations and Maintenance Manual 23 ...

Page 44: ...Startup procedure 24 Rosemount CT5400 ...

Page 45: ... therefore 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 Chapter 8 of this manual Provided that the start up procedure described in Chapter 3 has been followed the analyzer does not require any human intervention during normal operation other than...

Page 46: ...tly 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 down the list 4 3 Front panel controls and indicators There are two controls located on the front panel Figure 4 3 ...

Page 47: ...illuminates red when the switch is set to On Note that setting the front panel On Off switch to Off does not remove all electrical power from the instrument Part of the power distribution circuit will remain live To remove all electrical power from the instrument set the On Off switch on the rear panel refer to Section 4 4 to Off Operation of the analyzer is controlled primarily through the displa...

Page 48: ...f switch The function of the rear panel On Off switch is to control the application of electrical power to the complete instrument Rear Panel Figure 4 5 A On Off switch fused socket 4 5 Display controller Front Panel Display Controller Figure 4 6 A LCD display B Navigation buttons Operating the analyzer 28 Rosemount CT5400 ...

Page 49: ...ious screen No function from the Home screen Re ferred to as LEFT Used to access the context sensitive Help pages Referred to as HOME Generally used to select an alternative function Also allows you to toggle be tween gas and physical measurements from the Home screen Referred to as ENTER The analyzer employs Intelligent Device Management which enables self monitoring and diagnostics This ensures ...

Page 50: ...mmonia NH3 water H2O carbon monoxide CO and formaldehyde H2CO are being measured and for each gas the concentration detected is in parts per million ppm At the end of the startup procedure the gas measurements initially appear as 0 00 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 ...

Page 51: ...rr inside the analysis cell NOTICE A Torr is a non SI unit of pressure defined as 1 760 of standard atmospheric pressure and is equal to the fluid pressure of 1 mm of mercury 4 8 Help system The analyzer 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 ...

Page 52: ...s 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 known gas source verification or if necessary to calibrate the analyzer against that known gas source calibration DATA SERVICE Takes you to a screen that allows data to be downloaded from the instrument The downloaded data is used to diagnose faults...

Page 53: ...enu Figure 4 10 4 10 BACK button On most of the software screens is configured as a BACK button Press to return to the previous screen Operating the analyzer Installation Operations and Maintenance Manual 33 ...

Page 54: ...Operating the analyzer 34 Rosemount CT5400 ...

Page 55: ... the following procedure Prerequisites Run the analyzer at a stable temperature for at least thirty minutes prior to commencing this procedure Use nitrogen gas of instrument gas purity as the zero verification gas Procedure 1 Make sure that a pressure regulator is connected to the nitrogen gas bottle 2 Connect a hose from the nitrogen gas bottle through a T piece to the sample supply port on the r...

Page 56: ...ected Press The Select Type screen Figure 5 2 opens Select Type Screen Figure 5 2 7 Use and to move the cursor until the ZERO verification option is selected as shown in Figure 5 2 8 To perform a verification press The Manual Automatic screen Figure 5 3 opens Verifying Gas Concentrations 36 Rosemount CT5400 ...

Page 57: ...utomatically allow configuration verification in a future release of GasSensor 3 software The Verify Zero screen Figure 5 4 opens Verify Zero Screen Figure 5 4 10 Allow the concentrations to stabilize and wait for two minutes after stabilization Verifying Gas Concentrations Installation Operations and Maintenance Manual 37 ...

Page 58: ...f the reading is within tolerance no further action is required Press to end the zero verification process The display controller proceeds to the Result screen Figure 5 5 Result Screen Figure 5 5 12 If the reading is outside tolerance the instrument should be zero calibrated Refer to Section 6 3 1 13 In either case press to return to the Calibration Verification Complete screen Figure 5 6 Calibrat...

Page 59: ...equisites Run the analyzer at a stable temperature for at least thirty minutes prior to commencing this procedure Procedure 1 Use a certified reference gas cylinder as the source of the span verification gas 2 Make sure 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 t...

Page 60: ...ct gas screen Figure 5 8 opens Select gas Screen Figure 5 8 8 Use and to move the cursor until the gas that you wish to span verify is selected Press The Select Type screen Figure 5 9 opens Verifying Gas Concentrations 40 Rosemount CT5400 ...

Page 61: ...re 5 9 To perform a verification press The Mode selection screen opens Figure 5 10 for manual or automatic verification Mode selection Screen Figure 5 10 10 Press for manual verification The Span input screen Figure 5 11 opens Verifying Gas Concentrations Installation Operations and Maintenance Manual 41 ...

Page 62: ...decrease the value until the concentration displayed matches the cylinder you are using NOTICE The cylinder concentration must be entered in ppm 12 Press to proceed to the next step The Verify span screen Figure 5 12 opens Verify span Screen Figure 5 12 Verifying Gas Concentrations 42 Rosemount CT5400 ...

