Reference Manual
00809-0100-4245, Rev AB
July 2018
Rosemount™ CT4215 Leak Detection System
Important information
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 detector. To install, start up, operate, maintain,
and service the detector in a safe manner, it is MANDATORY to read all additional instruction manuals shipped with the detector.
The following instruction manual(s) are available and / or referenced within this manual:
RosemountTM CT4215 Quick Start Guide: 00825-0100-4245
User information
Important
All users must read this page before proceeding!
EmersonTM designs, manufactures, and tests its products to meet many national and international standards. The RosemountTM
CT4215 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 RosemountTM products.
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Failure to follow the proper instructions may cause:
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Loss of life
Personal injury
Damage to property
Damage to this instrument
Warranty invalidation
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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 the product.
Install your equipment as specified in the installation instructions of the appropriate manual and in accordance with
applicable local and national codes.
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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 requried, ensure that qualified people use replacement parts specified by EmersonTM
.
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.
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To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except
when maintenance is being performed by qualified personnel.
The information contained in this document is subject to change without notice.
General safety notice/residual risk
Installation, operation, and maintenance of the detector must be in accordance with these instructions.
When operated as intended and all applicable safety instructions are observed, an element of risk will remain, including, but not
limited to, the following:
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Explosion protection measures may become ineffective on the occurrence of one failure (for Category 3 instruments).
The emission of gases hazardous to health may be possible when all gas connections have been correctly made.
To avoid exposure to the dangers of residual risks, take particular care when installing, operating, maintaining, and servicing the
detector.
Authorized personnel
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:
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Train staff.
Observe safety regulations.
Follow the safety instructions and procedures in the product manual.
Operators must:
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Be trained.
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 instrument before reading and understanding this instruction manual and receiving appropriate training.
Regulations and standards
Regulations / Standards
2014/35/EU
Description
The Low Voltage Directive
2014/30/EU
The Electromagnetic Compatibility Directive
Waste Electrical and Electronic Equipment (WEEE) Directive
Laser products
2012/19/EU
USA 21 CFR 1040.1
BS EN 60825-1
Safety of laser products. Equipment classification and require-
ments (identical to IEC 608250-1 2007)
BS EN 61010-1 2010 IEC 61010-1 2010
BS EN 61326-1: 2013
Safety requirements for electrical equipment for measurements,
control, and laboratory use. General requirements
Electrical equipment for measurement, control, and laboratory
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 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 implemen-
tation 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
This article is in accordance with IEC 60079-0: 2011 Clause 30. This article must not be changed amended or removed.
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 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 Information
All authorized users, including installation, operation, and maintenance personnel, must observe the following safety precautions
and warnings.
DANGER!
ELECTRIC SHOCK
The detector operates using mains voltage that is dangerous to life. Make sure that the circuit breakers are set to OFF and tagged off
before removing the top cover or opening the front cover.
Failure to observe this precaution will cause death, personal injury, and/or damage to persons and/or property.
WARNING!
OPTICAL RADIATION EXPOSURE HAZARD
The detector contains lasers. Opening the detector and attempting to perfrom adustments and procedures other than those
specified in this manual may result in hazardous optical radiation exposure.
All lasers within the detector are Class 1. 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.
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. When performing repairs and
maintenance on the detector:
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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 according to the applicable local, national, or international health and safety
regulations and pollution regulations.
WARNING!
EXPLOSION HAZARD
Always lock-out tag-out the gas handling system when shutting down the detector. Unauthorized operation of the gas handling
system when maintenance is being performed on the detector or its associated pipes/hoses may result in highly flammable gas
being released, causing fire or explosion.
WARNING!
HIGH PRESSURE GAS AND AIR
The compressed air supply operates 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 detector.
WARNING!
EXPLOSION HAZARD
The sample gas in the system must be vented to prevent fire or explosion during maintenance and to prevent damage to the
detector during startup.
The sample gas in the pipes leading to the detector must be purged to prevent hazards to personnel during maintenance. Purge the
sample gas in accordance with the safe working procedures for the site.
Allow the detector and system for returning the sample gas to run for five minutes to allow any sample gas in the system to be
returned to the exhaust.
WARNING!
HEAVY INSTRUMENT
The detector weighs 119 kg (268 lb.) and is designed to be floor mounted. It must be moved in accordance with local safety
regulations. EmersonTM recommends that a minimum of two people using suitable tools for transportation and lifting are employed.
