ABB LS4000 User manual

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
LS4000
Diode laser analyzer
Version for measuring NH3and H2O
Highest precision under
harshest conditions
Measurement made easy

2 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Contents
Preface..............................................................................................................................4
Safety instructions......................................................................................................... 5
Description........................................................................................................................................................6
Design and measuring principle.................................................................................. 6
Specifications.................................................................................................................. 8
Labels.............................................................................................................................. 10
Preparing for installation..............................................................................................................................13
Preparing the system .................................................................................................. 13
Preparing the installation site ................................................................................... 14
Process purging............................................................................................................ 16
Scope of supply and delivery.......................................................................................17
Laying out tools and support materials .................................................................. 18
Determining cable runs and line runs....................................................................... 19
Installing components .................................................................................................................................. 20
Option: Installing the insertion tubes ............................................................... 20
Providing an overview .................................................................................................20
Installing insertion tubes............................................................................................ 21
Option: Installing the isolation flange................................................................22
Providing an overview ................................................................................................. 22
Follow the safety information ................................................................................... 23
Installing the isolation flange .................................................................................... 24
Installing the purging flanges..............................................................................26
Providing an overview .................................................................................................26
Installing the purging flanges.................................................................................... 27
Roughly pre-aligning the purging flanges............................................................... 28
Connecting the purging lines..................................................................................... 32
Option: Installing the validation cell...................................................................33
Providing an overview ................................................................................................. 33
Installing the validation cell........................................................................................34
Installing the transmitter unit and receiver unit...............................................35
Providing an overview ................................................................................................. 35
Installing the transmitter unit and receiver unit ....................................................36
Connecting the electrical leads ....................................................................................................................37
Providing an overview ................................................................................................. 37
Observing cable specifications .................................................................................38
Protecting the line voltage supply ............................................................................39
Installing the junction box ..........................................................................................40
Fitting the cable clips and line brackets .................................................................. 41
Selecting a suitable cable gland ................................................................................42
Leading cables through cable glands.......................................................................43
Establishing a protective grounding........................................................................44
Connecting the transmitter unit to the junction box............................................45
Connecting the receiver unit to the junction box ..................................................46
Option: connecting the T/P probes to the junction box ...................................... 47
Connecting the analog and digital outputs to the junction box ........................48
Connecting equipotential bonding...........................................................................49
Connecting the power supply....................................................................................50
Gas analyzer start-up.....................................................................................................................................51
Testing and approving gas analyzer......................................................................... 51
Connecting the supply voltage.................................................................................. 53

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O3
Recognizing the operating status.............................................................................54
Connecting the PC to the junction box....................................................................55
Connecting to the instrument software..................................................................56
Menu structure of the instrument software ........................................................... 57
Main menu .....................................................................................................................58
System time menu .......................................................................................................59
Fine alignment of the purging flanges.....................................................................60
Alignment menu............................................................................................................62
Installation procedure menu......................................................................................63
Installation - Cable length menu................................................................................64
Installation - Process parameters menu..................................................................65
Installation - Installation flanges menu.................................................................... 67
Installation - Ambient conditions menu ..................................................................69
Installation - Channels menu......................................................................................70
Installation - Analog and digital outputs menu...................................................... 72
Installation - Save settings menu.............................................................................. 74
Maintaining and servicing the gas analyzer................................................................................................75
Schedule ......................................................................................................................... 75
Monitoring optical transmission............................................................................... 76
Checking and cleaning the components.................................................................. 77
Testing the analyzer..................................................................................................... 79
Connecting to the instrument software.................................................................. 81
System information menu..........................................................................................82
Instrument status menu .............................................................................................83
Verification of I/O modules menu ............................................................................84
Diagnostics menu.........................................................................................................85
Service menu .................................................................................................................86
Network settings menu...............................................................................................87
Spectrum menu ............................................................................................................88
Logging menu ...............................................................................................................89
Validating and calibrating the gas analyzer ...............................................................................................91
Validating the gas analyzer..................................................................................91
Preparing for validation .............................................................................................. 91
Validation .......................................................................................................................93
Validate using the internal validation cell................................................................94
Checking absorption lines in the spectrum ............................................................96
Calibrating the gas analyzer ................................................................................97
Installing the calibration set ...................................................................................... 97
Temporarily changing the configuration...............................................................100
Calibration ...................................................................................................................103
Calibration options menu.........................................................................................105
Calibration settings menu........................................................................................106
Calibration menu ........................................................................................................ 107
Continuing measuring mode ...................................................................................108
Recognizing and resolving errors.............................................................................................................. 109
Error messages in "Measuring" mode....................................................................109
Error messages in "Malfunction" status ................................................................ 110
Gas analyzer shutdown................................................................................................................................ 112
Ending operation and shutting down the gas analyzer.......................................112
Disassembling the gas analyzer ...............................................................................113