Page 63: ...ent In the example shown in Figure 5 12 the gas being measured is NH3 ammonia and the instrument has detected a concentration of 2000 29 ppm 18 If the reading is within tolerance no further action is required Press to end the span verification process The display controller proceeds to the Result screen Figure 5 13 Result Screen Figure 5 13 19 If the reading is outside tolerance the instrument sho...

Page 64: ...Repeat steps 8 16 for the next gas 22 If you wish to perform a zero verification press Then follow the zero verification procedure in Section 5 1 1 23 If you are finished verifying the analyzer press The software returns to the Gas Sensor Main screen Figure 4 7 The span verification procedure is now complete Verifying Gas Concentrations 44 Rosemount CT5400 ...

Page 65: ...as Validating the other gases measured by the analyzer particularly any which are measured by the same laser as H2O can demonstrate that the system is functioning correctly meaning there is no need to calibrate the water measurement directly If 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 v...

Page 66: ...erance 2 At regular intervals such as once a day or once a shift 6 3 1 Zero calibration Zero calibration is calibrating the analyzer so that when no sample gas is flowing through it the gas concentrations measured by the instrument are zero Zero calibration is done by calibrating the analyzer measurements against a known sample gas using the following procedure Prerequisites Run the analyzer at a ...

Page 67: ...ct gas screen Figure 6 3 opens Select gas Screen Figure 6 3 6 Use and to move the cursor until the gas that you wish to zero calibrate is selected Press The Select Type screen Figure 6 4 opens Gas Calibration Procedures Installation Operations and Maintenance Manual 47 ...

Page 68: ...n is selected see Figure 6 4 8 To perform a calibration press The Mode selection screen Figure 6 5 opens Mode selection Screen Figure 6 5 9 Press for manual calibration Press for automatic calibration The Calibrate zero screen Figure 6 6 displays Gas Calibration Procedures 48 Rosemount CT5400 ...

Page 69: ...wo minutes after stabilization This screen gives a reading of the concentration of the selected gas that is present as an impurity in the nitrogen calibration gas as measured by the instrument In the example shown Figure 6 7 the gas being measured is NH3 ammonia and the instrument has detected a concentration of 0 530 ppm vol Gas Calibration Procedures Installation Operations and Maintenance Manua...

Page 70: ...6 If the calibration of the analyzer remains outside of tolerance press to display the Calibrate screen Figure 6 8 to re calibrate with a new zero offset value Calibrate screen Confirmation Figure 6 8 17 To proceed with the automatic re calibration press The automatic re calibration of the instrument s zero point starts and the offset shown on the screen 0 852 ppm vol in Figure 6 8 is applied to t...

Page 71: ...nown reference gas by using the following procedure Prerequisites Run the analyzer at a stable temperature 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 Make sure that a pressure regulator is connected to the reference gas bottle 3 Connect a hose from the reference gas bottle through a T...

Page 72: ...e the cursor until the gas that you wish to span calibrate is highlighted by the cursor Press The Select type screen Figure 6 11 opens Select Type Screen Figure 6 11 8 Use and to move the cursor until SPAN is selected Figure 6 11 To perform a calibration press The Mode selection screen Figure 6 12 opens Gas Calibration Procedures 52 Rosemount CT5400 ...

Page 73: ...ighlight each digit in turn then use and to increase or decrease the value until the concentration displayed matches the cylinder you are using Press to proceed to the next step NOTICE The cylinder concentration must be entered in ppm The begin Calibrate span screen Figure 6 14 opens Gas Calibration Procedures Installation Operations and Maintenance Manual 53 ...

Page 74: ...Figure 6 15 the gas being measured is NH3 ammonia and the instrument has detected a concentration of 119 41 ppm vol 13 If the reading is within tolerance no further action is required Press or to abort the span calibration process 14 If the reading is outside tolerance press ENTER The analyzer returns to its factory set calibration 15 Allow a minute to ensure the readings are stable 16 If the read...

Page 75: ...pan calibration starts and the offset shown on the screen in Figure 6 17 it is 0 997 is applied to the instrument Press or to abort the calibration process When the calibration or verification is complete the screen shown in Figure 6 17 is displayed Calibrate Complete Screen Figure 6 17 19 If you wish to perform a span calibration for another gas press The software returns to the Select gas screen...

Page 76: ...o the Main menu shown in Figure 6 2 6 4 Reference gas suggested concentration ranges Calibration gas ranges are recommended to be between 80 and 100 of the full range of the analyzer Please contact Emerson if you require assistance Gas Calibration Procedures 56 Rosemount CT5400 ...

Page 77: ...stomer Care Representative for further assistance Observe and obey all safety precautions when performing preventative maintenance on the analyzer Important The troubleshooting 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...

Page 78: ...the Ex d enclosure of the analyzer unless the atmosphere in the area is known to be below the ignitable concentration of combustible gases or materials Failure to observe this precaution will cause death personal injury and or damage to persons WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some ...

