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WARNING

EXPLOSION HAZARD

This article is in accordance with IEC 60079-0: 2011, Clause 30.

Failure to observe this warning and/or follow safety instructions could cause an explosion or potentially hazardous situation, which
if not avoided, could result in death or serious injury.

Read all instruction manuals (including versions for auxiliary equipment) before installing this instrument.

WARNING

EXPLOSION HAZARD

This article is in accordance with IEC 60079-0: 2011 Clause 30.

Failure to observe this warning and/or follow safety instructions could cause an explosion or potentially hazardous situation which,
if not avoided, could result in death or serious injury.

When installing and wiring this equipment, comply with all relevant national legislative requirements and regulations.
Consider all safety instructions within this manual and all associated analyzer manuals.

WARNING

EXPLOSION HAZARD

This article is in accordance with IEC 60079-0: 2011 Clause 30.

Failure to observe this warning and/or follow safety instructions could cause an explosion or potentially hazardous situation which,
if not avoided, could result in death or serious injury.

When the analyzer is out of order, shut off all inputs and outputs connected to external equipment.

WARNING

EXPLOSION HAZARD

This article is in accordance with IEC 60079-0: 2011 Clause 30.

Failure to observe this warning and/or follow safety instructions could cause an explosion or potentially hazardous situation which,
if not avoided, could result in death or serious injury.

Only properly trained personnel who understand the content of all applicable manuals and related instructions must conduct the
startup procedure.

WARNING

EXPLOSION HAZARD

This article is in accordance with IEC 60079-0: 2011 Clause 30.

Failure to observe this warning and/or follow safety instructions could cause an explosion or potentially hazardous situation which,
if not avoided, could result in death or serious injury.

Do not open in an explosive atmosphere.

WARNING

Do not open when energized

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Summary of Contents for Rosemount CT5800

Page 1: ...Reference Manual 00809 0100 5800 Rev AA September 2019 Rosemount CT5800 Continuous Gas Analyzer ...

Page 2: ...ublication and the products which it describes Document number 00809 0100 5800 Rev AA September 2019 Emerson 2019 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 additi...

Page 3: ... 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 clarification Follow all warnings cautions and instructions marke...

Page 4: ... 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: ...or 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 requirements General requirements BS EN60079 0 2012 Explosive atmospheres Part 0 Equipment General requirements BES EN 60079 1 2014 Explosive atmospheres Equipment protection by flameproof enc...

Page 6: ... regulators for operation of electrical electronic equipment in hazardous locations Waste disposal Do not dispose of measuring tools into household waste Only for EC countries In accordance with European Directive 2012 19 EU for Waste Electrical and Electronic Equipment and its implementation into national right measuring tools that are no longer usable must be collected separately and disposed of...

Page 7: ...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 7 ...

Page 8: ...is dangerous to life Make sure the circuit breakers are set to OFF and tagged off before opening the front cover DANGER FAILURE TO LOCK OUT GAS HANDLING SYSTEM MAY CAUSE DEATH This article is in accordance with IEC 60079 0 2011 Clause 30 Unauthorized operation of the gas handling system when maintenance is being performed on the analyzer or its associated pipes hoses may result in highly flammable...

Page 9: ...entrations of more than 25 of the lower explosion limit Emerson recommends implementing one or more additional safety measures Purging the unit with inert gas Stainless steel internal pipes Flame arrestors on gas inlets and outlets Infallible measuring cells WARNING CONNECTING UNITS FOR PERMANENT INSTALLATION Failure to complay may cause the risk of injury or death and invalidate the analyzer s wa...

Page 10: ... in accordance with IEC 60079 0 2011 Clause 30 Failure to observe this warning and or follow safety instructions could cause an explosion or potentially hazardous situation which if not avoided could result in death or serious injury When the analyzer is out of order shut off all inputs and outputs connected to external equipment WARNING EXPLOSION HAZARD This article is in accordance with IEC 6007...

Page 11: ...r contains lasers Opening the analyzer and attempting to perform adjustments or procedures other than those specified in this manual may result in hazardous optical radiation exposure Failure to follow the correct procedures may cause damage to the eye The Rosemount CT5800 is Class 1 The beams are fully enclosed and there is no access to the laser beams while the product is in operation or during ...

Page 12: ...eration of the gas handling system when maintenance is being performed on the analyzer or its associated pipes hoses may release highly flammable gas causing fire or explosion Always lock out tag out the gas handling system when shutting down the analyzer WARNING HEAVY ITEM Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crushing of hands feet o...

Page 13: ...Clause 30 The calibration gas supply and compressed air supply operate at a pressure that can cause injury e g damage to eyes and skin punctures from debris blown by the high pressure gas or compressed air Always lock off or tag off the calibration gas supply and compressed air supply when shutting down the analyzer WARNING BURNS Some parts of the analyzer may be heated to 150 F 65 C Failure to al...

Page 14: ...hin the facility CAUTION EQUIPMENT DAMAGE Failure to follow the startup procedure may result in damage to the analyzer Always follow the startup procedure CAUTION EQUIPMENT DAMAGE Failure to follow the shutdown procedure may result in damage to the analyzer Always follow the shutdown procedure CAUTION UNSERVICEABLE EQUIPMENT If the pressure and temperature measurements are out of tolerance refer t...

Page 15: ...e 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 CAUTION EQUIPMENT DAMAGE Additional notes for units with screw type terminals Cables for external data processing must be double insulated against mains power If this is not possible cables must be laid in ...

Page 16: ...r CT5800 Glendevon House Castle Business Park Stirling FK9 4TZ United Kingdom Tel 44 0 1786 447 721 Fax 44 0 1786 475 822 Emerson com RosemountGasAnalysis Bottom right Laser radiation CAUTION label Interior on analysis cell Laser module identification label On each laser module housing Earth identification label Back plate WARNING statement Interior adjacent to electric power connections AC power ...

Page 17: ...onnections 51 2 5 Closing the housing 54 2 6 Commissioning 56 Chapter 3 Startup procedure 57 3 1 Introduction 57 3 2 Preparation for use 57 3 3 Startup procedure 58 Chapter 4 Operating the analyzer 61 4 1 Introduction 61 4 2 Normal operation 61 4 3 Front panel controls and indicators 62 4 4 Display controller 64 4 5 Gas Sensor Main screen 65 4 6 Pressure and Temperature screen 66 4 7 Help system 6...

Page 18: ... 131 7 16 Optical and pneumatic repairs 150 7 17 Closing the enclosure 160 Chapter 8 Shutdown procedure 163 8 1 Shutdown procedure safety precautions 163 8 2 Shutdown procedure 164 Chapter 9 Preventative maintenance 169 9 1 Maintaining the analyzer 169 9 2 Scheduled maintenance 169 Appendix A ATEX IECEx Assessment Report Summary 171 A 1 Certification Overview 171 A 2 Applicant s name and address 1...

Page 19: ...Spare parts list 179 Appendix D Engineering Drawings 181 D 1 List of engineering drawings 181 Appendix E Glossary and abbreviations 183 Reference Manual Contents 00809 0100 5800 September 2019 Rosemount CT5800 xix ...