Use suitable fasteners for the weight of the unit.
Make sure the unit is mounted on a solid, stable, and suitable 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 qualified personnel, familiar with the resulting potential risks, should install these instruments.
Instruments providing screw terminals for electric connections may require working near live parts.
Failure to follow this warning could cause an explosion or potentially hazardous situation, which if not avoided, could result in
warranty invalidation, property damage, death, or serious injury.
WARNING!
HIGH PRESSURE HAZARD
The maximum compressed air pressure at the inlet valve must not exceed 10 bar (145 psi). Failure to follow this warning could cause
a potentially hazardous situation,which if not avoided, could result in death or serious injury.
WARNING!
LOOSE ITEMS
Do not place any loose items on top of the system or inside the compartments when doors or covers are open.
Make sure that all loose items, tools, and equipment are removed from the compartments before closing doors and covers.
Failure to follow this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
WARNING!
On completion of any maintenance and/or modifications, make sure:
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All tools and equipment are removed.
No contamination (water/dust) is in the compartments.
The detector is wiped clean.
Vents are clear and not obstructed.
The system is in a safe state for operation.
Failure to follow this warning could cause a potentially hazardous situation, which if not avoided, could result in death or serious
injury.
WARNING!
TRANSPORTATION HAZARD
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. Failure to verify that equipment meets the lifting ratings and is in good operational
condition may injure personnel or damage the detector.
CAUTION!
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 where the unit is to be installed corresponds to the unit’s nominal voltage as given on the name
plate label.
NOTICE
As a general principle, if any optical component other than the cell assembly, the laser modules, and the detectors is unserviceable,
EmersonTM must repair the detector. This is because the repair, replacement, and alignment of the optical components requires the use of
special optical testcalibration equipment and procedures. When an item is unserviceable, and no replacement procedure is given in this
manual, EmersonTM must repair the fault.
Symbols displayed on and inside the detector
To minimize risk, labels displaying warning signs are fixed to the transmitter. You must
understand their meaning, take suitable precautions, and read all instructions given in the
accompanying manuals before conducting any operations.
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 is possible that the image will show a voltage in the range of
100 to 240 Vac.
Contents
Contents
Leak detection overview ................................................................................................ 1
System overview ..........................................................................................................................2
Equipment and accessories ............................................................................................ 3
Typical installation ....................................................................................................................... 3
System connections .....................................................................................................................4
Typical sample head .................................................................................................................... 6
Air preparation plate ....................................................................................................................7
Upper enclosure .......................................................................................................................... 8
Installation requirements .............................................................................................................9
Installation instructions ............................................................................................................. 12
Shutdown .................................................................................................................... 19
Leak detector manager (LDM) software ..................................................................................... 22
Data logging and reporting ........................................................................................................25
Status lamps / errors .................................................................................................................. 27
Line stop .................................................................................................................................... 29
PLC configuration screen ........................................................................................................... 30
Maintenance ................................................................................................................ 33
Scheduled maintenance ............................................................................................................ 33
Clean cell mirrors ....................................................................................................................... 33
Air filter ......................................................................................................................................35
Control system .......................................................................................................................... 37
Sample head ..............................................................................................................................37
Recommended spare parts ........................................................................................................ 37
Troubleshooting and diagnostics ................................................................................. 39
Appendices and reference
Appendix A Specifications ...............................................................................................................43
Reference Manual
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Contents
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Rosemount CT4215
Leak detection overview
1
Leak detection overview
Gas concentrations are measured using mid-infrared optica absorption spectroscopy. The
light sources are Quantum Cascade Lasers (QCLs), which are operated to produce
wavelength sweeps that cover the absorption lines of the target gases.
The laser is mounted in the baseplate between the upper and lower enclosures of the leak
detector, and light is directed through the measurement 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 detection system consists of a
sampling head which draws air from around the product. The air is passed through the
measurement cell for high speed analysis.
Reference Manual
1
Leak detection overview
1.1
System overview
The Rosemount™ CT4215 Leak Detector is used on packaged lines and comprises an all
metal enclosure containing the Quantum Cascade 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.
Figure 1-1: Leak Detection System Block Diagram
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Rosemount CT4215
Equipment and accessories
2
Equipment and accessories
2.1
Typical installation
Figure 2-1: Rosemount™ CT4215 Parts
A.
