Emerson Rosemount CT5100 Manual de usuario

Reference Manual

00809-0100-4511, Rev AA

May 2020

Rosemount™ CT5100

Continuous Gas Analyzer

Preface

Published by Emerson.

All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no

liability for any inaccuracies that may be found. This manual reflects the state of the product at the issue date below, but further

enhancements while in service may mean that the manual does not reflect your particular system.

Emerson reserves the right to make changes without notice both to this publication and the products which it describes.

Document number: 00809-0100-4511

Rev AA, May 2020

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic,

mechanical, photocopying, recording, or otherwise without the express prior written permission of the copyright holder.

If you require additional technical assistance, request help from [email protected] or Emerson distribution partners.

Send general inquiries to [email protected].

All trademarks used within this document are the property of their respective owners.

Preliminary information

This section details important user information for the Rosemount CT5100 Continuous Gas Analyzer.

Important

Users must read, understand, and comply with the following information before proceeding.

All users, installers, operators, and maintainers must be familiar with operating the analyzer. To install, start up, operate, maintain,

and service the analyzer in a safe manner, it is MANDATORY to read all additional documents shipped with the analyzer. The

following information is also available and/or referenced in the Rosemount CT5100 Quick Start Guide: 00825-0100-4511.

Save all instructions for future use. Contact your local service center or sales office when missing documents.

Authorized personnel

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 personnel of the operating company

for hazardous areas and the manufacturer. It is the responsibility of the operating company to:

•Train staff

•Observe safety regulations

•Follow the safety instructions and procedures in the product manual

Operators must:

•Have been trained

•Have read and understand all relevant sections of the product manual before commencing work

•Know the safety mechanisms and regulations

WARNING

To avoid explosions, loss of life, personal injury, and damage to this equipment and on-site property, do not install, operate,

maintain, or service this analyzer before reading and understanding this document and receiving appropriate training.

Important instructions

Important

All users must read this page before proceeding!

Emerson designs, manufactures and tests its products to meet many national and international standards. The Rosemount

CT5100 is a sophisticated technical product, and to ensure it continues to operate as designed and within normal specifications it

MUST be installed, used, and maintained correctly. The following instructions MUST be adhered to and integrated into your safety

program when installing, using, and maintaining Emerson products.

•Failure to follow the proper instructions may cause:

—Loss of life

—Personal injury

—Damage to property

—Damage to this analyzer

—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 representative for clarification.

•Follow all warnings, cautions, and instructions marked on and supplied with the product.

•Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

•Install your equipment as specified in the installation instructions of the appropriate Reference Manual and in accordance with

applicable local and national codes.

•Connect all products to the proper electrical and pressure sources.

•To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

•When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.

•Unauthorized parts and procedures can affect the product’s performance; place the safe operation of your process at risk, and

VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

Regulations and standards

Regulations/standards Description

2014/35/EU The Low Voltage Directive

2014/30/EU The Electromagnetic Compatibility Directive

2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive

USA 21 CFR 1040.1 Laser products

NEC 505 National Electrical Code (issued by ANSI: American National Standards

Institute and NFPA 70: National Fire Protection Association)

BS EN 60825-1:2007 Safety of laser products. Equipment classification and requirements

(identical to IEC 608250-1 2007)

BS EN 61010-1 2010

IEC 61010-1 2010

Safety requirements for electrical equipment for measurements,

control, and laboratory use. General requirements

BS EN 61326-1: 2013 Electrical equipment for measurement, control, and laboratory use.

EMC requirements. General requirements

Associated publications

Rosemount CT5100 Quick Start Guide

Compliance approvals

Important

The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.

This product complies with USA 21 CFR 1040.10.

This product is designed and manufactured under an approved quality management

system to ISO 9001: 2015.

Emerson and the Rosemount CT5100 have satisfied the requirements for applying

the CE marking to the Rosemount CT5100 Gas Analyzer.

This equipment meets all requirements of the EMC and Low Voltage directives.

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 in an

environmentally correct manner.

Safety and information notices

DANGER

WILL CAUSE 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 death or 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.

Safety precautions

Important

The precautions in this manual MUST NOT be changed amended or removed. All authorized users, installation, operation and

maintenance personnel, must observe the following safety precautions and warnings.

The Rosemount CT5100 analyzer is designed for use in Non Hazardous areas ONLY.

WARNING

ELECTRIC SHOCK

The analyzer operates using mains voltage, which may cause death or serious injury to personnel. Death, personal injury, and/or

damage to persons and/or property may result if this is not observed.

Confirm that the circuit breakers are set to OFF and locked out and tagged out before removing the top cover or opening the front

cover. The analyzer must be earthed.