Page 20: ...Contents Reference Manual September 2019 00809 0100 5800 xx Emerson com Rosemount ...

Page 21: ...0079 0 2011 Clause 30 Failure to properly handle the analyzer may cause injury to personnel Make sure the wall the unit is mounted on is solid stable and of a suitable material to hold the weight of the analzyer Handle the analyzer with caution during unpacking installing maintenance and transporting to prevent crushing of hands feet or other body parts The analyzer weighs 176 4 lb 80 kg Emerson r...

Page 22: ... or equivalent type of battery 1 1 3 Installing and connecting the unit The following notices should be followed to ensure compliance with the low voltage directive Europe and other applicable regulations Suitably ground all connectors provided for this purpose Properly reinstate all safety covers and grounding connections after maintenance work or troubleshooting Provide a fuse at the installatio...

Page 23: ...can be displayed in the process control center The Rosemount CT5800 is supplied by Emerson The gas handling system may be provided by either you or Emerson depending upon the specific installation The circuit breakers used to control the application of electrical power to the analyzer the interconnecting wires and gas piping are provided by you In Figure 1 2 the items supplied by Emerson are color...

Page 24: ...ch are operated to produce wavelength sweeps that cover the absorption lines of the gases The light from each laser is routed through an optical 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 directe...

Page 25: ...r Customer choice 1 9 Excess flow line Customer Customer choice 1 Required for calibration 10 240 Vac power cable Customer Customer 1 Connect CT5800 to mains power supply 11 Cable from analyzer to control center Customer Customer choice 1 1 12 Main circuit breaker Customer Customer choice 1 4 Customer information This manual contains all the important information that must be followed to ensure th...

Page 26: ...mepaths which differ from those in IEC60079 1 EN 60079 1 Contact Cascade qcl csc emerson com for guidance when maintaining the flamepaths The fasteners which secure the cover are non standard only replace them with fasteners supplied by the manufacturer for this purpose The fasteners must always be fitted with the washer supplied by the manufacturer The equipment has non conductive surfaces which ...

Page 27: ...d maintenance personnel with the level of knowledge required to safely start operate and switch off the analyzer Only technically qualified personnel in the field of analysis and control who are familiar with this manual and have been specially trained on the analyzer should install operate switch off and service the analyzer Only qualified and trained persons have the required specific knowledge ...

Page 28: ...stud or partitioned walls Table 1 3 General Characteristics Rosemount CT5800 Value Units Comment Voltage 220 240 10 110 120 10 Vac 50 Hz 5 factory set 60 Hz 5 factory set Peak power consumption 1100 W Max consumption per gas analyzer Continuous steady state power consumption 800 W Electrical compartment enclosure Aluminum Optical compartment enclosure Aluminum Measurement technique Mid IR absorpti...

Page 29: ... continued Rosemount CT5800 Value Units Comment Warm up time 90 minutes Figure 1 3 Rosemount CT5800 Dimensions Front View A User interface B 2 off lifting eyelets Reference Manual Plan 00809 0100 5800 September 2019 Rosemount CT5800 29 ...

Page 30: ...Figure 1 4 Rosemount CT5800 Dimensions Side View A Rating plate B External earth point Plan Reference Manual September 2019 00809 0100 5800 30 Emerson com Rosemount ...

Page 31: ...se North America 122 to 176 F 50 to 80 C Factory set specify on order Sample gas moisture content 8 Maximum Sample gas particulate density 5 mg m3 Maximum Sample gas particulate size 10 µm Maximum IP code 66 IP to IEC 60529 Sensor humidity range 10 to 95 Relative humidity non condensing at 113 F 45 C 1 9 1 Optical description The laser modules are located in the core of the analyzer Each laser mod...

Page 32: ... 1 10 Unpacking the analyzer WARNING HEAVY ITEM In accordance with IEC 60079 0 2011 Clause 30 Failure to propery handle the analyzer may cause injury to personnel Make sure the wall the analyzer is mounted on is solid stable and of suitable material to hold the weight of the analyzer Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crushing of ha...

Page 33: ...er The Rosemount CT5800 contains sensitive electronic equipment Do not subject it to any shock or vibration Procedure 1 On receipt of goods look for any visible damage to the analyzer and verify that all items noted to be shipped were received Record on the goods receipt note any damage or missing items noting both the item s and the quantity missing 2 Visually inspect the exterior of the analyzer...

Page 34: ...Plan Reference Manual September 2019 00809 0100 5800 34 Emerson com Rosemount ...

Page 35: ...t strong vibrations and frost Observe the advisable operating temperatures given in Detailed system specifications Do not subject analyzer to direct sunlight or heat sources For outdoor installation Emerson recommends installing the analyzer in a cabinet At a minimum protect it against rainfall WARNING FIRE AND EXPLOSION In accordance with IEC 60079 0 2011 Clause 30 Failure to ensure the area is s...

Page 36: ... The analyzer has a T4 temperature classification which specifies the maximum surface temperature of the instrument under a fault condition is 275 F 135 C You must ensure that no combustible gas concentrations are present whether on a continual or occasional basis which have an ignition temperature below the T classification of the unit WARNING FIRE AND EXPLOSION Failure to observe this precaution...

Page 37: ...of the analyzer Handle the analyzer with caution during unpacking installing maintaining and transporting to prevent crushing of hands feet or other body parts The analyzer weighs 176 4 lb 80 kg Emerson recommends that a minimum of two people move and lift the analyzer Wear suitable protective gloves and protective footwear Make sure that the wall fixing points are capable of supporting a load of ...

Page 38: ...face the analyzer is mounted on Emerson recommends installing the analyzer in an upright vertical position other orientations may affect the measuring results 3 If you want to increase security on the installation of the analyzer by thread locking the fittings only do this with compounds compatible with the hazardous area zone classification of the installation location Install Reference Manual Se...

Page 39: ...he enclosure WARNING HEAVY FRONT HOUSING Failure to properly support the lid may cause injury to personnel The analyzer s front housing is heavy 68 1 lb 30 kg After removing the captive bolts provide support when opening the lid CAUTION EQUIPMENT HAZARD Inspect the hinges for damage before removing the M16 x 45 captive bolts to open the housing Make sure no obstructions are in the opening radius w...

Page 40: ...ure 2 2 Rosemount CT5800 Housing A 20 off M16 captive bolts 3 Carefully lower the front enclosure to the fully open position Install Reference Manual September 2019 00809 0100 5800 40 Emerson com Rosemount ...

Page 41: ...ratches chipping and other forms of damage of deformation CAUTION PROTECT FLAMEPATH Any damage to the flamepath will invalidate certification Protect the flamepath with masking tape 5 Continue the installation with the power and signal cables See AC power safety information Reference Manual Install 00809 0100 5800 September 2019 Rosemount CT5800 41 ...

Page 42: ...ircuit breaker in building installation The analyzer provides a protective earth terminal To prevent electrical shock hazards connect the instruments to a protective earth The instruments must be connected to power with a three wire power cable with earth conductor Any interruption of the earth connector inside or outside the instrument or disconnecting the earth terminal may cause potential elect...