Page 79: ... wet fingers eyes or any exposed skin Pack used gas handling components for disposal in sealed packaging and label them Contaminated Dispose of contaminated items as hazardous material according to the applicable local national or international health and safety regulations and pollution regulations 7 2 Using the Built in Test BIT fault diagnostics The analyzer has a limited BIT diagnostics functi...

Page 80: ...gure 7 2 2 When the analyzer is running correctly the STATUS displays Running and OK see Figure 7 1 3 If a fault is detected the STATUS display in the bottom left hand corner of the screen changes from OK to a flashing Troubleshooting and diagnostics 60 Rosemount CT5400 ...

Page 81: ...ges to a Fault Status Analyzer Stopped Figure 7 4 4 From either the Gas sensor main screen see Figure 7 1 or the Pressure and Temperature screen see Figure 7 2 press to go to the Main menu 5 Press and to scroll to the Faults screen Troubleshooting and diagnostics Installation Operations and Maintenance Manual 61 ...

Page 82: ...een is blank Faults Screen No Faults Detected Figure 7 6 If the faults are identified by the BIT the display controller indicates the fault The precise data displayed varies depending upon where the fault has occurred in the analyzer Faults Detected Screen Figure 7 7 Troubleshooting and diagnostics 62 Rosemount CT5400 ...

Page 83: ...ary information to determine if the suspect component is faulty contact your local Customer Care representative 9 From the Main menu press and to scroll to DIAGNOSTICS Main Menu Figure 7 9 The Diagnostics screen lists those main components of the analyzer where problems can be diagnosed using the BIT system The Diagnostics screen also enables you to check on the status and where appropriate the va...

Page 84: ...s selected for diagnosis 12 Examine the data shown on the Component Diagnostic screen to determine if the suspect component has failed or is operating outside of its correct parameters If you do not have the necessary information to determine if the suspect component is faulty contact your local Customer Care representative 7 3 Visual examination A visual examination of the analyzer is recommended...

Page 85: ...rs before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Procedure 1 Power down the 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 optical and electrical componen...

Page 86: ...ylinder Cylinder near empty Replace cylin der Readings re turn to normal Cylinder was empty Drift persists Refer to step 2C 2C Check calibra tion pipework Pipework dam aged Replace pipe work Readings re turn to normal Pipework was damaged Drift persists Unknown Contact Cas cade Technolo gies Ltd 3 Measurement invalid flag Check display controller to assess which measurements are invalid All gas re...

Page 87: ...m display control ler Temperature too low Allow system time to heat up System heats up with time System was re cently started from cold System does not heat up Heater failure Contact Cas cade Technolo gies Ltd Temperature too high Contact Cas cade Technolo gies Ltd 7 Sensor frozen or unrespon sive Attempt a re boot System re boots success fully No further ac tion required System re boots success f...

Page 88: ...against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment WARNING HEAVY ITEM Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crush...

Page 89: ...ting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment 7 7 Removing the top cover Remove the top cover to...

Page 90: ...e analyzer may cause injury to personnel WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some parts of the analyzer may be heated to 190 C 374 F Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hours before fitting rem...

Page 91: ...the analyzer to cool for at least two hours Allow it to cool for twelve hours if replacing the analysis cell 3 Disconnect all external cables Tag if necessary 4 Remove the analyzer from the rack and place on a flat stable surface that can accommodate the weight This step requires two people to lift and transport the analyzer Troubleshooting and diagnostics Installation Operations and Maintenance M...

Page 92: ...unpacking installing maintaining and transporting to prevent crushing of hands feet or other body parts The analyzer weighs 31 kg 68 lb Emerson recommends that the analyzer is only moved and lifted by a minimum of two people Wear suitable protective gloves and protective footwear Failure to properly handle the analyzer may cause injury to personnel WARNING BURNS Do not touch any part of the analyz...

Page 93: ... it upside down on a flat stable surface that can accommodate the weight This step requires two people to lift and transport the analyzer 5 Remove and retain the four button head socket screws and associated flat washers 6 Lift the cover vertically clear of the chassis assembly Set it aside out of the working area 7 Examine the cover for signs of physical damage If it is undamaged retain and reins...

Page 94: ...nd allowed to cool down Some parts of the analyzer may be heated to 190 C 374 F Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hours before fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any mainten...

Page 95: ...necessary pry it off with a small flat bladed screwdriver 7 Remove the display B and the display controller PCB A by pulling them out to the rear from the front panel 8 Make sure the display bezel seal is present and free from cuts 9 Unpack and visually inspect the replacement LCD display for damage If damage has occurred contact your local Emerson Customer Care Representative 10 Insert the displa...

Page 96: ...RIC SHOCK Do not operate without covers secure Do not open while energized Installation requires access to live parts which can cause death or serious injury For safety and proper performance this instrument must be connected to a properly grounded three wire source of power WARNING HEAVY ITEM Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crus...

Page 97: ...least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Procedure 1 Power down the analyzer and allow it to cool 2 Remove the analyzer from the rack and place it on a stable workbench This step requires two people to properly lift an...