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 qualified personnel, familiar with potential risks, should install the analyzer.

DANGER

EXPLOSION HAZARD

Failure to observe this precaution will cause death, personal injury, and/or damage to persons.

The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the

analyzer during prolonged shutdowns.

The sample gas in the pipes leading to the analyzer must be purged for a minimum of 2 minutes and 30 seconds at a minimum

flow rate of 280 L/m at 1.5 ± 0.5 bar to prevent hazards to personnel during maintenance.

Purge the sample gas in accordance with the safe working procedures for this site.

WARNING

FLAMMABLE SUBSTANCES

Some parts of the analyzer may reach temperatures of 374 °F (190 °C) and may present an ignition source. The interior of a

analyzer is always hot unless it has been switched off and allowed to cool down. A fire may result if this precaution is not observed.

Exercise care when using oil, paint, cleaning rags, or other flammable substances near the analyzer.

WARNING

TRANSPORTATION HAZARD

The analyzer weighs 117 lb. (53 kg) and should always be lifted and moved using suitable lifting/moving equipment.

Handle the analyzer with caution during unpacking, installation, maintenance, and transport to prevent crushing of hands, feet, or

other body parts.

Wear suitable protective gloves and protective footwear. When preparing the analyzer for transport by air, road, or rail, safeguard

the analyzer against movement or break-away during transport by securely strapping it in place.

Use safety approved lifting equipment. Ensure that the equipment is tested, meets the lifting ratings for the weight of the

equipment, and is in good operational condition.

WARNING

FIRE AND EXPLOSION

Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may cause death,

personal injury, and/or damage to persons and/or property.

Do not open the analyzer's electrical compartment unless the atmosphere in the area is known to be below the ignitable

concentration of combustible gases or materials, or unless all equipment within the protected enclosure is de-energized .

The protective gas supply valve must be kept open unless the atmosphere in the area is known to be below the ignitable

concentration of combustible gases or materials or unless all equipment within the protected enclosure is de-energized.

Always lock out the gas handling system when shutting down the analyzer.

After opening the enclosure, do not restore power until the enclosure has been purged for a minimum of 2 minutes and 30

seconds at a minimum flow rate of 280 L/m at 1.5 ± 0.5 bar.

DO NOT operate the analyzer with doors or covers open.

Refer to local regulations as this may require a competent hot work supervisor to issue a hot work permit.

When the analyzer is out of order or if the pressurization unit shuts off due to a failure, all inputs and outputs connected to

external equipment MUST be shut off.

This will ensure that no hazardous voltages are present within the analyzer enclosure when not pressurized.

Only properly trained personnel who understand the contents of all applicable manuals and related instructions should start up

the analyzer.

Do not keep operating the analyzer if the enclosure shows permanent deformations after performing the overpressure test.

Use only replacement parts and components authorized by Emerson.

All replacement parts and components must be certified and approved for use in hazardous areas.

The analyzer contains a battery for data backup purposes.

Under normal operating conditions, there is no need to replace the battery during the analyzer life time. Battery replacement

MUST only be conducted by Rosemount Customer Care personnel. It is NOT a customer serviceable item.

WARNING

FIRE, BURN, AND OPTICAL RADIATION EXPOSURE HAZARD

Electrical shock, thermal burns, or loss of vision may occur. Failure to observe this warning could cause an explosion or potentially

hazardous situation, which if not avoided, may cause death, personal injury, and/or damage to persons and/or property.

Operators and service personnel do not have access to the laser/electrics or upper cell compartments for general maintenance or

service.

WARNING

BURNS

Personal injury and/or damage to property may result if these precautions are not observed. These precautions are particularly

important when working at heights.

Some parts of the analyzer may be heated to 374 °F (190°C). To prevent burns, do not touch any of the hot parts. All parts of a

analyzer are always hot unless it has been switched off and allowed to cool down.

Before fitting, removing, or performing any maintenance on the analyzer, ensure that it has been switched off and allowed to cool

for at least two hours. Before performing any maintenance on, or in the vicinity of, the analysis cell, allow the analyzer to cool for

at least 12 hours as the analysis cell is insulated against heat loss.

When handling the analyzer, always wear suitable protective gloves.

If you receive a burn, seek medical treatment immediately.

WARNING

HAZARDOUS SUBSTANCES

Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, may cause death, personal

injury, and/or damage to persons and/or property.

The analyzer may contain hazardous substances. Always handle the analyzer assemblies and components with extreme caution.

Wear personal protective equipment (PPE) when handling the equipment.

Gas handling components within the analyzer contain particulate matter residue from the sample gases. Over the life of the the

analyzer, the concentration of particulate matter will become enriched within the gas handling components. When performing

repairs and maintenance on the 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 them Contaminated.

