Rosemount CT4215 Reference Manual Download

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Reference Manual

00809-0100-4245, Rev AB

July 2018

Rosemount

™

CT4215 Leak Detection System

Summary of Contents for CT4215

Page 1: ...Reference Manual 00809 0100 4245 Rev AB July 2018 Rosemount CT4215 Leak Detection System ...

Page 2: ...this publication and the products which it describes Document number 00809 0100 4245 Rev AB July 2018 Emerson 2018 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 addit...

Page 3: ...o 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 RosemountTM representative for clarification Follow all warnings cautions and instructions marked on and supplied with the product Inform and educate your personnel in the proper installation operation and maintenance of...

Page 4: ...ersonnel In depth specialist knowledge is an absolute requirement for working with and on the detector Personnel installing operating servicing and maintaining the detector 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 Train staff Observe safety regulations Follow the safety in...

Page 5: ...ry use EMC requirements General requirements Associated publications Quick Start Guide Compliance approvals This product complies with USA 21 CFR 1040 10 This product is designed and manufactured under an approved quality manage ment system to ISO 9001 2008 Emerson and the detector have satisfied the requirements for applying the CE marking to the detector This equipment meets all requirements of ...

Page 6: ...USE 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 ...

Page 7: ... optical measuring device WARNING HAZARDOUS SUBSTANCES The detector may contain hazardous substances Always handle the detector assemblies and components with extreme caution Gas handling components within the detector will contain particulate matter from the sample gases Over the life of the detector the concentration of particulate matter will become enriched within the gas handling components W...

Page 8: ...itable floor Failure to follow this warning could cause an explosion or potentially hazardous situation which if not avoided could result in death or serious injury WARNING ELECTRICAL SHOCK HAZARD Only trained qualified personnel may install and connect power and signal cables The installation connection must be in accordance with all legislative requirements and applicable standards Only qualifie...

Page 9: ... EQUIPMENT DAMAGE Always follow the startup procedure Damage to the detector may result from a failure to follow this procedure Failure to perform pre system startup checks may cause damage to equipment CAUTION EQUIPMENT DAMAGE Always follow the shutdown procedure Damage to the detector may result from a failure to follow this procedure CAUTION EQUIPMENT DAMAGE Ensure that the local power voltage ...

Page 10: ... The following table gives examples and definitions of each symbol used Symbol Definition General warning Refer to instruction manual before proceeding Danger electricity Make sure that the system is disconnected from all electrical power supplies prior to opening doors or removing covers Laser radiation Earth ground identification AC power supply Note The label shown is for illustration only It i...

Page 11: ...s 12 Chapter 4 Startup 17 Chapter 5 Shutdown 19 Chapter 6 Operation 21 6 1 Leak detector manager LDM software 22 6 2 Data logging and reporting 25 6 3 Status lamps errors 27 6 4 Line stop 29 6 5 PLC configuration screen 30 Chapter 7 Maintenance 33 7 1 Scheduled maintenance 33 7 2 Clean cell mirrors 33 7 3 Air filter 35 7 4 Control system 37 7 5 Sample head 37 7 6 Recommended spare parts 37 Chapter...

Page 12: ...Contents ii Rosemount CT4215 ...

Page 13: ...rement cell and onto a detector When molecules from a leaking container enter the measurement cell they partially absorb the laser light The variation in the intensity of the light indicates a leaking container and the container is rejected from the line The leak detector identifies packaged products that have a break in seal integrity as they are carried along a conveyor belt at speed The leak de...

Page 14: ...ascade Laser QCL analyzer PLC control compressed air preparation and vacuum The external component may include light gates sample head and a rejection mechanism to safely remove defective products from the line Figure 1 1 shows the leak detection system Leak Detection System Block Diagram Figure 1 1 Leak detection overview 2 Rosemount CT4215 ...