4 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Preface
This operating instruction contains all the information necessary for the safe
and compliant installation, start-up, operation and maintenance of the gas
analyzer.
Analyzer data sheet
The version of the delivered gas analyzer is described in the "Analyzer data
sheet" supplied with the gas analyzer.
DVD-ROM "Software tools and technical documentation"
The DVD-ROM "Software tools and technical documentation" with the follow-
ing contents is included in the scope of supply of the gas analyzer:
Software tools
Operating instructions
Data sheets
Technical information
Certificates
Internet
You will find information on ABB Analytical products and services online at
http://www.abb.com/analytical.
Service contact
If the information in this operating instruction does not cover a particular
situation, ABB Service will be pleased to supply additional information as
required. Please contact your local service representative. For emergencies,
please contact
ABB Service,
Telephone: [phone], Fax: [phone] 29031,
E-Mail: [email protected].com
indicates safety instructions that must be followed when handling
the gas analyzer in order to prevent danger to the user.
indicates specific information on the operation of the gas analyzer
as well as on the use of these operating instructions.
1, 2, 3, … identifies reference numbers in figures.
Content of the
operating instruction
Additional
information
Symbols and
typefaces in the
operating instruction

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O5
Safety instructions
The gas analyzer is designed for the continuous measurement of the concen-
tration of individual components in a gas mix.
Any other use is not approved.
The intended use also includes taking note of this operating instruction.
The transmitter unit, receiver unit and junction box must be
properly grounded to prevent electrical hazards and disturb-
ances.
The glass lenses of the transmitter unit and the receiver unit
must be protected against mechanical influences.
The analyzer must only be installed in accordance with regional
and national regulations.
Installation and connection work must only be performed by
qualified personnel.
The analyzer must only be operated in accordance with regional
and national regulations.
Only genuine spare parts from the manufacturer may be used to
replace mechanical, electrical and optical components.
Classification Standard Degree of protection
Safety of electric devices EN 61010-1 Protection class I
Safety of laser devices EN 60825-1 Laser class 1
Intended use
General safety
instructions
Safety when
installing and
connecting
Safety when
operating
Safety during
maintenance, service
and repair work
Applied safety
standards

6 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Description
Topic Page
Design and measuring principle.......................................................................... 6
Specifications.......................................................................................................... 8
Labels...................................................................................................................... 10
Design and measuring principle
No. Meaning
1 Receiver unit
2 Transmitter unit
3 Process gas
4 Optical path length of the laser beam
5 Connection cable between receiver unit and junction box
6 Connection cable between transmitter unit and junction box
7 Junction box
8 Power supply
9 T/P probe(s)
10 PC
11 Analog and digital outputs
The analyzer consists of a transmitter unit and a receiver unit, which are in-
stalled opposite one another on a process line or stack and connected to each
other via a junction box.
The following components are connected to the junction box:
Transmitter unit and receiver unit
T/P probe(s) for dynamic temperature and pressure correction (depending
on application)
Power supply
Sensors for analog and digital outputs
A PC can be temporarily connected to the junction box for service purposes.
Analyzer design