Page 43: ...supplied with this equipment You must supply a suitably rated switch or circuit breaker to be included with this installation Check the installation of the switch for conformity in accordance with national local regulations and standards by inspection The switch or circuit breaker must be suitably located easily reached and identified as the disconnection device for the analyzer Figure 2 4 Rosemou...

Page 44: ...0 mm from the Ex d entry point Unused entries are provided with plugs secured in place with thread locking compound WARNING INSTALLATION USING CABLE GLANDS All cable glands must be suitable certified for use in area of application Zone Class Division When installing the analyzer in a hydrogen environment and or applying hydrogen to the analyzer do not use the standard compression type cable glands...

Page 45: ...ng the M5 stud bonded to the rear of the system and the connector inside with cable between 1 5 and 4 mm square NOTICE This section is in accordance with IEC 60079 2011 Clause 30 This article must not be changed amended or removed WARNING ELECTRIC SHOCK In accordance with IEC 60079 0 2011 Clause 30 Failure to observe this warning may cause death or personal injury The analyzer must be earthed grou...

Page 46: ...Figure 2 6 Earth Bond Install Reference Manual September 2019 00809 0100 5800 46 Emerson com Rosemount ...

Page 47: ...n in Figure 2 7 and Figure 2 9 All signal cables are to be minimum 20 AWG tri rated switchgear cables Customer supplied conduit and cables must be terminated in the conduit outlets in accordance with local electrical codes Figure 2 7 Cable Glands Conduits and Gas Line Connections A Breather B Gas connection out flame arrestor M18 x 1 5 C Gas connection in flame arrestor M18 x 1 5 D Conduit cable e...

Page 48: ...tal output 5 8 Digital output 6 9 Digital output 7 10 Digital output 8 11 Digital output 9 12 Digital output 10 13 Digital output 11 14 Digital output 12 15 Analog output 1 16 Analog output 2 17 Analog output 3 18 Analog output 4 19 Analog output 5 20 Analog output 6 21 Analog output 7 22 Analog output 8 23 Status output 1 check function Install Reference Manual September 2019 00809 0100 5800 48 E...

Page 49: ...on the base of the analyzer Figure 2 7 The gas sample that is to be measured for impurities enters the instrument through the sample gas input port Once the sample gas has been examined for impurities it is expelled from the instrument through the sample gas return port NOTICE Remove the breather blanking cap and never connect anything to this port To avoid the risk of gas leaks make sure that the...

Page 50: ...used for downloading data for failure diagnostic purposes The analyzer outputs the results of the gas analysis through the 4 20 mA analog outputs and sends them to your process control center The status outputs provide fault indications to your process control center Each digital output is connected to a normally closed relay located inside the analyzer which will open in response to the detection...

Page 51: ...ow risk of mechanical damage Protect the cable glands suitably Temporarily seal the cable glands with a suitable sealant to allow testing The tests described below are a basic check to prove function rather than a test of sensor capability To start the analyzer follow the steps in Startup procedure WARNING INSTALLER RESPONSIBILITY In accordance with IEC 60079 0 2011 Clause 30 Failure to observe th...

Page 52: ...cedure 1 Set the main circuit breaker to ON 2 Check that the display controller lights up The instrument begins to power up Install Reference Manual September 2019 00809 0100 5800 52 Emerson com Rosemount ...

Page 53: ... around 122 F 50 C This takes approximately 90 minutes 2 4 3 Pressure sensor The pressure sensor monitors the pressure in the analysis cell NOTICE This section is in accordance with IEC 60079 0 2011 Clause 30 This section must not be changed amended or removed Procedure 1 Check that a pressure reading is displayed under Pressure on the display controller The reading is approximately 760 Torr at at...

Page 54: ... air applied as described in the startup procedure Startup procedure when the system is operating correctly an open contact is created between the two contact wires white Procedure To test the Error state shut off the sample gas and allow the pump to reduce the cell pressure below 180 Torr At this point the contact should close and there should be no resistance between the two white wires WARNING ...

Page 55: ...r form of damage deformation If any damage is detected stop the process immediately and report to maintenance 5 Carefully lift the housing up and align with the rear housing 6 Make sure that all holes are aligned If necessary use the two holes Figure 2 10 to assist alignment Figure 2 10 Alignment holes A Alignment holes 7 Insert the captive M16 bolt and engage the threads on the rear housing 8 Ref...

Page 56: ...s to secure the enclosure shut Figure 2 11 Torque sequence Tighten all bolts in sequence to a torque value of 18 44 ft lb 25 Nm 2 6 Commissioning Once the sensor is fully installed as described above commission it according to the commissioning plan agreed on between you and Emerson Install Reference Manual September 2019 00809 0100 5800 56 Emerson com Rosemount ...

Page 57: ...ed prior to startup WARNING BURNS Failure to allow sufficient cooling may cause serious burn injury to personnel 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 150 F 65 C Always wear proper protective equipment when handling the analyzer Switch off the analyzer and a...

Page 58: ... proceed further until the door has been repaired 4 Make sure that the gas handling system is turned OFF 5 Make sure that the external circuit breaker is set to OFF 6 Visually examine the gas ports to make sure that the sample supply line and the sample return line are correctly attached to the analyzer If necessary refer to Replacing the gas input and output lines 7 Visually check that the electr...

Page 59: ...the analyzer to warm up in accordance with the Detailed system specifications before the sample gas supply is turned on At the end of the startup procedure the gas measurements initially appear as 0 00 ppm until the first readings are taken After a few seconds the initial gas concentrations will be displayed Reference Manual Startup procedure 00809 0100 5800 September 2019 Rosemount CT5800 59 ...

Page 60: ...Startup procedure Reference Manual September 2019 00809 0100 5800 60 Emerson com Rosemount ...

Page 61: ...intenance The shutdown procedure used to switch off the analyzer is described in Shutdown procedure Provided that the Startup procedure has been followed the analyzer does not require any human intervention during normal operation other than occasional calibration checks as described in Gas calibration During normal operation either the Gas Sensor Main screen Figure 4 1 or the Pressure and Tempera...

Page 62: ...oth 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 The analyzer is configured from the display controller located on the front panel Operating the analyzer Reference Manual September 2019 00809 0100 5800 62 Emerson com Rosemount ...

Page 63: ...e application of electrical power to the analyzer is controlled through an 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 Reference Manual Operating the analyzer 00809 0100 5800 September 2019 Rosemount CT5800 63 ...

Page 64: ...perform different functions according to which software screen is shown on the LCD display Table 4 1 Display Controller Navigation Button Functions Button Description Normally used to scroll up Referred to as UP Normally used to scroll down Referred to as DOWN Normally used to select Also accesses the Main Menu from the Home screen Referred to as RIGHT Used to go back to the previous screen No fun...

Page 65: ...nal Out of specification signal out of the specified range Indicates the analyzer is performing a calibration or validation or that the software has been deliberately stopped Failure non valid output signal 4 5 Gas Sensor Main screen When the analyzer is switched on at the end of the start up procedure the Gas Sensor Main screen Figure 4 5 appears The Gas Sensor Main screen is the screen that is n...