B.
C.
D.
E.
Sample head1: draws air from around the packaged product into the measurement cell.
Analysis cell: the laser beam and sample gas pass through here for analysis.
Electronics: laser, detector, PLC, and DC power supply.
Air preparation: compressed air must be filtered and dried for optimum performance.
Vacuum pump: high flow rate pump for fast sample delivery to measurement cell.
Reject mechanism2: compressed air reject mechanism.
F.
G.
H.
Touchscreen HMI: user interface for system.
PLC panel screen: screen set to certain PLC parameters. This will be locked to operators under
normal operation.
1.
2.
Sample head is modular and may differ depending on application.
May differ depending on application.
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3
Equipment and accessories
2.2
System connections
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.
Figure 2-2: External Connections
A.
B.
C.
D.
E.
Ethernet
Status, 24 Vdc (line stop)
Reject
Input gate
Air in
F.
Air out
G.
Mains supply
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Rosemount CT4215
Equipment and accessories
Table 2-1: External Connections
Letter
Designation
Type
Max rating
Description
A
Ethernet
RJ45 Ethernet
N/A
Communication with
sensor
B
Status, 24 Vdc (line stop) Bulgin 4P female
250 Vac/dc, 6 A
Customer supplied 24 V
signal when line is run-
ning. Rosemount™
CT4215 health status is
returned (see
C
Reject
Bulgin 3P female
Bulgin 4P female
250 Vac/dc, 10 A
250 Vac/dc, 6 A
24 V signal to the rejec-
tion solenoid when a de-
fective pack is detected.
D
Input gate
Gate signal to the sensor
to count incoming
packs.
E
F
Air in
8 mm push fit
8 mm push fit
10 bar (145 psi)
6 bar (90 psi)
Customer supplied com-
pressed air
Air out
Regulated compressed
air for accessories, i.e.,
rejection
G
AC supply
Mennekes right angle
2P+E
Yellow: 110 - 130 V
Blue: 200 - 250 V
16A
Customer supplied
mains
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5
Equipment and accessories
2.3
Typical sample head
The sample head is used to draw air from around the product and deliver it to the
measurement cell.
To ensure a high air flow rate, the sample head is connected to the leak detector using a ¾-
Note
The sample head shown is for food packaging; this may change depending on the product/
production line.
Figure 2-3: Sample Head (Closed)
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.
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Rosemount CT4215
Equipment and accessories
2.4
Air preparation plate
The customer supplied compressed air is filtered to remove impurities and is pressure-
regulated.
cabinet.
Figure 2-4: Compressed Air Preparation Plate
A.
B.
C.
D.
E.
Shut off valve
Pressure regulator with 40 µm filter
0.1 µm filter
Pressure switch (MPa)
Membrane dryer
F.
Solenoid switch
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7
Equipment and accessories
2.5
Upper enclosure
The upper enclosure is accessible with an 8 mm Allen key and comprises the following
Figure 2-5: Upper enclosure
A.
B.
C.
D.
E.
Measurement cell with insulating jacket
Manual purge button
Cell lid clamps
Cell input mirror, directs laser into cell
Cell output mirror, directs laser onto the detector
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Rosemount CT4215
Installation
3
Installation
3.1
Installation requirements
The customer provides the following:
Table 3-1: Installation Requirements
Customer provided
Specification
110/120 Vac, 50 Hz
or
Mains supply (defined by customer)
Mains supply (defined by customer)
Circuit breaker
220/240 Vac, 60 Hz
16A (maximum)
Mounting
Affix to floor or building structure
8-10 bar / 115 - 145 psi
Compressed air
For the electrical power wiring, use 16 AWG stranded, three conductor copper plain or tin
plated wire, rated for a minimum of 250 Vac for the required cable length. Cables must be
terminated in accordance with national/local electrical standards and must be rated 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 located, easily
reached, and identified as the disconnection device for the leak detection system.
The leak detection system provides a protective earth terminal. To prevent electrical shock
hazards, connect the instruments to a protective earth. Any interruption of the earth
connector inside or outside the instrument or disconnecting the earth terminal may cause
potential electrical shock hazard.