Page 98: ...7 15 A Earth lead B M4 nut C Tag connector D Threaded spacer front panel part E USB circuit board F M4 flat washer G M4 spring washer 5 Disconnect the USB cable F from the USB PCB A Troubleshooting and diagnostics 78 Rosemount CT5400 ...

Page 99: ...USB PCB 8 Use caution when unpackaging and handling the USB PCB Examine the replacement USB PCB for physical damage and delamination CAUTION EQUIPMENT DAMAGE Wear an ESD wrist strap or ground yourself to prevent damage to the USB PCB electronics 9 Place the replacement USB PCB A on the four threaded spacers B that form part of the front panel Troubleshooting and diagnostics Installation Operations...

Page 100: ...w the equipment to cool down before performing this procedure The same procedure is used to replace both external fuses therefore the replacement of only one is described 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 tagged off before removing the top cover The analyzer mus...

Page 101: ...ng any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Procedure 1 Power down the analyzer using the ON OFF switches on the front panel and back panel 2 Disconnect the external power supply from the power socket Note Do not remove the top cover The external fuses ar...

Page 102: ...he fuse holder A 8 Close the fuse cover C 9 Reconnect the external power supply to the power socket 10 Start up the analyzer by turning the ON OFF switches to the ON position 7 12 Replacing the internal fuses The analyzer contains a number of internal fuses The same procedure is used to replace all of the internal fuses therefore the replacement of only one is described Troubleshooting and diagnos...

Page 103: ...t two hours before fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Procedure 1 Shut down the an...

Page 104: ... x 20 mm fast acting 12 Vdc PSU F3 1 A 250 V 5 x 20 mm fast acting Line heater number 1 F4 2 A 250 V 5 x 20 mm fast acting Line heater number 2 F5 2 A 250 V 5 x 20 mm fast acting Cell heaters F6 1 A 250 V 5 x 20 mm fast acting Line heater controllers 5 No tools are required to remove the fuse Place a finger on the catch at the top of fuse holder and lift up the upper part of the fuse holder Troubl...

Page 105: ...Only replace fuses with fuses of the same type and rating Failure to do so may result in personal injury 6 Refer to Figure 7 20 Fully raise the upper part of the fuse holder B and then push out the old fuse A Troubleshooting and diagnostics Installation Operations and Maintenance Manual 85 ...

Page 106: ...nd rating Failure to do so may result in personal injury 7 Fit the replacement fuse A into the fuse holder B Refer to Table 7 3 and make sure that the fuse is of the correct type and rating 8 Lower the upper part of the fuse holder ensure that it clicks into place when fully lowered 9 Remove the Lock Out Tag out tag Troubleshooting and diagnostics 86 Rosemount CT5400 ...

Page 107: ...gloves and protective footwear Failure to properly handle the analyzer may cause injury to personnel WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some parts of the analyzer may be heated to 190 C 374 F Always wear proper protective equipment when handling the analyzer Switch off the analyzer an...

Page 108: ...wo way mini fit terminal block as applicable 5 Remove and retain the four nuts F and associated spring washers E and flat washers D Replacing the Analyzer Fan s Figure 7 21 A Fan finger guard B Fan C Threaded stud D M4 flat washer E M4 spring washer F M4 plain nut 6 Remove and retain the nuts spring washers and flat washers D E and F 7 Remove and retain the fan finger guard A 8 Remove and discard ...

Page 109: ...lb Emerson recommends that the analyzer is only moved and lifted by a minimum of two people when lifting and transporting the equipment Wear suitable protective gloves and protective footwear Failure to properly handle the analyzer may cause injury to personnel WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed t...

Page 110: ...ews attaching the top cover to the chassis 4 Open the locking arms of the ribbon cable connector B and disconnect the ribbon cable H from the TEC Board C Replace the TEC Board Figure 7 22 A PCB mounting plate B Ribbon cable connector C TEC board D Spacer E M3 flat washer F M3 spring washer G M3 x 6 mm socket head cap screw H Ribbon cable to Motherboard I Wiring harness J Wiring harness to USB port...

Page 111: ... position on the PCB Mounting Plate A Secure the TEC Board by fitting the four screws G and associated spring washers F flat washers E and spacers D that were retained during the removal procedure Torque tighten the screws to 0 5 Nm 11 Connect the USB wiring harness J to the motherboard K 12 Connect the wiring harness I to the TEC board C 13 Connect the ribbon cable H to the ribbon cable connector...

Page 112: ...S Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some parts of the analyzer may be heated to 190 C 374 F Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hours before fitting removing or performing any maintenance The analysis cell...

Page 113: ...board G Wiring harness to fan A H Wiring harness to fan B I 12 V power wiring harness to J17 on motherboard J M3 flat washer K M3 spring washer L M3 x 6 socket head cap screw 4 Disconnect the ribbon cable F from the peripheral PCA board A 5 Disconnect the two fan wiring harnesses G and H from the peripheral PCA 6 Disconnect the cell heater relay wiring harness E Troubleshooting and diagnostics Ins...