Page 66: ...lts have been identified If a fault is identified is displayed if maintenance is required is displayed To access other screens through the Main menu press Refer to Figure 4 5 is a link between the Gas Sensor Main screen Figure 4 5 and the Pressure and Temperature screen Figure 4 6 Press to toggle between the two screens is a link to the Help system Press to go to a Help screen described in Help sy...

Page 67: ...m 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 4 7 shows an example of a help screen Reference Manual Opera...

Page 68: ...t diagnosis FAULTS Takes you to a screen that lists any faults affecting the analyzer This option is used as part of the failure diagnosis procedures GAS SERVICE Allows you to check the sensor readings against a 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 ...

Page 69: ... button On most of the software screens the top left hand button is configured as a BACK button Press BACK to return to the previous screen Reference Manual Operating the analyzer 00809 0100 5800 September 2019 Rosemount CT5800 69 ...

Page 70: ...Operating the analyzer Reference Manual September 2019 00809 0100 5800 70 Emerson com Rosemount ...

Page 71: ...on confirms that when no sample gas is flowing through the analyzer the gas concentrations measured by the instrument are zero To zero verify compare the analyzer measurements to a known sample gas using the following procedure Procedure 1 Refer to Figure 4 8 Using and select GAS SERVICE 2 Press The Select gas screen Figure 5 1 opens Figure 5 1 Select gas Screen 3 Use and to move the cursor until ...

Page 72: ... 5 2 5 To perform a verification press The Manual Automatic screen Figure 5 3 opens Figure 5 3 Manual Automatic Screen 6 Press for manual verification Press for automatic verification The Verify Zero screen Figure 5 4 opens Verifying gas concentrations Reference Manual September 2019 00809 0100 5800 72 Emerson com Rosemount ...

Page 73: ...he instrument has detected a concentration of 0 40 ppm 8 If 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 Figure 5 5 Result Screen 9 If the reading is outside tolerance you need to zero calibrate the analyzer Refer to Zero calibration 10 In either case press to return to the C...

Page 74: ...lowing Prerequisites Run the analyzer at a stable temperature for at least thirty minutes before starting this procedure Procedure 1 Use a certified reference gas cylinder as the source of the span verification gas 2 Ensure 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 ...

Page 75: ... opens Figure 5 8 Select gas Screen 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 Reference Manual Verifying gas concentrations 00809 0100 5800 September 2019 Rosemount CT5800 75 ...

Page 76: ...rform a verification press The Mode selection screen opens Figure 5 10 for manual or automatic verification Figure 5 10 Mode selection Screen 10 Press for manual verification The Span input screen Figure 5 11 opens Verifying gas concentrations Reference Manual September 2019 00809 0100 5800 76 Emerson com Rosemount ...

Page 77: ...tches 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 Figure 5 12 Verify span Screen 13 Press to cancel the manual verification 14 Press to finish Reference Manual Verifying gas concentrations 00809 0100 5800 September 2019 Rosemount CT5800 77 ...

Page 78: ...ure 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 Figure 5 13 Result Screen 19 If the reading is outside tolerance the span calibrate the analyzer Refer to Span cal...

Page 79: ...h Step 16 for the next gas 23 If you wish to zero verify press Then follow the zero verification procedure in Zero verification 24 If you are finished verifying the analyzer press The software returns to the Gas Sensor Main screen Figure 4 5 The span verification procedure is now complete Reference Manual Verifying gas concentrations 00809 0100 5800 September 2019 Rosemount CT5800 79 ...

Page 80: ...Verifying gas concentrations Reference Manual September 2019 00809 0100 5800 80 Emerson com Rosemount ...

Page 81: ...ssible to obtain calibrated gas cylinders it will usually be measured by the same laser as some other gas 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 you need to calibrate e g for legal requirements you...

Page 82: ...ements until the next calibration There are two circumstances in which you may want to calibrate 1 After you verify gas concentrations see Verifying gas concentrations and find that the analyzer readings are outside of tolerance 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...

Page 83: ...T piece and route the excess flow line to a suitable extractor 3 On the display controller of the analyzer browse to the Main menu as described in Main menu Figure 6 2 Main Menu 4 Using and select GAS SERVICE 5 Press The Select gas screen Figure 6 3 opens Figure 6 3 Select gas Screen 6 Use and to move the cursor until the gas that you wish to zero calibrate is selected Press Reference Manual Gas c...

Page 84: ... is selected see Figure 6 4 8 To calibrate press The Mode selection screen Figure 6 5 opens Figure 6 5 Mode selection Screen 9 Press for manual calibration Press for automatic calibration 10 Press to confirm The Result screen Figure 6 6 displays Gas calibration Reference Manual September 2019 00809 0100 5800 84 Emerson com Rosemount ...

Page 85: ...for at least 30 minutes prior to commencing this procedure Startup takes 90 minutes to achieve the required temperature 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 piece to the sample supply port on the rear panel...

Page 86: ...hlighted by the cursor Press The Select type screen Figure 6 8 opens Figure 6 8 Select Type Screen 8 Use and to move the cursor until SPAN is selected Figure 6 8 To calibrate press The Mode selection screen Figure 6 9 opens Gas calibration Reference Manual September 2019 00809 0100 5800 86 Emerson com Rosemount ...

Page 87: ...highlight 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 Enter the cylinder concentration in ppm The Begin Calibrate span screen Figure 6 11 opens Reference Manual Gas calibration 00809 0100 5800 September 2019 Rosemount CT5800 87 ...

Page 88: ...e reading is now 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 Allow a minute to ensure the readings are stable 15 If the reading is now within tolerance no further action is required Press or to abort the calibration process 16 If the calibration o...

Page 89: ... the screen shown in Figure 6 13 is displayed Figure 6 13 Calibrate Complete Screen 18 If you wish to perform a span calibration for another gas press The software returns to the Select gas screen Figure 6 7 Repeat steps Step 7 through Step 17 for the next gas 19 If you are finished calibrating the analyzer press The software returns to the Main menu shown in Figure 6 2 Reference Manual Gas calibr...

Page 90: ...Gas calibration Reference Manual September 2019 00809 0100 5800 90 Emerson com Rosemount ...

Page 91: ...e been authorized to perform maintenance on the analyzer Emerson customer care engineers In all the cases described in this chapter maintenance personnel must perform the repairs by directly replacing the faulty item with a known serviceable spare part supplied by Emerson All other items must be repaired or replaced by the manufacturer NOTICE As a general principle if any optical component other t...

Page 92: ... analyzer may cause injury to personnel Use a minimum of two people when lifting and transporting the equipment Wear suitable protective gloves and protective footwear WARNING TRANSPORTATION HAZARD Failure to secure the equipment may cause a break away and injure personnel When preparing the analyzer for transport by air road or rail safeguard it against movement or break away during transport by ...

Page 93: ...r or optical measuring device The use of control or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure In accordance with USA 21 CFR 1040 the Rosemount CT5800 has warning labels at appropriate positions The locations of the safety labels in the analyzer are specified in Safety and system labels and annotation There are three types ...