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O7
The LS4000 uses the optical measurement method of tunable diode laser
absorption spectroscopy (TDLAS), which is based on the fact that gases ab-
sorb light of specific wavelengths.
In this method, a configurable laser diode in the transmitter unit emits a laser
beam, which passes through the process gas and shines onto the photode-
tector in the receiver unit. The molecules of the measuring components lo-
cated in the optical path of the laser beam absorb the laser light, thereby
reducing the light intensity at the receiver.
A sophisticated signal algorithm records the measured reduction in light in-
tensity and uses this value to calculate the gas concentration in accordance
with the Beer-Lambert law. The influence of temperature and pressure varia-
tions is eliminated by a dynamic automatic correction function.
Analyzer measuring
principle

8 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Specifications
Specifications
Dimensions (W x H x D) 118 x 163 x 237 mm
Weight 4.1 kg each
Installation location Suitable for outdoor use
Ambient temperature Operation: -20...+55 °C,
Storage: -40...+70 °C
Relative humidity Up to 80 % at max. +31 °C, linearly de-
creasing to 50 % at +40 °C
Operating voltage DC 24 V nominal (DC 18...32 V)
Total power consumption max. 10 W
Housing protection IP65
IP rating III
Specifications
Dimensions (W x H x D) 300 x 200 x 155 mm
Weight 4.7 kg
Housing protection IP65
Installation location Suitable for outdoor use
Ambient temperature Operation: -20...+55 °C
Specifications
Operating voltage AC 100...240 V ± 10 %; 50...60 Hz
Power consumption 30 VA
IP rating I
Overvoltage category II
Degree of pollution 2
Safe isolation Safety extra-low voltage (SELV) on the low
voltage side
Overload protection Voltage and current limitation
Transmitter unit and
receiver unit
Junction box
Power supply
(in the junction box)

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O9
Specifications
Analog outputs Three 4...20 mA outputs (one per measur-
ing component and for transmission), load
max. 500 Ω, not insulated
Analog inputs Two 4...20 mA inputs for dynamic process
temperature and pressure correction, load
max. 100 Ω, not insulated
Digital outputs Two outputs: 2 pin with DC/AC 30V/1A
NO contacts wired in accordance with the
requirements for Class 2 circuits 1)
Service port Ethernet 10/100BASE-TX
1) Class 2 circuits are energy-limited circuits with a maximum voltage of
AC 30 V or 42 V, a maximum current of 5 A and a maximum power of
100 VA.
Safety Tested to EN 61010-1:2010
Safety in accordance with U.S.
and Canadian standards – UL,
CSA
The LS4000 gas analyzer is certified for use
in “General Purpose” environments. It is in
line with the CAN/CSA-C22.2 no. 61010-1-12
and UL no. 61010-1 (3rd Edition) standards.
EMC: Interference immunity Testing in accordance with EN 61326-1:2013
Testing accuracy for industrial sector,
fulfills at a minimum the evaluation criteria
in accordance with Table 2 of EN 61326-1.
EMC: Emission interference Testing in accordance with EN 61326-1:2013
Limit Class B for interference field strength
and interference voltage is complied with.
The permissible environmental conditions for the transmitter unit
and receiver unit may differ from those of the junction box.
In such instances, compliance with the limit values of all modules
must be guaranteed by means of a suitable spatial arrangement on
site.
Inputs and outputs
(in the junction box)
Safety and
electromagnetic
compatibility

10 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Labels
No. Meaning
1 Name plate
2 Laser warning
The transmitter unit and receiver unit are each fitted with a name plate.
No. Meaning
1 Details of the manufacturer
2 Model name
3 Transmitter unit, receiver unit
5 Permissible ambient temperature for operation
Transmitter unit and
receiver unit:
position of labels
Transmitter unit and
receiver unit:
deciphering name
plates

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O11
No. Meaning
6 Supply voltage and power consumption
7 CE mark
8 CSA marking
9 EFUP marking (EFUP = environment friendly use period): 50 years
of operating time in accordance with the EU's RoHS Directive
without any leaks of substances hazardous to health or the envi-
ronment under normal conditions of use
10 Symbol: See operating instructions
11 Serial number, displayed as a bar code and in plain text
The transmitter unit and receiver unit are each fitted with a laser warning.
Meaning:
Class I infrared laser beam invisible to the human eye.
No. Meaning
1Details of the manufacturer
2Model name
3F-no. = Manufacturing number, A no. = Order no.
4Supply voltage and power consumption
Transmitter unit and
receiver unit:
deciphering the laser
warning
Junction box:
interpreting the
name plate