Page 114: ... four cap head screws L spring washers K and flat washers J retained during the removal procedure 13 Torque tighten the screws to 0 6 Nm 14 Connect the three gas cell temperature monitoring harness connectors B C and D 15 Connect the cell heater relay wiring harness E to connector J50 on the peripheral PCA 16 Connect the two fan wiring harnesses G and H to connectors J4 and J18 on the peripheral P...

Page 115: ...earthed Death or personal injury may result if this is not observed To gain access to the electrical pneumatic and optical components it is necessary to remove the top cover Procedure 1 Shut down the analyzer as described in Section 8 2 2 Power down the analyzer and allow it to cool 3 Remove the analyzer from the rack and place it on a stable workbench This step requires two people to properly lif...

Page 116: ...ribbon cable connector J21 K TRIGGER OUT connector J32 L TRIGGER OUT wiring harness M Ribbon cable connector to J7 N Ribbon cable connector to Peripheral PCA board O 12 V power out connector J17 P 12 V power in connector J16 Q 12 V power input wiring harness R 12 V power output wiring harness S Laser module ribbon cable T Serial port wiring harness U HMI display wiring harness V Connector J22 Trou...

Page 117: ... ESD wrist strap or ground yourself to prevent damage to the motherboard electronics 18 Inspect the replacement motherboard for signs of damage or delamination 19 Place the motherboard in position on the PCB mounting plate and secure it by fitting the six screws G and the associated spring washers F and flat washers D retained during the removal procedure Torque tighten the screws to 0 6 Nm 20 Con...

Page 118: ...s 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 tagged off before removing the top cover The analyzer must be earthed Death or personal injury may result if this is not observed WARNING HEAVY ITEM Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crushing of hands feet or other ...

Page 119: ...rs before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Procedure 1 Shut down the analyzer by switching the ON OFF switches on the front and rear panels to the OFF position and allow the analyzer to cool 2 Remove the analyzer from the rack using two...

Page 120: ...nit 8 Inspect the replacement unit for damage If damage has occurred contact your local Emerson Customer Care Representative 9 Insert the replacement analog input unit in its correct location on the DIN rail Press the small lever on the underside of the unit and push the unit onto the DIN rail Release the small lever and check that the unit is secure 10 Connect the two wiring harness connectors C ...

Page 121: ... F Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hours before fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient c...

Page 122: ...to the rack 14 Apply power to restart the analyzer 7 17 3 Replacing the temperature controller The two temperature controllers are identical therefore the replacement procedure for only one is described Each temperature controller plugs into a base unit that is mounted on the DIN rail The base unit has no active components and should not require replacement DANGER ELECTRIC SHOCK The analyzer opera...

Page 123: ...e fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical treatment Replacing a temperature controller Figure 7 2...

Page 124: ...ller is secure 5 Attach the cables and wiring connections to the temperature controller 6 Refit the top cover as described in Section 7 25 7 Reinstall the analyzer in the rack This step requires two people to properly lift and transport it to the rack 8 Remove the protective masking tape from the flanges seal and flamepath Use care not to damage the flamepath Any damage to the flamepath will inval...

Page 125: ...lyzer and allow it to cool for at least two hours before fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any maintenance on or in the vicinity of the analysis cell Failure to allow sufficient cooling may cause serious burn injury to personnel If burns occur seek immediate medical ...

Page 126: ...ON OFF switches on the front and rear panel to the OFF position and allow the core to cool for twelve hours 2 Lock out tag out the power supply 3 Remove the analyzer from the rack using two people to lift the analyzer and place it on a clean workbench 4 On the Ethernet switch B disconnect the Ethernet cable that links the Ethernet switch to the analog input unit from Ethernet connector number 1 A ...

Page 127: ...ring harness F to the Ethernet switch 13 On the Ethernet switch connect the Ethernet cable from the motherboard to Ethernet connector number 5 D 14 Connect the Ethernet cable from the external Ethernet Port to Ethernet connector number 4 C 15 Connect the Ethernet cable from the analog input unit to Ethernet connector number 1 A 16 Refit the top cover as described in Section 7 25 17 Close the enclo...

Page 128: ... out the power circuit breaker 3 Apply masking tape to the flanges seal and flamepath to protect them from scratches chipping and other forms of damage or deformation 4 Remove the twenty M16 captive bolts securing the enclosure and carefully open the enclosure 5 Unscrew the two 14 mm connections to the gas input and output lines see Section 7 21 and Section 7 22 6 Remove the lower DIN rail as desc...

Page 129: ... locating pins B on the Base Plate 10 Secure the laser module by tightening the two captive screws D and F 11 Connect the ribbon cable E to the laser module C 12 Remove the protective masking tape from the flanges seal and flamepath Use care not to damage the flamepath Any damage to the flamepath will invalidate certification 13 Remove lock out tag out labels 14 Apply power to the analyzer Trouble...