Page 94: ...the analyzer Handle used gas handling components with extreme caution 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 ...

Page 95: ...yzer 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 Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 95 ...

Page 96: ...ure 7 4 Fault Status Analyzer Stopped 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 Reference Manual September 2019 00809 0100 5800 96 Emerson com Rosemount ...

Page 97: ...blank Figure 7 6 Faults Screen No Faults Detected If the BIT has identified faults the display controller indicates the fault The precise data displayed varies depending upon where the fault has occurred in the analyzer Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 97 ...

Page 98: ...ault 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 9 From the Main menu press and to scroll to DIAGNOSTICS Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 98 Emerson c...

Page 99: ...k on the status and where appropriate the values of any of the listed components Figure 7 10 Diagnostics Menu 10 Press and to scroll to the component for further troubleshooting 11 Press to display the component s diagnostic information See Figure 7 11 for a diagnostics example for Laser 1 Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 99 ...

Page 100: ... to determine if the suspect component is faulty contact your local Customer Care representative 7 3 Faults menu The Faults menu displays an example list of faults affecting the analyzer that have been identified by the BIT If no faults have been identified by the BIT the central area of the Faults menu is blank Figure 7 12 Fault screen no information However if the BIT identifies a fault the disp...

Page 101: ...igure 7 14 Cell Heater Fault By examining the data shown on the Faults display it is possible 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 Cascade Technologies Ltd for advice and assistance Reference Manual Troubleshooting and diagnostics 00809 ...

Page 102: ...t you wish to diagnose has been highlighted press to select it The Diagnostics screen for that component opens In the example shown in Figure 7 15 LASER 1 is highlighted Press to select LASER 1 The Laser 1 component diagnostics screen opens as shown in Figure 7 16 Figure 7 16 Laser 1 Diagnostics Screen The component diagnostic screen shows the parameters of the component that was selected on the D...

Page 103: ...s to life Make sure that the circuit breakers are set to OFF and tagged off before opening the front cover WARNING TRANSPORTATION HAZARD Failure to secure the equipment may cause a break away and injure personnel When preparing the analyzer for transport by air road or rail safeguard it against movement or break away during transport by securely strapping it in place Use suitable fasteners for the...

Page 104: ...ribed in Opening the enclosure 3 Visually examine the exterior of the analyzer for signs of damage 4 Perform a visual inspection of the optical and electrical components inside the analyzer 5 If any loose connections are found in the electrical compartment refer to the wiring diagrams see Engineering Drawings to identify and repair the connection 6 Refit the front housing see Closing the enclosure...

Page 105: ...mal Potential cause Cylinder was empty Recommended action Replace cylinder Readings return to normal Potential cause Pipework was damaged Recommended action Replace pipework Readings return to normal Potential cause Unknown Recommended action Contact Cascade Related information Measurement invalid flag 7 6 3 Measurement invalid flag Check display controller to assess which measurements are invalid...

Page 106: ...lid Analysis cell pressure out of range Analysis cell temperature out of range 7 6 4 Single gas reading invalid Check which gas Then check fault reading If Fault reading is active Recommended actions 1 Use Fault to access further diagnostic information 2 Contact Cascade If Fault reading is not displayed Unknown cause Recommended action Contact Cascade Related information Measurement invalid flag 7...

Page 107: ...m heats up with time Potential cause Heater failure temperature is too high or too low Recommended action Contact Cascade Related information Measurement invalid flag 7 6 7 Sensor frozen or unresponsive Potential cause Computer freeze up or connection failure Recommended actions 1 Attempt a reboot System reboots successfully 2 Contact Cascade Potential cause PC or HMI failure Recommended actions 1...

Page 108: ... hazardous area Ex compliant If any items other than those listed require service Emerson must perform the repair Before starting to repair the analyzer allow it to cool down as detailed in the safety precautions below DANGER FLAMMABLE SUBSTANCES This article is in accordance with IEC 60079 0 2011 Clause 30 Some parts of the analyzer may reach temperatures of 150 F 65 C and may present an igintion...

Page 109: ...lb 80 kg Failure to properly handle the analyzer may cause injury to personnel Use a minimum of two people when lifting and transporting the equipment Wear suitable protective gloves and protective footwear NOTICE As a general principle if any optical component other than the cell assembly and the laser modules is unserviceable then the manufacturer must repair the analyzer This is because the rep...

Page 110: ... Engineering Drawings 7 9 Opening the enclosure To gain access to the electrical and optical components it is necessary to open the front enclosure Refer to Figure 7 17 and proceed as follows Figure 7 17 20 off M16 Captive Bolts A M16 captive bolts Procedure 1 Make sure that the hinges are securely connected to the enclosure Troubleshooting and diagnostics Reference Manual September 2019 00809 010...

Page 111: ...ng radius when the front housing is opened 2 Undo the 20 off M16 x 1 5 captive bolts holding the front and rear housings of the enclosure together 3 Carefully lower the front enclosure to the fully open position Refer to Figure 7 18 Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 111 ...

Page 112: ... Seal C Flanges 4 Apply masking tape to the flanges seal and flamepath to protect them from scratches chipping and other forms of damage or deformation Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 112 Emerson com Rosemount ...

Page 113: ... Examine the front housing for signs of physical damage If it is undamaged retain the front housing You can retouch minor damage to the paintwork on the front housing 10 Make sure that the faces of the flamepath on both the front and back housings are protected 7 10 Replacing the display and control buttons The display and button controls are supplied and fitted as one assembly To replace the disp...

Page 114: ...lyzer 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 12 hours before performing any maintenance on or in the vicinity of the analysis cell If burns occur seek immediate medical treatment Procedure 1 Shut down the analyzer See Shutdown p...

Page 115: ...Figure 7 19 LCD Display and Controller Assembly Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 115 ...

Page 116: ... the display into the front panel of the chassis assembly through the front of the chassis assembly 9 Tighten all the captive screws until the display is held securely against the front panel of the chassis assembly 10 Make sure that the bolts operate if necessary adjust the display position by loosening M5 Hex nuts and align accordingly 11 Plug the connector and attached wiring harness into the v...

Page 117: ...re in place and of the correct rating DANGER ELECTRIC SHOCK This article is in accordance with IEC 60079 0 2011 Clause 30 Death or personal injury may result if this is not observed The analyzer uses mains voltage that is dangerous to life Make sure that the circuit breakers are set to OFF and tagged off before opening the front cover Figure 7 21 Fuses Reference Manual Troubleshooting and diagnost...

Page 118: ... ceramic 2 Neutral line 110 240 Vac following mains filter 3 15 A 240 V fast acting ceramic Procedure 1 Shut down the analyzer as described in Shutdown procedure and allow it to cool 2 Follow the procedure for opening the enclosure described in Opening the enclosure The fuses are located inside a fuse holder that is mounted on the DIN Rail of the Power Supply Unit see Figure 7 23 Troubleshooting a...

Page 119: ...ty Figure 7 24 shows one of the fuse holders which is shown in both the closed and partially open positions Figure 7 24 Fuse Block Sub Assembly Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 119 ...