12 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
No. Meaning
5Sample component and measuring range
6Symbol: See operating instructions
7CSA marking
8EFUP marking (EFUP = environment friendly use period): 50 years
of operating time in accordance with the EU's RoHS Directive
without any leaks of substances hazardous to health or the envi-
ronment under normal conditions of use
9CE mark

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O13
Preparing for installation
Topic Page
Preparing the system ...........................................................................................13
Preparing the installation site ........................................................................... 14
Process purging.....................................................................................................16
Scope of delivery ...................................................................................................17
Laying out tools and support materials ...........................................................18
Determining cable runs and line runs................................................................19
Preparing the system
Perform the following steps in accordance with the system documentation:
Step Procedure
1 Shut down the system in which the laser analyzer is to be fitted.
2 Wait until the system temperature has fallen to its original level.
3 Ensure that the system is no longer pressurized.
4 Secure the system against startup.
Shutting down and
securing the system

14 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Preparing the installation site
Installation flanges must be fitted to the process line opposite one another at
the laser analyzer installation site.
The installation flanges at the installation site can be designed as follows:
The installation flange forms part of a valve that is welded to the process
line.
The installation flange forms part of a valve that is flanged to the process
line.
The installation flange is welded to the process line.
Ensure that the installation flanges have the correct dimensions.
Dimensions of the installation flange with DN 50/PN 10-40 DIN EN 1092-1
Form A (DIN 2526 Form B) – Smooth (machined) sealing surface
No. Meaning Dimension Tolerance
1Outer diameter 165 mm Max. ± 0.5 mm
2Pitch circle diameter 125 mm Max. ± 0.3 mm
3Internal diameter 49.7...65.3 mm
4Hole diameter 18 mm Max. ± 0.2 mm
Installation flange dimensions for ANSI 2 in./150 lbs – Smooth sealing sur-
face (flat face)
No. Meaning Dimension Tolerance
1Outer diameter 152.4 mm Max. ± 0.5 mm
2Pitch circle diameter 120.6 mm Max. ± 0.3 mm
3Internal diameter 49.7...65.3 mm
4Hole diameter 19 mm Max. ± 0.2 mm
Fitting the
installation flanges
at the installation
site
Dimensions and form
of the installation
flange

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O15
Ensure that the installation flanges are as parallel to one another as possible.
No. Meaning Tolerance
1Installation flange symmetry axes
290° to the axle of the installation flange for the
transmitter unit
Max. ± 1.5°
390° to the axle of the installation flange for the
receiver unit
Max. ± 1.5°
To the greatest degree possible, ensure that the orifice installation flanges
are not offset.
No. Meaning Dimension
1-2 Imaginary connection lines between the trans-
mitter unit and the receiver unit
3-4
5Clearance for installation flanges DN 50 and
ANSI 2 in.
Min. 40 mm
Once the installation flanges are fitted, it is advisable to close them with blind
flanges until the analyzer is installed.
If... then...
all values are within the tol-
erancerange
the installation process can be started.
one or more values are outside
the tolerance range
the laser analyzer must not be installed.
Parallel installation
flanges
Installation flange
offset
Installing blind
flanges
Approving start of
installation