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Installation
Figure 3-1: Line Installation Location
Figure 3-2: Ground Fixing
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Rosemount CT4215
Installation
Figure 3-3: Installation of Reject Mechanism
Figure 3-4: Sample Head Installation
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Installation
3.2
Installation instructions
Only Rosemount™ Customer Care Representatives should install this instrument.
WARNING!
LIFTING HAZARD
The system weighs 268 lb. (119 kg). Beware of collision injury and topple injury when moving.
Emerson™ recommends using a forklift to move the system.
WARNING!
CRUSH HAZARD
Be careful not to crush hands and feet when moving the system.
WARNING!
DRILL INJURY
Be careful to avoid injuring hands and eyes when drilling. Wear correct personal protective
equipment (PPE) at all times.
Procedure
1.
Place the delivery crate in an open and easily accessible area, close to where the unit
will be assembled 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 crate and place them to the side of the unit.
3.
Ensure that all additional parts shown are present after unloading the crate.
Required parts are shown below.
Table 3-2: Rosemount™ CT4215 Installation Parts
Item
Description
Quantity
A
B
Reject assembly
Light gate assembly
Sample head
1
1
1
1
C
D
Hardware kit
4.
Place the unit enclosure at the desired position on the product line.
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Rosemount CT4215
Installation
Figure 3-5: Line Installation Location
5.
Ground the instrument.
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.
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Installation
Figure 3-6: Ground Fixing
Refer to the fastener manufacturer's guide for fixing instructions and torque.
g. Place the cap covers over the access holes.
6.
Attach the light gate to the track.
a. Drill the location hole(s) into the track side faces in the approximate positions
required for input gate.
Use track location T slots if 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 in place using the fasteners fitted previously.
e. Torque the fasteners to 7.6 Nm (5.6 ft.-lb.).
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Rosemount CT4215
Installation
7.
Attach the reject mechanism.
WARNING!
DRILL INJURY
Be careful to avoid injuring hands and eyes when drilling. Wear correct PPE at all times.
a. Drill two location holes into the track side face in the approximate positions
required for the reject mechanism.
Use track location T slots if available (no drilling required).
b. Attach the reject mechanism on the track in the approximate position required
using two M6 socket head cap screws, two spring washers, and two washers.
c. Leave the reject mechanism loose by hand tightening the fasteners only.
d. Secure the reject mechanism in place using previously fitted bolts.
e. Torque fasteners to 5.6 ft-lb. (7.6 Nm).
f. Adjust the angle and depth of the the reject mechanism as required. Loosen 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 on the track in the approximate position required using
four M6 socket head cap screws, two spring washers, and two washers.
c. Leave the sample head loose by hand tightening the fasteners only.
d. Secure the sample head in place using previously fitted fixings.
e. Torque fasteners to 5.6 ft-lb. (7.6 Nm).
f. Adjust the sample head height to the track as required to suit pack thickness.
Loosen side bolts to adjust the height on the slots and then tighten them when
aligned to the required pack height.
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15
Installation
16
Rosemount CT4215
Startup
4
Startup
The Leak Detection System must be installed and fully commissioned by qualified
Rosemount™ personnel prior to customer operation.
1.
Turn the unit isolator switch (shown below) to the ON position.
Once power has been started, the system takes approximately two minutes to boot.
Figure 4-1: Isolation Switches
2.
3.
Ensure the compressed air supply is open.
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 green light
on the beacon.
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Startup
18
Rosemount CT4215
Shutdown
5
Shutdown
Complete the following steps to safely shut down the system when it is not in use.
CAUTION!
EQUIPMENT DAMAGE
Failure to follow the correct shutdown procedure may damage 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).
Figure 5-1: Shutting Down the System
This shuts down the HMI.
2.
Turn the unit isolator to the OFF position.
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Shutdown
NOTICE
Turning the unit isolator switch to OFF switches the 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.
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Rosemount CT4215
Operation
6
Operation
The packaged Leak Detection System is designed to run autonomously with minimal user
green light to run.
There are up to three components mounted onto the packaged production line. The
Figure 6-1: Schematic Layout of the System On Line
The packs flow 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 the production line without
the need to stop the line. The distances between the components is set at the time of
install and is determined by the speed of the production line.
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Operation
6.1
Leak detector manager (LDM) software
The LDM software is designed to give clear information at-a-glance.
Figure 6-2: LDM Home screen
A.