Page 120: ...the replacement fuse into the fuse holder Refer to Table 7 2 and make sure 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 enclosure as described in Closing the enclosure and secure with the captive M16 bolts and engage the threads on the rear housing 7 Remove Lock Out Tag Out labels 8 A...

Page 121: ... 150 F 65 C Failure to allow sufficient cooling may cause serious burn injury to personnel 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 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 ...

Page 122: ... 26 Replace the TEC Board A TEC board B M3 flat washer C M3 spring washer D M3 x 5 mm socket head cap screw E Ribbon cable to motherboard F Wiring harness to detector module G Backplate H Connector for ribbon cable 5 Remove the TEC Board from the backplate G Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 122 Emerson com Rosemount ...

Page 123: ... Nm 9 Connect the wiring harness F to the TEC board A 10 Connect the ribbon cable E to the ribbon cable connector H on the TEC board Make sure that the ribbon cable securely clicks into place in the ribbon cable connector 11 Close the enclosure as described in Closing the enclosure and secure with the captive M16 bolts and engage the threads on the rear housing 12 Remove Lock Out Tag Out labels DA...

Page 124: ...e the analyzer may cause injury to personnel Use a minimum of two people when lifting and transporting the equipment Wear suitable protective gloves and protective footwear WARNING BURNS Some parts of the analyzer may be heated to 150 F 65 C Failure to allow sufficient cooling may cause serious burn injury to personnel Do not touch any part of the analyzer Assume all parts of the analyzer are hot ...

Page 125: ...ow it to cool 2 Tag or otherwise identify all wiring harnesses before disconnecting 3 Refer to Figure 7 27 Disconnect the 12 V power wiring harness E from the peripheral board A Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 125 ...

Page 126: ... wiring harness J Gas cell temp monitoring K Gas cell temp monitoring L Gas cell temp monitoring 4 Cut the cable tie C that secures the TEC board ribbon cable D to the connector of the peripheral board ribbon cable B Carefully move the TEC board ribbon cable clear of the peripheral board 5 Disconnect the ribbon cable B from the peripheral PCA board A Troubleshooting and diagnostics Reference Manua...

Page 127: ...rature monitoring harness respectively to connectors J9 J24 and J37 on the peripheral printed circuit card PCA 15 Connect the relay wiring harness I to the peripheral board 16 Connect the peripheral board ribbon cable B to the peripheral board 17 Secure the TEC board ribbon cable D to the connector of the peripheral board ribbon cable B with a cable tie C 18 Connect the 12 V power wiring harness D...

Page 128: ...allow it to cool 2 Follow the procedure for opening the enclosure described in Opening the enclosure 3 Tag or otherwise identify all wiring harnesses before disconnecting Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 128 Emerson com Rosemount ...

Page 129: ...s J Ribbon cable connector J7 K Ribbon cable to peripheral PCB L 12 V power out connector J17 M 12 V power in connector J16 N 12 V power output wiring harness O 12 V power input wiring harness P Laser module ribbon cable Q HMI display wiring harness R Connector J22 S Ethernet cable T Ethernet connector 4 Disconnect the TRIGGER OUT wiring harness H from connector J32 F Reference Manual Troubleshoot...

Page 130: ...d the associated spring washers C and flat washers A retained during the removal procedure Torque tighten the screws to 0 6 Nm 17 Insert the SD card removed from the old motherboard 18 Connect the HMI display wiring harness Q to connector J22 R 19 Connect the Ethernet cable S to the Ethernet connector T 20 Connect the peripheral PCB ribbon cable K to connector J7 J 21 Connect the 12 V power output...

Page 131: ... replacement Refer to Replacing the DC power supply for replacing the DC power supply Refer to Replacing the temperature controller for replacing the temperature controller Before removing any of the active components from the DIN rails perform the following steps Procedure 1 Shut down the analyzer as described in Shutdown procedure 2 Open the enclosure as described in Opening the enclosure 3 Tag ...

Page 132: ...efer to Replacing the gas input and output lines 5 Remove the two M5 socket head cap screws two M5 Spring washers and two M5 plain washers securing the lower DIN rail support bracket to the base of the enclosure Retain the screws and washers for future use Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 132 Emerson com Rosemount ...

Page 133: ...s to life Make sure that the circuit breakers are set to OFF and tagged off before opening the front cover WARNING HEAVY ITEM The analyzer weighs 176 4 lb 80 kg Failure to properly handle the analyzer may cause injury to personnel Use a minimum of two people when lifting and transporting the equipment Wear suitable protective gloves and protective footwear Reference Manual Troubleshooting and diag...

Page 134: ...is cell If burns occur seek immediate medical treatment CAUTION The core can weigh approximately 44 1 lb 20 kg and does not have dedicated lifting handling points Two people must handle the core when removing it from the housing Take care not to damage any of the components Procedure 1 Shutdown the analyzer as described in Shutdown procedure 2 Open the enclosure as described in Opening the enclosu...

Page 135: ... 7 31 Removing the Core 7 Carefully lift the core from the enclosure and place on a suitable table or bench Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 135 ...

Page 136: ...ause serious burn injury to personnel 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 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 agains...

Page 137: ...rrect 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 9 Connect Ethernet cable to the Moxa 10 Close the enclosure as described in Closing the enclosure and secure with the captive M16 bolts and engage the threads on the rear housing 11 Remove Lock Out Tag Out labels 12 Apply po...

Page 138: ... protective footwear WARNING BURNS Some parts of the analyzer may be heated to 150 F 65 C Failure to allow sufficient cooling may cause serious burn injury to personnel 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 Always wear proper protective equipment when handling the analyzer Switch off the analyzer and ...

Page 139: ...he replacement temperature controller for damage If damage has occurred contact your local Customer Care Representative 6 Fit the replacement temperature controller A onto the upper DIN rail Make sure the orientation of the temperature controller is correct Press the small lever C on the base unit and while holding the lever in the down position push the temperature controller home into the base u...

Page 140: ...me parts of the analyzer may be heated to 150 F 65 C Failure to allow sufficient cooling may cause serious burn injury to personnel 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 Always wear proper protective equipment when handling the analyzer Switch off the analyzer and allow it to cool for at least two hou...

Page 141: ...enclosure 3 Disconnect the wiring harness F from the Ethernet switch B 4 Press the small lever E on the underside of the Ethernet switch to release it from the DIN rail While pressing the lever remove the Ethernet switch from the DIN rail 5 Inspect the replacement Ethernet connector for damage If damaged contact your local Customer Care Representative 6 Discard the unserviceable Ethernet switch Re...

Page 142: ...they differ in internal settings Each laser module is a sealed unit and can only be repaired by Emerson Repair therefore consists of removing the unserviceable laser module and returning it to Emerson for repair DANGER ELECTRIC SHOCK This article is in accordance with IEC 60079 0 2011 Clause 30 Death or personal injury may result if this is not observed The analyzer uses mains voltage that is dang...

Page 143: ... in position on the base plate A The laser module must mate with the two locating pins B on the Base Plate 6 Secure the laser module by tightening the two captive screws D and F 7 Connect the ribbon cable E to the laser module C 8 Remove the protective masking tape from the flanges seal and flamepath Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 1...