Page 15: ...er detector PLC and DC power supply D Air preparation compressed air must be filtered and dried for optimum performance E Vacuum pump high flow rate pump for fast sample delivery to measurement cell F Reject mechanism2 compressed air reject mechanism G Touchscreen HMI user interface for system H PLC panel screen screen set to certain PLC parameters This will be locked to operators under normal ope...

Page 16: ...ne Figure 2 2 shows the external connections of the packaged leak detection system These are located at floor level on the rear of the unit External Connections Figure 2 2 A Ethernet B Status 24 Vdc line stop C Reject D Input gate E Air in F Air out G Mains supply Equipment and accessories 4 Rosemount CT4215 ...

Page 17: ...t Bulgin 3P female 250 Vac dc 10 A 24 V signal to the rejec tion solenoid when a de fective pack is detected D Input gate Bulgin 4P female 250 Vac dc 6 A Gate signal to the sensor to count incoming packs E Air in 8 mm push fit 10 bar 145 psi Customer supplied com pressed air F Air out 8 mm push fit 6 bar 90 psi Regulated compressed air for accessories i e rejection G AC supply Mennekes right angle...

Page 18: ... in Figure 2 3 There is a central roller with a sample head at either side Note The sample head shown is for food packaging this may change depending on the product production line Sample Head Closed Figure 2 3 WARNING CRUSH AND CUT HAZARD Moving parts can crush and cut Do not operate with the sample head open Failure to observe this warning may cause serious injury to personnel Equipment and acce...

Page 19: ...ulated The assembly shown in Figure 2 4 is mounted inside the leak detector control system cabinet Compressed Air Preparation Plate Figure 2 4 A Shut off valve B Pressure regulator with 40 µm filter C 0 1 µm filter D Pressure switch MPa E Membrane dryer F Solenoid switch Equipment and accessories Reference Manual 7 ...

Page 20: ...re 2 5 The upper enclosure is the main area for maintenance access see Chapter 7 Upper enclosure Figure 2 5 A Measurement cell with insulating jacket B Manual purge button C Cell lid clamps D Cell input mirror directs laser into cell E Cell output mirror directs laser onto the detector Equipment and accessories 8 Rosemount CT4215 ...

Page 21: ...ated for operation in ambient temperatures 176 F 80 C Emerson does not supply a switching system with the instrument The customer 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 loca...

Page 22: ...Line Installation Location Figure 3 1 Ground Fixing Figure 3 2 Installation 10 Rosemount CT4215 ...

Page 23: ...Installation of Reject Mechanism Figure 3 3 Sample Head Installation Figure 3 4 Installation Reference Manual 11 ...

Page 24: ...embled and installed 2 Remove the instrument from the crate a Remove the fixing screws marked in red from the front panel of the crate and the front panel section Place the front panel section from the crate in a safe place well away from the working area b Release the two straps located on the unit upright section c Carefully remove the unit from the crate d Remove all additional parts from the c...

Page 25: ... a Lower the feet to the ground b Raise the unit a few inches off the ground c Remove the wheel brackets d Lower the unit to the floor e Use the feet to level of unit if required f Bolt the unit to the floor as per site standards Installation Reference Manual 13 ...

Page 26: ...available no drilling required b Place the light gate in the required position on the track using the fasteners supplied in the hardware kit Hand tighten the fasteners only at this time WARNING DRILL INJURY Be careful to avoid injuring hands and eyes when drilling Wear correct PPE at all times c Adjust the angle and height of the light gate to suit the package being scanned d Secure the light gate...

Page 27: ...n the side bolts to adjust the angle and then tighten them when aligned 8 Attach the sample head WARNING DRILL INJURY Be careful to avoid injuring hands and eyes when drilling Wear correct PPE at all times a Drill four location holes into the track side face in the approximate position required for the sample head Use track location T slots if available no drilling required b Place the sample head...

Page 28: ...Installation 16 Rosemount CT4215 ...

Page 29: ...ximately two minutes to boot Isolation Switches Figure 4 1 2 Ensure the compressed air supply is open 3 When production begins turn the blower isolator to the ON position NOTICE Emerson recommends that the blower is switched off when the production line is not running This will extend the lifetime of the sample air filter 4 Press the Reset button on the front of the console and ensure there is a g...