16 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Process purging
Process purging is a continuous purging process used to protect the optical
surfaces (lenses) against the build-up of dirt. This process also cools the
transmitter and receiver units.
The purging medium is connected to the purging flange and flows into the
process, where it mixes with the process gas.
Ensure that a purging flange is fitted for both the transmitter unit and the
receiver unit.
Ensure that the purge air can be monitored. Failure of the purging process
can result in irreversible damage to the lenses and cause the transmitter and
receiver units to overheat.
The following are suitable for use as purging fluids, depending on the applica-
tion (see data sheet):
Compressed air or
Nitrogen
Compressed air quality: dry and oil-free (in accordance with ISO 8573.1, Class
2-3)
Recommended pressure: typically around 25 % above the process pressure.
Recommended flow rate: 20–100 l/min.
If... then...
all requirements are met the receiver unit and the transmitter unit
can be installed.
one or more of the requirements
are not met
the receiver unit and the transmitter unit
must not be installed.
To avoid damage to the parts of the gas analyzer affected by the process gas,
process purging should be commissioned right after the gas analyzer is in-
stalled.
Ensuring purging
Ensuring purge air
monitoring
Checking purging
medium
requirements
Purging after
installation

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O17
Scope of supply and delivery
Unpack all parts included in the scope of delivery.
Ensure that all delivered parts match your order.
Quantity Designation
1 Transmitter unit with connection cable and protective cap for the
lens
1 Receiver unit with connection cable and protective cap for the lens
1 Junction box, power supply unit fitted, cable glands pre-installed
1 Ethernet adapter
2 Purging flanges with seals and fastening clips (as per the order)
1 Analyzer data sheet (in the junction box)
1 Operating Instruction
1 DVD-ROM "Software tools and technical documentation"
Accessories included as per customer order
Keep the transport packaging of the transmitter unit and receiver unit for any
possible required transport in the future. Keep the yellow protective caps of
the lenses for service purposes. Dispose of the remaining packaging material
in accordance with local regulations.
Finally, check that all parts are complete and in perfect condition.
If... then...
all parts are in perfect condition the installation process can be started.
one or more parts are missing or
are not in perfect condition
the laser analyzer must not be installed.
Unpacking devices
and accessories
Identifying devices
and accessories
Keeping or disposing
of packaging
material
Final check

18 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Laying out tools and support materials
Lay out the following tools:
Quantity Tool Size
1 Spanner 13 mm
1 Spanner 16 mm
2 Spanner 24 mm
1 Slot screwdriver 3 mm or 4 mm
1 Slot screwdriver 6.5 mm
1 Phillips screwdriver Phillips No. 2
1 Allen key 5 mm
Lay out the following support materials:
Quantity Tools
1 Laser alignment tool (optional)
Laying out tools
Laying out support
materials

OI/LS4000/NH3/H2O-EN Operating instruction LS4000 for NH3and H2O19
Determining cable runs and line runs
The cable runs must meet the following requirements:
No crossing of walkways
No risk of mechanical stress
No chemical or corrosive influences
No extreme temperature effects
Possibility of secure cable attachment
Lay out all cables and lines for connecting the devices.
Select the cable lengths and line lengths according to the conditions in the
area.
For details of cable specifications, see Observing cable specifications (see
page 38).
The cable clips and line brackets must meet the following conditions:
They must allow the cables and lines to be laid securely.
It must be possible to open the cable clips and line brackets to allow the
cables and lines to be removed temporarily for calibration of a separate
calibration set or for servicing.
Determining cable
runs and line runs
Laying out cables and
lines
Requirements for
cable clips and line
brackets

20 Operating instruction LS4000 for NH3and H2OOI/LS4000/NH3/H2O-EN
Installing components
Topic Page
Option: Installing the insertion tubes .............................................................. 20
Option: Installing the isolation flange.............................................................. 22
Installing the purging flanges............................................................................ 26
Option: Installing the validation cell................................................................. 33
Installing the transmitter unit and receiver unit ............................................ 35
Option: Installing the insertion tubes
Topic Page
Providing an overview ......................................................................................... 20
Installing insertion tubes.....................................................................................21
Providing an overview
If... then...
the measuring section through the process
does not allow for clear laser transmission (e.g.
due to high dust load)
insertion tubes must be
installed.
the measuring path through the process en-
sures proper laser light transmission
no insertion tubes must be
installed.
Insertion tubes cannot be installed in conjunction with isolation
flanges.
No. Meaning
1Transmitter unit
2Purging flange
3Insertion tube
4Process
5Insertion tube
6Purging flange
7Receiver unit
When must insertion
tubes be installed?
Providing an
overview