Start/Stop Monitoring: Automatically starts monitoring during startup. Pressing the button again
will pause the system and stop measuring.
B.
C.
D.
E.
Configure: Accesses the settings and parameters of the system and is password protected.
Reset Alarms: Clears alarms and resets status alarms to green.
Reset Counters: Returns the counters to 0.
Reports: Accesses the logging features of the system. Use a USB to log and export production
statistics and rejection data.
F.
G.
H.
I.
Power Down: Safely shuts down the HMI.
Counters
Tab selection: Toggle between the three tabs to change which visual information is displayed.
B. Concentration: Displays the CO2 measurement plot and shows a spike for a leaking pack (see
C. UNIT: Displays the measurement plot between the gates, refreshing for each pack (see
22
Rosemount CT4215
Operation
Figure 6-3: Concentration Tab
the blue 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.
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23
Operation
6.2
Data logging and reporting
The system can store production statistics like packs processed and number of rejects. This
can be transferred from the HMI on a USB stick to be analyzed elsewhere.
To enable the Reporting screen, click the Reports tab. The Reporting screen is password
protected, and the password will be supplied or changed during installation.
Figure 6-5: Reports Popup Window
A.
B.
C.
D.
E.
Enable/Disable Reports: Turn reporting on or off.
Delete Report: Delete a file from a specified location.
Create report: Set the file name and save location.
Save Report: Save the current file to a specified location.
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 stick and process it elsewhere. If you open the
file using Microsoft® Excel or a similar program, it will look like the example below.
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25
Operation
Figure 6-6: Sample Report File
•
•
•
Client/Product/Batch: These are entered during the creation of the log file.
Date/Time: The timestamp for each unit; this is set by the PC.
Leak (abs): The maximum concentration value for each unit. If this value is greater than the upper
threshold, this package will be rejected.
•
Leak (cal): For certain applications, a calibration factor may be applied in order to have units for
leakage (i.e., bubbles/second 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 want to view only rejected packages, then filter column Hto show only rows with 1in them.
NOTICE
The CanInfo type is logged for all units processed; the Reject type only shows the reject value.
26
Rosemount CT4215
Operation
6.3
Status lamps / errors
There are a number of errors that the Leak Detection System monitors, which may occur
during the normal operation of the system. The errors are displayed as an illuminated lamp
on the front of the enclosure. All errors latch and are cleared by the RESET button on the
front of the enclosure. The errors are detailed below and, when activated, will trigger the
red beacon bulb and line stop (if applicable).
Figure 6-7: Cabinet Status Indicators
A.
B.
C.
D.
Alarm beacon: Green for healthy; red for unhealthy/line stop.
RESET button to clear latched alarms.
AIR status bulb. Illuminates when blower or compressed air is off.
Blower status: A status bulb turns on when power is supplied to the blower. If the power is
interrupted, the bulb doesn't turn on, and the AIR warning bulb turns on.
Reference Manual
27
Operation
Figure 6-8: LDM Software Errors
1.
2.
System Ready: Shows when the system is ready for use. This is red during system
start up.
System Healthy: The system can become unhealthy if the gate in/out count is
different or if there have been n consecutive rejects (the default value is five
consecutive rejects). Press Reset counters on the HMI to clear the error.
3.
4.
5.
Laser Healthy: The laser becomes unhealthy if it is below the threshold value (see the
is above the threshold.
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 clears when the pulse amplitude is above the warning threshold.
Too many Consecutive Rejects: If several packs are rejected in a row, this error is
the Reset Alarms button on the touch screen.
28
Rosemount CT4215
Operation
Figure 6-9: Consecutive Rejects Error
6.4
Line stop
The control system provides a signal that can stop the production line if there are errors on
the system.
free contact and can be configured in Normally Closed (NC) and Normally Open (NO) from a
customer supplied 24 V.
Table 6-1: Line Stop Plug Pin Numbering
24 V line
0 V line
Normally Closed (NC)
Normally Open (NO)
1
3
2
2
The overall system is high when healthy (green light) and low when unhealthy (red light).
Reference Manual
29
Operation
6.5
PLC configuration screen
CAUTION!
EQUIPMENT DAMAGE
The PLC settings directly control the analysis and rejection of defective containers. Only trained
personnel should change the settings listed below. The PLC screen has password protection in
order to prevent unauthorized access. The credentials are 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.