Page 30: ...Startup 18 Rosemount CT4215 ...

Page 31: ... the instrument Only use the isolation switch on its own to shut down the system in an emergency as a last resort to remove power from the system Procedure 1 Press the PowerDown button at the upper right corner of the human machine interface HMI Shutting Down the System Figure 5 1 This shuts down the HMI 2 Turn the unit isolator to the OFF position Shutdown Reference Manual 19 ...

Page 32: ...he system off At this point mains voltage is still applied inside the enclosure Before opening the packaged Leak Detection System isolate the mains to the enclosure at the mains supply 3 Close the compressed air supply if required Shutdown 20 Rosemount CT4215 ...

Page 33: ...on the schematic above from left to right The packs pass through the input gate which is located before the sample head A space of at least 1 in 2 5 cm is required between packs in order to ensure correct counting and rejection A space of at least 6 in 15 2 cm is advised for best operation The sample head then analyzes the pack container The reject mechanism safely removes faulty containers from t...

Page 34: ... Counters Returns the counters to 0 E Reports Accesses the logging features of the system Use a USB to log and export production statistics and rejection data F Power Down Safely shuts down the HMI G Outputs Explained in Section 6 3 H Counters I Tab selection Toggle between the three tabs to change which visual information is displayed A Pulse Displays the laser pulse amplitude in volts see Figure...

Page 35: ...line reaches the upper threshold red line the sensor sends a rejection signal to the PLC and then the rejection solenoid to remove the faulty pack from the line The lower threshold is typically approximately 80 percent of the upper threshold and prevents the system from missing a marginal leak Operation Reference Manual 23 ...

Page 36: ...re 6 4 Figure 6 4 shows the UNIT tab when a leaking pack has passed through The plot shows all data points between the input and output gate and records the size of the rejection spike Operation 24 Rosemount CT4215 ...

Page 37: ...eports Popup Window Figure 6 5 A Enable Disable Reports Turn reporting on or off B Delete Report Delete a file from a specified location C Create report Set the file name and save location D Save Report Save the current file to a specified location E Copy Report File Move a file from one location to another Note The file must be saved as filename txt You can export the txt report file to a USB sti...

Page 38: ...econd or mg day UT The upper threshold value If the concentration exceeds this value the package is rejected LT The lower threshold If two consecutive concentration points exceed this value the package is rejected Noiselevel the noise value at the time when the package is logged Reject Packages which do not breach thresholds are reject 0 and those which breach thresholds are reject 1 Note If you w...

Page 39: ...ure The errors are detailed below and when activated will trigger the red beacon bulb and line stop if applicable Cabinet Status Indicators Figure 6 7 A Alarm beacon Green for healthy red for unhealthy line stop B RESET button to clear latched alarms C AIR status bulb Illuminates when blower or compressed air is off D Blower status A status bulb turns on when power is supplied to the blower If the...

Page 40: ...r clean the cell mirrors as described in Section 7 2 This error automatically clears when the pulse amplitude is above the threshold 4 Maintenance The yellow warning triangle appears if the laser pulse amplitude is below the warning threshold value System performance is not affected but you should consider activating the mirror purge or cleaning the cell mirrors soon This error automatically clear...

Page 41: ...TATUS connector shown in Figure 2 2 The connection is a volt free contact and can be configured in Normally Closed NC and Normally Open NO from a customer supplied 24 V Line Stop Plug Pin Numbering Table 6 1 24 V line 0 V line Normally Closed NC 1 2 Normally Open NO 3 2 The overall system is high when healthy green light and low when unhealthy red light Operation Reference Manual 29 ...

Page 42: ...re provided to the relevant department during installation Following any change to line speed pack size or pack spacing qualified personnel should verify the system The system is designed to accommodate changes in pack size and line speed There are five configurable parameters highlighted in red below PLC Configurable Parameters Figure 6 10 The PLC screens are shown in Figure 6 11 with an explanat...