Page 144: ...ult if this is not observed The analyzer uses mains voltage that is dangerous to life Make sure that the circuit breakers are set to OFF and tagged off before opening the front cover Prerequisites See Figure 7 29 Remove the DIN rails and gas inlet and outlet lines to access the analyzer electronics Procedure 1 Insert the lower DIN rail in the enclosure 2 Install the two M5 socket head cap screws t...

Page 145: ...otective masking tape from the flanges seal and flamepath CAUTION PROTECT FLAMEPATH Any damage to the flamepath will invalidate certification Use care not to damage the flamepath 6 Close the enclosure as described in Closing the enclosure and secure with the captive M16 bolts and engage the threads on the rear housing 7 Apply power to the analyzer Reference Manual Troubleshooting and diagnostics 0...

Page 146: ...re hot unless it has been switched off and allowed to cool down 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 12 hours before performing any maintenance on or in the vi...

Page 147: ...ly A DC power supply B Wiring harness connector top C Wiring harness connector bottom D Lever 4 Disconnect the wiring harness connector C from the bottom of the DC power supply A 5 Tag and disconnect all cables and connections as appropriate Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 147 ...

Page 148: ...Figure 7 38 Fuse DIN Rail Screws A Fuse DIN rail bolts B Power supply unit Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 148 Emerson com Rosemount ...

Page 149: ...Secure the bracket assembly to the enclosure housing with the two M5 screws spring washers and flat washers 11 Reinstall the fuse assembly to the power supply DIN rail 12 Refer to Figure 7 37 Connect the wiring harness connector C to the bottom of the DC power supply A 13 Connect the wiring harness connector B to the top of the DC power supply A 14 Close the enclosure as described in Closing the e...

Page 150: ... may cause serious burn injury to personnel 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 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 ...

Page 151: ...the analyzer Procedure 1 Shut down the analyzer as described in Shutdown procedure 2 Open the enclosure as described in Opening the enclosure 3 Carefully cut and remove any cable ties used to secure the temperature sensor wiring harness 4 Disconnect the temperature sensor wiring harness from the connector block on the DIN rail Reference Manual Troubleshooting and diagnostics 00809 0100 5800 Septem...

Page 152: ...en installing the temperature sensor in the factory was 30 Nm 7 Discard the faulty temperatures sensor E retaining the cap D follower C and seal B 8 Inspect the replacement temperature sensor E for damage If damaged contact your local customer care representative 9 Slide in order the cap D follower C and seal B onto the temperature sensor E and insert the assembly into the main body A Adjust the h...

Page 153: ... attachment to tighten cap D The required torque is 30 Nm 11 Reconnect the wiring harness fitting cable ties as required 12 Close the housing and secure in accordance with Closing the enclosure 13 Restart the analyzer in accordance with Startup procedure Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 153 ...

Page 154: ...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 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...

Page 155: ...card the faulty sensor and Dowty washer 7 Inspect the replacement sensor and washer for damage If damaged contact your local Customer care Representative 8 Insert the replacement Dowty washer on the base of the temperature sensor and insert into the baseplate 9 Use a spanner to tighten the sensor fitting NOTICE The Swagelok recommendation for pipe fittings of this size is to tighten the nut finger...

Page 156: ...Clause 30 Death or personal injury may result if this is not observed The analyzer uses mains voltage that is dangerous to life Make sure that the circuit breakers are set to OFF and tagged off before opening the front cover Procedure 1 Shut down the analyzer as described in Shutdown procedure 2 Open the enclosure as described in Opening the enclosure 3 Tag and disconnect all cables and connectors...

Page 157: ...ns to the gas input and output lines See Figure 7 44 7 Replace the gas input and output lines as required 7 16 4 Replacing the analysis cell DANGER ELECTRIC SHOCK This article is in accordance with IEC 60079 0 2011 Clause 30 Death or personal injury may result if this is not observed The analyzer uses mains voltage that is dangerous to life Make sure that the circuit breakers are set to OFF and ta...

Page 158: ...ol for at least 12 hours before performing any maintenance on or in the vicinity of the analysis cell If burns occur seek immediate medical treatment To gain access to the electrical pneumatic and optical components it is necessary to open the front enclosure Procedure 1 Shut down the analyzer as described in Shutdown procedure 2 Open the enclosure as described in Opening the enclosure 3 Tag and d...

Page 159: ...pring washers 12 Attach the four protective caps 13 Attach the DIN rail with two M5 socket head cap screws M5 Spring washers and M5 plain washers securing the DIN rail support bracket to the base of the enclosure 14 Connect all the component cables and connections on the lower DIN rail 15 Connect the two 14 mm gas input and output line connectors at the flame arrestor Refer to Replacing the gas in...

Page 160: ...p the process immediately and report to maintenance 3 Clean the seal to remove any adhesive from the protective cover 4 Inspect the flanges flamepath for damage i e scratches chipping or other forms of damage deformation If any damage is detected stop the process immediately and report to maintenance 5 Carefully lift up the housing and align with the rear housing 6 Make sure that all holes are ali...

Page 161: ...re to follow this warning will invalidate hazardous area Ex d explosion proof protection Always use captive M16 x 45 screws and form A washers to secure the enclosure Figure 7 47 Torque sequence Important Tighten all bolts in sequence to a torque value of 20 Nm 14 75 ft lb Reference Manual Troubleshooting and diagnostics 00809 0100 5800 September 2019 Rosemount CT5800 161 ...

Page 162: ...Troubleshooting and diagnostics Reference Manual September 2019 00809 0100 5800 162 Emerson com Rosemount ...

Page 163: ...ar analyzer The screenshots indicate the functionality of the software which is the same regardless of the gases or gas concentrations being measured WARNING BURNS Some parts of the analyzer may be heated to 150 F 65 C Failure to allow sufficient cooling may cause serious burn injury to personnel Do not touch any part of the analyzer Assume all parts of the analyzer are hot unless it has been swit...

Page 164: ...s 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 air or nitrogen supply 3 Allow the an...

Page 165: ...he display controller in either the Gas Sensor Main screen Figure 8 1 or the Pressure and Temperature screen Figure 8 2 Figure 8 1 Gas Sensor Main Screen Figure 8 2 Pressure and Temperature Screen The Main menu Figure 8 3 opens Reference Manual Shutdown procedure 00809 0100 5800 September 2019 Rosemount CT5800 165 ...

Page 166: ...EM 7 Press The System screen opens Refer to Figure 8 4 Figure 8 4 System Screen 8 Use and to select SHUTDOWN as shown in Figure 8 4 Then press The Shutdown screen Figure 8 5 opens Shutdown procedure Reference Manual September 2019 00809 0100 5800 166 Emerson com Rosemount ...

Page 167: ...reen Figure 8 6 and then stops running Figure 8 6 Shutting down Screen 10 Wait until the heart icon at the top right of the screen stops flashing You can now isolate the analyzer by turning off the power supply Reference Manual Shutdown procedure 00809 0100 5800 September 2019 Rosemount CT5800 167 ...