Page 130: ...ction 7 7 4 Refer to Figure 7 29 Note the routing of the gas temperature sensor wiring harness B and the location of the cable ties that secure the wiring harness NOTICE It is NOT necessary to open up the insulation around the analysis cell in order to replace the gas temperature sensor 5 Carefully cut and remove any cable ties that secure the gas temperature sensor wiring harness 6 Disconnect the...

Page 131: ...e C and tube fitting A to the analysis cell Apply a small quantity of Loctite 567 liquid PTFE compound to the threads of the tube fitting before it is fitted Secure the thermocouple by tightening the tube fitting spanner tight NOTICE The Swagelok recommendation for pipe fittings of this size is to tighten the nut finger tight and then tighten an additional one and a quarter 1 1 4 turns with a span...

Page 132: ...d off and allowed to cool down Some parts of the analyzer may be heated to 190 C 374 F Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hours before fitting removing or performing any maintenance The analysis cell is insulated against heat loss Allow the analyzer to cool for at least twelve hours before performing any ...

Page 133: ...he twenty M16 bolts from the housing and carefully lower the front housing to the fully open position 8 Carefully cut and remove any cable ties that secure the gas sensor wiring harness 9 Disconnect the gas sensor wiring harness from connector block on the DIN rail 10 Use a spanner on the sensor s 6 mm hex fitting and remove the sensor from the baseplate 11 Discard the faulty sensor and Dowty wash...

Page 134: ...tch at the rear of the panel is set to OFF and tagged off before removing the top cover The analyzer must be earthed Death or personal injury may result if this is not observed To gain access to the electrical pneumatic and optical components it is necessary to remove the top cover Procedure 1 Power down the analyzer and allow it to cool 2 Remove the analyzer from the rack and place it on a stable...

Page 135: ...Top insulation B Insulation side flap C Insulation end flaps D Insulation side flap 6 Refer to Figure 7 32 Pull the insulation E away from the side of the analysis cell B Troubleshooting and diagnostics Installation Operations and Maintenance Manual 115 ...

Page 136: ...on with a rating of 35 Watts or less solder the wiring harness to the terminals of the thermal cut out A Use high temperature solder and place a heat shrink sleeve over each soldered terminal 12 Fit the thermal cut out to the analysis cell B and secure by fitting the screws D and washers C that were retained in step 6 13 Return the insulation to its correct position against the side of the analysi...

Page 137: ...tions 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 tagged off before removing the top cover The analyzer must be earthed Death or personal injury may result if this is not observed To gain access to the electrical pneumatic and optical compon...

Page 138: ... Release the pipe bulkhead C from the rear panel D 6 Use your fingers to push the analysis cell insulation F inwards until the tube adapter E is exposed Release the tube adapter from the analysis cell Then remove the gas input line Gas input line Figure 7 34 A Wiring harness B Gas Input Line C 6 mm pipe to 6 mm pipe bulkhead 774L stainless steel 6 mm D Rear panel E Stainless steel 316 tube adapter...

Page 139: ...zer 7 22 Replacing the gas output line Complete the following steps to replace the gas output line 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 tagged off before removing the top cover The analyzer must be earth...

Page 140: ...A 6 Release the pipe bulkhead I from the rear panel G 7 Use your fingers to push the analysis cell insulation D inwards until the tube adapter E is exposed Release the tube adapter from the analysis cell Then remove the gas output line H from the analysis cell Note It is only necessary to disconnect the wiring harness F from the gas output line if the gas output line is being replaced If the gas o...

Page 141: ...ulkhead I Tighten the pipe bulkhead spanner tight 13 Fit the insulation A to the gas output line and secure it with two cable ties B and C 14 Refit the top cover as described in Section 7 25 15 Reinstall the analyzer in the rack This step requires two people to properly lift and transport it to the rack 16 Apply power to restart the analyzer 7 23 Replacing the analysis cell Complete the following ...

Page 142: ... tube fitting A is exposed Pressure sensor pipe Figure 7 36 A Stainless steel 316 male connector Let Lok tube fitting 6 mm x male ISO tapered thread 1 4 in pressure connector B Analysis cell insulation C Pipe 7 Release the tube fitting A and slide it up the pipe C Remove and retain the pipe complete with tube fitting 8 Remove the gas temperature sensor as described in Section 7 18 9 Remove the the...

Page 143: ...t washers C that were retained during the removal procedure 14 Fit the thermal cut out as described in Section 7 20 steps 13 through 15 15 Fit the gas temperature sensor as described in Section 7 18 steps 11 through 13 16 Refer to Figure 7 36 Use your fingers to push the insulation B until the port for the pipe C is exposed 17 Fit the pipe to the port in the analysis cell and secure it with the tu...

Page 144: ...ns 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 tagged off before removing the top cover The analyzer must be earthed Death or personal injury may result if this is not observed To gain access to the electrical pneumatic and optical components it is necessary to remove the top cover Procedure 1 Power down the analyzer and allow...