—Dispose of contaminated items as hazardous material in accordance with applicable local, national, or international health

and safety regulations and pollution regulations.

Take special care to ensure that the sample gas return port either returns the sample gas to the product stream or discharges the

sample gas to a location that will not cause a hazard.

WARNING

OPTICAL RADIATION EXPOSURE HAZARD

There are three types of laser that may be included in the Rosemount CT5100: Quantum Cascade Lasers (QCLs), Interband

Cascade Lasers (ICLs), and diode lasers. The lasers within the analyzer are Class 1. The characteristics of the lasers contained within

the analyzer are given in the table below.

The emitted laser light is invisible (mid-infrared), and the combined laser powers are sufficiently low at the first accessible aperture

that the unprotected eye will not be damaged. This class is eye safe under all operating conditions.

It is, however, possible to cause damage to the eye through not following correct procedures. Do not look at the laser with any

kind of magnifier or optical measuring device.

Parameter QCL ICL Diode Comment

Operation mode Pulsed Pulsed Pulsed N/A

Lasers per system 1 - 6 1- 6 1- 6 Maximum of 6 lasers per system

Wavelength 4 - 10 µm 2 - 5 µm Approximately 760 nm N/A

Power < 5 mW < 5 mW < 5 mW Combined power of QCL at first accessible

aperture: < 9.62 mW

Pulse duration < 1 µs < 1 µs < 5 µs N/A

Pulse repetition

frequency

< 100 kHz < 100 kHz < 100 kHz N/A

Duty cycle < 5 % < 5 % < 25 % N/A

The combined power of the QCL, ICL, and diode lasers at the first accessible aperture is < 9.62 mW.

The analyzer has warning labels in appropriate positions according to USA 21 CFR 1040.10. The location of laser safety labels on

the analyzer is specified in Safety and system labels and annotation.

The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous

radiation exposure.

WARNING

HIGH PRESSURE GAS AND AIR

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 out the calibration gas supply and compressed air supply when shutting down the analyzer.

The maximum gas pressure valve must not exceed 100 psig (690 kPa).

WARNING

EXPLOSIONS HAZARD DUE TO ELECTROSTATIC DISCHARGE

In the event of a sudden discharge from electrostatically charged devices or individuals, there is a risk of an explosion. 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.

Take suitable measures to ensure that no electrostatic discharge can build up in the explosions risk area.

Clean the device surface by gently wiping it with a damp or antistatic cloth only.

WARNING

HAZARD BY WRONG INPUT VOLTAGE

Applying a rated voltage other than specified on the analyzer´s nameplate label may cause an explosion, injury, or damage to the

installation. Failure to observe this warning could cause an explosion or potentially hazardous situation, which if not avoided, may

cause death, personal injury, and/or damage to persons and/or property.

This type of analyzer is always setup for a specific rated input voltage; see nameplate label.

Ensure the voltage at site of installation meets the rated analyzer input voltage.

WARNING

LOOSE ITEMS

Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious

injury.

Do not place any loose items on top of the system or inside the compartments when doors / covers are open.

Confirm that all loose items, tools, and equipment are removed from compartments before closing doors and covers.

WARNING

MAINTENANCE/MODIFICATIONS

Failure to observe this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious

injury.

On completion of any maintenance and or modifications verify:

—All tools and equipment are removed.

—No contamination (water/dust) is in the compartments.

—Analyzer is wiped clean.

—Vents are clear and not obstructed.

—Verify that system is in a safe state for operation.

WARNING

Physical access

Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could

be intentional or unintentional and needs to be protected against.

Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access

by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.

CAUTION

EQUIPMENT DAMAGE

Failure to perform pre-system start-up checks may cause damage to equipment.

Do not power up or try to operate the analyzer unless it is physically secure and all electrical and pneumatic connections to the

analyzer are in place.

Before starting up the analyzer, ensure that electrical power, sample gas handling facilities, and any calibration gases that are

required are available to the analyzer.

Always follow the Start-up procedure.

Always follow the Shutdown procedure.

CAUTION

UNSERVICEABLE EQUIPMENT

If the pressure and temperature screen does not display measurements similar to those shown in Figure 8-1 and Figure 8-2, refer

to Troubleshooting and diagnostics.

CAUTION

EMC

This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be

required to take adequate measures.

As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is

unserviceable, the analyzer must be repaired by Emerson. This is because the repair, replacement, and alignment of the optical

components requires the use of special optical test/calibration equipment and procedures.

Some faults can only be repaired by Emerson. Where an item is unserviceable, and no replacement procedure is given in this

manual, then the fault must be repaired by Emerson.

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