Page 43: ...ng it IN and beginning analysis 0 9000 ms Measurement End The delay between the pack being counted in and the sensor finishing analysis This ensures complete in spection from leading edge to trailing edge This also generates the pack OUT count on the software screen 0 10000 ms Reject Delay The time between the bag being counted OUT and the rejection mech anism 60000 ms 1 minute Reject Duration The...

Page 44: ...Operation 32 Rosemount CT4215 ...

Page 45: ...nce activities and their related frequencies are shown below 7 2 Clean cell mirrors Follow the steps below to clean the cell mirrors in the Rosemount CT4215 CAUTION EQUIPMENT DAMAGE The cell mirrors are an optical device only clean them when required Avoid over cleaning the mirrors Use only the cleaning parts listed in this document If the laser pulse amplitude drops below the laser warning thresh...

Page 46: ...witch off the BLOWER ISOLATOR and compressed air supply 2 Open the upper enclosure to see the red measurement cell jacket 3 Release the two clamps on top of the cell lid 4 Remove the top cover of the cell jacket 5 Remove the black cell cover 6 Use only Thor Labs lens cleaning tissue P 5000 0613 to gently wipe the mirrors on each side of the cell see Figure 7 3 CAUTION EQUIPMENT DAMAGE Avoid skin c...

Page 47: ...closure and prevents dust and debris from reaching the cell Emerson recommends inspecting the filter at monthly intervals The steps below show how to access the air filter for inspection or changing 1 Isolate the blower so that there is no air flow through the filter and cell 2 Using circlip pliers remove the circlip from the end of the filter housing Figure 7 4 Removing the Circlip from the Filte...

Page 48: ... Fitting from the Filter Housing Figure 7 5 4 Remove the filter for inspection cleaning or replacement Figure 7 6 Retain the O ring Removing the Filter from the Filter Housing Figure 7 6 Maintenance 36 Rosemount CT4215 ...

Page 49: ... the system is switched off compressed air is off and the conveyor is off 7 6 Recommended spare parts The following parts are available from Emerson Spare Parts Table 7 1 Part number Part description P 6000 00358 Valve solenoid P 6000 00357 Filter regulator 40 m P 6000 00355 Filter 0 01 m P 6000 00495 Lens cleaning tissue pack of 5 B 6000 0007 C PCB digitiser Mk5 E 4004 6002 B PCB motherboard E 40...

Page 50: ...Maintenance 38 Rosemount CT4215 ...

Page 51: ...stribution box Laser pulse is not displayed Check the network connection on the motherboard for flashing LED Check the HMI ethernet for flashing LED Check network switch hub for flashing LED Check UDP addresses match in Config uration screen and Setup screen Default values for the UDP addresses are 65501 and 65502 Check the laser ribbon cable Reconnect the cable do not hot plug if loose Check the ...

Page 52: ...he Reset alarms button on LDM Press the Reset button see Section 6 3 If the IN OUT count does not match reset the counters Reset the counters AIR warning light illuminated Check the blower isolator is in the ON position and the blower status bulb is illuminated Switch the isolator ON Check the compressed air supply is open Turn on the air Check the compressed air supply pres sure is within the spe...

Page 53: ...o be replaced Check that the orange LED is flashing on the light gate when a pack enters the system Gate sensitivity can be adjusted using the dial on the light gate It should flash orange when the beam is broken at a distance of approximately 20 to 200 mm Troubleshooting and diagnostics Reference Manual 41 ...

Page 54: ...Troubleshooting and diagnostics 42 Rosemount CT4215 ...

Page 55: ...etectable gases Standard Ethanol drinks Specify on order CO2 food Environment Air temperature 23 to 86 F 5 to 30 C Ambient Humidity range 10 to 95 Relative humidity non condensing at 95 F 35 C Production line area services required System operating voltage 110 240 Vac 50 60 Hz Specify on order System power consumption 600 W Maximum power requirement Factory air supply 116 psi to 145 psi 8 to 10 Ba...

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