Figure 6-10: PLC Configurable Parameters
Figure 6-11: PLC Configuration Screens
30
Rosemount CT4215
Operation
Table 6-2: PLC Configuration Parameters
Parameter name
Description
Range
Pack Length
The length of time a pack takes to pass 0 - 2000 ms
the input gate. This timer is a de-
bounce to prevent double counting of
uneven packs.
Measurement Start
Measurement End
The delay between the pack passing
the input gate and the sensor count-
ing it IN and beginning analysis.
0 - 9000 ms
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 length of time for which the rejec- 10000 ms
tion solenoid is open for rejection.
Reference Manual
31
Operation
32
Rosemount CT4215
Maintenance
7
Maintenance
The packaged Leak Detection System is inherently reliable at reducing the requirement for
routine maintenance. This section provides information on the schedule of maintenance
you should perform to ensure the reliable performance of the system.
WARNING!
ELECTRIC SHOCK
For all maintenance inside the lower section of the console, the system must be powered off
dangerous voltages.
7.1
7.2
Scheduled maintenance
The maintenance activities and their related frequencies are shown below.
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 threshold (default 0.4 V), then
Figure 7-1: Error Message for Pulse Amplitude below Warning Threshold
The system performance is not affected and runs as normal, but consider purging the cell
or prepare to clean the cell mirrors soon.
Reference Manual
33
Maintenance
If the laser pulse amplitude drops below the laser threshold (default 0.2 V), the Laser
Healthy alarm turns red, and the LASER bulb on the front of the control system is red. At
this point, the line stops, because of the red light; clean the mirrors.
Figure 7-2: Error Message for Pulse Amplitude below Threshold
Procedure
1.
2.
3.
4.
5.
6.
Switch off the BLOWER ISOLATOR and compressed air supply.
Open the upper enclosure to see the red measurement cell jacket.
Release the two clamps on top of the cell lid.
Remove the top cover of the cell jacket.
Remove the black cell cover.
Use only Thor Labs lens cleaning tissue (P-5000-0613) to gently wipe the mirrors on
CAUTION!
EQUIPMENT DAMAGE
Avoid skin contact with the mirrors as oils can be deposited.
Figure 7-3: Cleaning the Cell Mirrors
34
Rosemount CT4215
Maintenance
7.
Once the mirrors have been cleaned, check the pulse amplitude on the HMI and
ensure it is > 0.4 V, resetting any alarms.
8.
9.
Replace the black cell lid, red cell cover, and clamps.
Switch on the BLOWER ISOLATOR and press the Purge button for a few short bursts.
10. Clsoe the upper enclosure and reset any alarms.
7.3
Air filter
The air filter is located externally at the rear of the upper enclosure 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.
2.
Isolate the blower so that there is no air flow through the filter and cell.
Figure 7-4: Removing the Circlip from the Filter Housing
3.
Remove the end fitting from the filter housing, taking care not to damage the O-ring
Reference Manual
35
Maintenance
7.4
Control system
The leak detector system is inherently tolerant to high levels of contamination/dust
without a reduction in performance.
Depending on the factory cleaning regulations, wipe down the control cabinet with
suitable cleaning products as required. Emerson™ recommends doing this monthly.
7.5
7.6
Sample head
The sample head comes into contact with packages, so it should be cleaned and inspected
in line with the factory standards. Only clean the sample head when the system is switched
off, compressed air is off, and the conveyor is off.
Recommended spare parts
The following parts are available from Emerson™.
Table 7-1: Spare Parts
Part number
Part description
Valve, solenoid
P-6000-00358
P-6000-00357
P-6000-00355
P-6000-00495
B-6000-0007-C
E-4004-6002-B
E-4004-6001-D
E-4001-9001-B
M-3000-0936 Assy
M-3000-1367-B
P-6001-00052
P-6000-00139
P-6000-01303
B-6000-0007-C
Filter/regulator, 40 m
Filter 0.01 m
Lens cleaning tissue (pack of 5)
PCB, digitiser, Mk5
PCB, motherboard
PCB, pulse module
PCB, opto
Assy, cell mirror
Assy, pneumatic plate
Module, detector
Relay, 110 Vac
Blower, side channel
PCB, digitiser
Reference Manual
37
Maintenance
38
Rosemount CT4215
Troubleshooting and diagnostics
8
Troubleshooting and diagnostics
The Rosemount™ CT4215 leak detection system is designed to run unattended and to
recover from system issues where possible. This section is designed to assist in the
identification and solution of potential problems. If in doubt, contact Rosemount™
customer services for clarification on solutions before continuing.