Page 145: ... be necessary to use a small flat blade screwdriver to lever the lid off NOTICE The pressure inside the cell must be at atmospheric pressure in order to remove the lid With the lid removed the mirrors are exposed 6 Clean the mirrors by applying a small quantity of methanol to a clean dry lens tissue and then gently wiping the mirrors with the lens tissue If methanol is unavailable IPA may be used ...

Page 146: ... with the six socket head cap screws and associated spring washers and flat washers retained in step 6 8 Refer to Figure 7 38 Fold the top insulation A back into position on top of the analysis cell Secure the top insulation by folding in the two side flaps B and D and the two end flaps C Make sure that the Velcro strips on the inside of the side flaps and end flaps mate with the Velcro strips on ...

Page 147: ...to attach the top cover to the chassis assembly 7 26 Installing the bottom cover 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 31 kg 68 lb Emerson recommends that the analyzer is only moved and lifted by a minimum of two people Wear suitable protective gloves and...

Page 148: ...data to monitor the health of the analyzer and to debug any faults When to download the data Only download the data following a failure of the analyzer Then send the data to Emerson for analysis Methods of downloading the data There are two methods of downloading the data from the analyzer To a USB flash drive stick By trivial file transfer protocol TFTP Note Downloading the data to a USB flash dr...

Page 149: ...lyzer They indicate the functionality of the software which is the same regardless of the gases or gas concentrations being measured Procedure 1 From the Gas Sensor Main screen press to go to the Main menu Main menu Figure 7 41 2 Use and to scroll to DATA SERVICE Troubleshooting and diagnostics Installation Operations and Maintenance Manual 129 ...

Page 150: ...SB Flash Drive into the USB port on the analyzer s front panel USB Access Port Figure 7 42 A USB flash drive access port 4 Press The Service menu screen displays Troubleshooting and diagnostics 130 Rosemount CT5400 ...

Page 151: ... is no USB Flash Drive in the USB port or the USB flash drive is not fitted correctly an error message displays USB Dump Error Figure 7 44 6 If the USB flash drive is correctly fitted to the USB port the data transfer automatically starts and the USB Dump screen displays when the data transfer is completed Troubleshooting and diagnostics Installation Operations and Maintenance Manual 131 ...

Page 152: ...lash drive Release USB Flash Drive Figure 7 46 If for any reason it is necessary to repeat the data download then press on either the USB Dump Dump finished screen see Figure 7 45 or USB Dump USB released screen see Figure 7 46 Troubleshooting and diagnostics 132 Rosemount CT5400 ...

Page 153: ...trol of the analyzer software using TFTP routines built into the software Refer to Section 4 5 for the display controller functions Procedure 1 Establish an Ethernet connection to the analyzer from your laptop 2 Switch on the analyzer and wait for the Gas Sensor Main screen to display Gas Sensor Main Screen Figure 7 47 Note The gas concentrations shown in the screenshots may be different from thos...

Page 154: ...Main menu Figure 7 48 4 Use and to scroll to DATA SERVICE DATA SERVICE menu Figure 7 49 5 Press The Service Menu screen displays Troubleshooting and diagnostics 134 Rosemount CT5400 ...

Page 155: ...ic Connectors Figure 7 51 A Ethernet connector B Ventilation holes C Sample supply stainless steel tubing D Sample return stainless steel tubing E Main power supply F Analog outputs 4 20 mA G Digital outputs H Status output 10 way connector Troubleshooting and diagnostics Installation Operations and Maintenance Manual 135 ...

Page 156: ... the TFTP data transfer 8 From the Service Menu screen use and to scroll to TFTP TRANSFER 9 Press The TFTP Dump screen displays TFTP Dump Screen Figure 7 52 10 Press to start the TFTP data transfer The TFTP Dump Progress screen displays TFTP Transfer Progress Screen Figure 7 53 Troubleshooting and diagnostics 136 Rosemount CT5400 ...

Page 157: ...When the data download completes the TFTP Transfer Successful screen displays TFTP Transfer Successful Screen Figure 7 54 Troubleshooting and diagnostics Installation Operations and Maintenance Manual 137 ...

Page 158: ...Troubleshooting and diagnostics 138 Rosemount CT5400 ...

Page 159: ...ions shown in the following screenshots may be different from those shown in your particular analyzer The screenshots indicate the functionality of the software which is the same regardless of the gases or gas concentrations being measured WARNING BURNS Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been switched off and allowed to cool down Some parts...

Page 160: ...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 system for returning the sample gas to run for five minutes to allow any sample gas in the instrument to be returned to the exhaust Failure to vent sample gas may cause death 2 Purge any sample gas in the pipe hose from the...

Page 161: ...ress on the display controller in either the Gas Sensor Main screen Figure 8 1 or the Pressure and Temperature screen Figure 8 2 Gas Sensor Main Screen Figure 8 1 Pressure and Temperature Screen Figure 8 2 The Main menu Figure 8 3 opens Shutdown procedure Installation Operations and Maintenance Manual 141 ...