Page 168: ...Shutdown procedure Reference Manual September 2019 00809 0100 5800 168 Emerson com Rosemount ...

Page 169: ...is insulated against heat loss Allow the analyzer to cool for at least 12 hours before performing any maintenance on or in the vicinity of the analysis cell If burns occur seek immediate medical treatment 9 2 Scheduled maintenance This schedule lists the tasks required by the analyzer and the recommended frequency Variation in customer sites may require these activities to be performed more or les...

Page 170: ...Preventative maintenance Reference Manual September 2019 00809 0100 5800 170 Emerson com Rosemount ...

Page 171: ...he issue of prime ATEX and IECEx certification A 2 Applicant s name and address Cascade Technologies Ltd Glendevon House Castle Business Park Stirling FK9 4TZ UK A 3 Manufacturer s name and address As applicant A 4 Trademark A 5 Product name model number Rosemount CT5800 Continuous Gas Analyzer A 6 Rating 110 V to 120 V 60 Hz 220 V to 240 V 50 Hz 1100 W Reference Manual ATEX IECEx Assessment Repor...

Page 172: ... Control and Laboratory Use Part 1 General Requirements CAN CSA C22 2 No 0 10 R2015 Canadian Electrical Code Part II General Requirements CAN CSA C22 2 No 60079 0 15 Electrical Apparatus for Explosive Gas Atmospheres Part 0 General Requirements CAN CSA C22 2 No 60079 1 16 Explosive Atmospheres Part 1 Equipment Protection by Flameproof Enclosures d ANSI UL 60079 0 6th Edition Electrical Apparatus f...

Page 173: ...G HAZARD SEE INSTRUCTIONS WARNING DO NOT OPEN WHEN ENERGIZED Maximum supply pressure 1 Bar Table A 4 North America Detail CSA North American Marking Certificate number CSA 70068210 Marking class Class 2258 02 Certification code Class 1 Division 2 Groups B C D T4 Ex db IIB H2 T4 Gb Marking class Class 2258 82 Class 1 Division 2 Groups B C D T4 Class 1 Zone 1 AEx db IIB H2 T4 Gb Model number Rosemou...

Page 174: ...idance The user shall ensure that the flow process gas is limited to a maximum flow rate of 6 liters per minute The equipment shall only be uses with process gases which are classified for equipment group IIB H2 and must not contain oxygen or any other oxidizer in concentrations greater than those found in normal air North American conditions The equipment has flameproof joints with dimensions whi...

Page 175: ...able function performance or other properties of the equipment not related to safety The equipment is to be installed using wire no larger than 1 mm2 18 AWG The equipment is only to be installed by manufacturer trained personnel If at any time there is a conflict between the system safety provisions and any relevant local national or regional requirements the local requirements always take precede...

Page 176: ...ATEX IECEx Assessment Report Summary Reference Manual September 2019 00809 0100 5800 176 Emerson com Rosemount ...

Page 177: ... is determined by adjusting the physical thickness of the semiconductor layers giving access to high power lasers covering the mid infrared spectral region A QCL has no need for cryogenic cooling excellent spectral quality in chirped mode and good tuneability B 3 Measurement process In the analyzer gas concentrations are measured using mid infrared optical absorption spectroscopy The light sources...

Page 178: ...Theory of operation Reference Manual September 2019 00809 0100 5800 178 Emerson com Rosemount ...

Page 179: ...V output G in BSP male P 6001 00036 Crydom SPST NO solid state relay DIN rail mount zero cross 5 A rms 15 V P 6001 00030 1 output switch mode DIN rail panel mount power supply 12 Vdc 10 A P 6001 00037 PT100 lead assembly 6 mm dia x 50 long P 6001 00040 O2 detector P 6001 00052 Detector P 6001 00038 110 V Watlow cartridge in 6 4 mm OD x 7 5 in 190 5 mm x 200 W P 6001 00031 Hasselroth XSTREAM displa...

Page 180: ...Spare parts list Reference Manual September 2019 00809 0100 5800 180 Emerson com Rosemount ...

Page 181: ...g Drawings D 1 List of engineering drawings Drawing number Description W 2000 0038 Sheets 1 5 Rosemount CT5800 Gas Analyzer Reference Manual Engineering Drawings 00809 0100 5800 September 2019 Rosemount CT5800 181 ...

Page 182: ...reen White 4 Not Used Blue 5 Not Used Blue White 6 Rx Green 7 Not Used Brown White 8 Not Used Brown NOTES 1 To Connect to ethernet signal using muticore cable tails connect the cable as per the above table 2 To connect to ethernet network using an RJ45 connector unplug the ethernet cable marked that goes from the ethernet interafce module to the Moxa moudle at the Moxa module end and plug in the e...

Page 183: ...ERMINAL V ADJ TO ANALOGUE OUTPUT TERMINALS 3 2B TO MOTHER BOARD CERTIFICATION RELATED DOCUMENT UNAUTHORISED ALTERATION STRICTLY NON PERMISSIBLE DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 DIG O P RELAY 12 11 14 A1 A2 68 69 70 71 72 73 51 52 53 54 55 56 DIG O P RELAY 12 11 14 A1 A2 74 75 57 58 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 BUSIN...

Page 184: ... FOR 240 V OPERATION HEATER RODS WIRED IN PARALLEL FOR 110 V OPERATION TO DIN RAIL EARTH TERMINAL PT 100 10 9 11 2 6C TO HEATER CONTROL RELAY 14 2 5D 8 4 1 2 3 4 8 4 11 2 6C TO HEATER CONTROL RELAY 8A 8A 4A 8 4 7A 1 2 3 4 8 4 8 4 4A 8A 8 110V operation link cable 4 way mini fit to 4 way mini fit Insulated soldered joints 1 2 3 4 62 61 3 4 10 9 BOX HEATER PLATE CTRL CERTIFICATION RELATED DOCUMENT U...

Page 185: ...HNOLOGIES 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 ISO14617 PNEUMATIC SYMBOLS DRAWN TO...

Page 186: ...ONSENT 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 I...

Page 187: ...Engineering Drawings Reference Manual September 2019 00809 0100 5800 182 Emerson com Rosemount ...

Page 188: ...e gas being measured Lower explosion limit LEL Volume ratio of flammable gas in air below which an explosive gas atmosphere will not be formed the mixture of gas and air lacks sufficient fuel gas to burn Measurement frequency The frequency at which all gas concentrations are updated NAMUR NAMUR is an international user association of automation technology in process industries This organization ha...

Page 189: ... units of bars above or below atmospheric pressure BS British Standard C Celsius CDA Compressed dry air CE European Conformity CH4 Methane 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 Inch...

Page 190: ...rogram cubic meter Mid IR Mid Infrared min Minute mm Millimeter NEC National Electrical Code NFPA National Fire Protection Association nm Nanometer No Number 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 USA United States of A...

Page 191: ...ion Description V Volt Vac Volt alternating current Vdc Volt direct current W Watt WEEE Waste electrical and electronic equipment µm Micro meter Glossary and abbreviations Reference Manual September 2019 00809 0100 5800 186 Emerson com Rosemount ...

Page 192: ...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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