Table 8-1: Possible Problems and Solutions
Fault symptom
Order of troubleshooting
Action or item to be replaced
System is not switching on.
Check the mains power is connected
and on at the supply. (There may be a
customer-provided circuit breaker fit-
ted in a nearby cabinet).
Reset customer MCB if tripped.
Check the system isolator is set to the Switch the isolator ON.
ON position.
Check the 12/24 V MCBs Q1/Q2 have Reset MCBs if tripped.
not tripped.
Check inside AC distribution 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- Default values for the UDP addresses
uration screen and Setup screen.
are 65501 and 65502.
Check the laser ribbon cable.
Reconnect the cable (do not hot plug
if loose).
Check the detector ribbon cable and
SMA.
Reconnect the cable (do not hot plug
if loose).
Concentration graph is not updating. 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- Default values for the UDP addresses
uration screen and Setup screen.
are 65501 and 65502.
Check the laser ribbon cable.
Reconnect the cable (do not hot plug
if loose).
Check the detector ribbon cable and
SMA (do not hot plug).
Reconnect the cable (do not hot plug
if loose).
Reference Manual
39
Troubleshooting and diagnostics
Table 8-1: Possible Problems and Solutions (continued)
Fault symptom
Order of troubleshooting
Action or item to be replaced
Maintenance alarm on LDM.
If the pulse is below the LASER warn-
ing threshold, consider purging the
cell with compressed air.
Purge the cell.
Note
The system will still be healthy.
Consider cleaning the cell mirrors
soon when pulse is below threshold.
Clean the mirrors.
Clean the mirrors.
Laser unhealthy.
If the pulse is below the laser thresh-
old, clean the cell mirrors.
Check the laser beam path for ob-
structions.
Clear any obstructions from the laser
beam path.
System unhealthy.
If the pulse is below the laser thresh-
old, clean the cell mirrors.
Clean the mirrors.
Check the laser beam path for ob-
structions.
Clear any obstructions from the laser
beam path.
If the system has rejected n consecu-
tive rejects, press the Reset alarms
button on LDM.
Press the Reset button (see
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- Confirm the supply pressure. (See
sure is within the specified range of
the pressure switch (0.3 - 0.5 MPa).
Pressure switch should be green.
Section 2.4 for location of the pressure
regulator).
Traffic light is red and does not reset
to green when Reset pressed.
Check if the LDM dasboard is green.
Repeat the rows Laser unheathy and
System unhealthy above.
Check if the AIR warning light is illumi- Repeat the row AIR warning light illu-
nated. minated above.
System is not counting packs.
Check the INPUT gate cable is attach- Attach the cable (do not hot plug if
ed at both ends: control system and
light gate.
loose).
40
Rosemount CT4215
Troubleshooting and diagnostics
Table 8-1: Possible Problems and Solutions (continued)
Fault symptom
Order of troubleshooting
Action or item to 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.
Reference Manual
41
Troubleshooting and diagnostics
42
Rosemount CT4215
Specifications
Appendix A
Specifications
The following table shows the general characteristics of the Leak Detection System.
Table A-1: System Specifications
Item
Measurement
Notes
Control enclosure
Dimensions
33 x 23 x 69 (74) in.
Depth x width x height (top of beacon)
840 x 588 x 1743 (1900) mm
Weight
268 lb.
119 kg
Sample head
Dimensions
19 x 20 x 13 in.
Depth x width x height
480 x 500 x 320 mm
Weight
30.9 lb.
14 kg
Detectable gases
Standard
Ethanol - drinks
CO2 - food
Specify on order
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
System power consumption
Factory air supply
110/240 Vac, 50/60 Hz
600 W
Specify on order
Maximum power requirement
Clean, dry, and oil free
116 psi to 145 psi
8 to 10 Bar
Line space requirement
Air filter particulate filter
3.9 ft.
1.2 m
Standard free line (approximate, de-
pendent on line speed)
5 µm
Inline filter
Reference Manual
43
00809-0100-4245
Rev AB
2018
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