Page 162: ... down to select SYSTEM as shown in Figure 8 3 Then press The System screen Figure 8 4 opens System Shutdown Screen Figure 8 4 7 Use and to select SHUTDOWN as shown in Figure 8 4 Then press The Shutdown screen Figure 8 5 displays Shutdown procedure 142 Rosemount CT5400 ...

Page 163: ...he analyzer displays the Shutdown screen Figure 8 6 and then stops running Shutdown Screen Figure 8 6 9 Once the heartbeat icon stops blinking it is safe to power off the analyzer Shutdown procedure Installation Operations and Maintenance Manual 143 ...

Page 164: ...Shutdown procedure 144 Rosemount CT5400 ...

Page 165: ... in customer sites may require these activities to be performed more or less often than indicated Details of the tasks to be performed are contained in Table 9 1 Scheduled checks Table 9 1 Frequency Action Monthly 1 Check the zero and span calibration 2 Perform the calibration more or less frequently if necessary to meet quality control or plant operation requirements Preventative maintenance Inst...

Page 166: ...Preventative maintenance 146 Rosemount CT5400 ...

Page 167: ...antum Cascade Lasers to detect and measure the gases Each Quantum Cascade Laser QCL measures between one and three gases Inside the QCL which is about the size of a pin head electrons cascade down a series of quantum wells producing a photon at each step This cascade of electrons can produce between 20 and 100 photons per electron giving QCLs higher output power than traditional semi conductor las...

Page 168: ...nto the analyzer Inside the analyzer the sample gas is fed into an analysis cell where the beams from the QCLs are passed through the gas The analysis cell contains a set of mirrors that bounce the light back and forth many times which lengthens the path of the lasers through the gas On exiting the analysis cell the light is detected by a receiver unit The variation in the intensity of light in th...

Page 169: ... NC 10 A thermostat solder tag termination 0 to 260 C 32 to 500 F P 5000 0900 PT100 stainless steel dia 6 mm 0 2 in length 60 mm 2 4 in 400 C 752 F max 2 5 m 98 4 in lead P 5000 0366 RS PT100 200 C 392 F max platinum resistance temp sensor 6 mm 0 2 in probe diame ter P 5000 0924 Interface relay module DIN rail SPST NO coil 12 V contact 6 A 250 V P 5000 0566 Pressure sensor CTE8001AY7V 0 1bara 0 5 ...

Page 170: ...Recommended quantity P 5000 0938 Temperature controller 1 P 5000 0415 Thermostat 2 P 5000 0900 Temperature sensor 2 P 5000 0366 Temperature sensor 2 P 5000 0924 Relay 2 P 5000 0310 Fan 2 P 5000 1443 Fuse 3 15 A 5 P 5000 0264 240 V cartridge heater 2 Spare parts list 150 Rosemount CT5400 ...

Page 171: ...e diagrams may be used to locate the position of a wiring connector should it become disconnected C 1 Engineering drawings Engineering drawings Table C 1 Drawing number Description W 2000 0028 Sheets 1 3 Rosemount CT5400 wiring diagram for 19 in rack mount unit Engineering Drawings Installation Operations and Maintenance Manual 151 ...

Page 172: ...Engineering Drawings 152 Rosemount CT5400 ...

Page 173: ... Analogue Channel 5 Set In Config File Analogue Channel 4 Set In Config File 6 14 7 15 8 16 DIGITAL OUTPUTS 16 WAY SOCKET FUNCTION PINS 1 9 Reading Valid Channel 3 Set In Config File Reading Valid Channel 2 Set In Config File Reading Valid Channel 1 Set In Config File Reading Valid Channel 0 Set In Config File 2 10 3 11 4 12 5 13 Reading Valid Channel 7 Set In Config File Reading Valid Channel 6 S...

Page 174: ...LK RED BLK RED 1 2 2 WAY MINFIT BLK RED RED BLK RESISTOR TO BE SOLDERED IN LINE 6 5 INTERNAL PT100 THERM No CONNECTOR PIN OUTS FUNCTION THERM 1 J9 1 2 GAS TEMP THERM 2 J37 1 2 CELL TEMP THERM 3 J9 3 4 PRESS COMP THERM 4 J37 3 4 N A THERM 5 J9 5 6 INTERNAL AMB 92 91 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 THIS DRAWING ...

Page 175: ...D E B A C D E A3 CASCADE TECHNOLOGIES LTD GLENDEVON HOUSE CASTLE 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 ISO1461...

Page 176: ...CA REGIONAL OFFICE Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai United Arab Emirates P O Box 17033 T 971 4 811 8100 F 971 4 886 5465 qcl csc emerson com ASIA PACIFIC REGIONAL OFFICE Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 6 777 8211 F 65 6 777 0947 qcl csc emerson com Linkedin com company Emerson Automation Solutions twitter ...

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