Siemens LDS 6 User manual

A5E00912721D-02 GN: 30490_CD_6C
Operating Instructions Edition 12/2007
Siemens Aktiengesellschaft
Automation and Drives (A&D)
Sensors and Communication
Process Analytics
76181 KARLSRUHE
GERMANY
LDS 6
In-situ Laser Gas Analyzer
Sensor CD 6C manual
www.siemens.com/processanalytics
gy gas analysis
A5E00912721-02
@A5E00912721@
A5E00912721

Introduction
1
Preparations for
Installation
2
Installation Guidelines
3
Technical Description
4
Spare Parts List
5
Dimensional Drawings
6
Appendix
A
ESD guidelines
B
In Situ Laser Gas Analyzers
LDS 6
Sensor CD 6C Operating
Instructions
Operating Instructions
12/2007
A5E00912721-02

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Ordernumber: A5E00912721
Ⓟ 02/2008
Copyright © Siemens AG 2007,,
2008.
Technical data subject to change

Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 3
Table of contents
1 Introduction................................................................................................................................................ 5
1.1 Introduction ....................................................................................................................................5
2 Preparations for Installation ....................................................................................................................... 7
2.1 Flanges ..........................................................................................................................................7
2.1.1 Flange Installation Requirements ..................................................................................................7
2.1.2 Installation of Flanges ....................................................................................................................8
2.1.3 Measurement of Path Length.........................................................................................................9
2.2 Sensor Installation Requirements................................................................................................10
2.3 The Hybrid and Loop Cables .......................................................................................................10
2.3.1 Cable Installation Requirements..................................................................................................10
2.3.2 Identification of Cables.................................................................................................................11
2.4 Check list......................................................................................................................................12
3 Installation Guidelines.............................................................................................................................. 13
3.1 Installation....................................................................................................................................13
3.2 Electrical connections ..................................................................................................................16
3.3 Alignment .....................................................................................................................................17
3.4 ATEX considerations ...................................................................................................................24
3.5 Purging.........................................................................................................................................25
4 Technical Description .............................................................................................................................. 27
4.1 The Hybrid Cable .........................................................................................................................27
4.2 The Loop Cable ...........................................................................................................................27
4.3 The CD 6C sensor .......................................................................................................................28
4.4 The CD 6C Ex sensor ..................................................................................................................29
4.5 Technical Specification ................................................................................................................30
5 Spare Parts List....................................................................................................................................... 33
5.1 Spare Parts ..................................................................................................................................33
5.2 Repair/Upgrade............................................................................................................................35
6 Dimensional Drawings ............................................................................................................................. 37
6.1 Process Flange Dimensions ........................................................................................................37
6.2 Sensor Dimensions......................................................................................................................39

Table of contents
Sensor CD 6C Operating Instructions
4 Operating Instructions, 12/2007, A5E00912721-02
A Appendix.................................................................................................................................................. 41
A.1 Gas Flow Calculations ................................................................................................................ 41
A.2 Tool kits....................................................................................................................................... 42
B ESD guidelines ........................................................................................................................................ 45
B.1 ESD (ElectroStatic Discharge).................................................................................................... 45

Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 5
Introduction 1
1.1 Introduction
Purpose
The purpose of this manual is to provide support for the customer when installing,
maintaining and servicing the sensor for the LDS 6 laser gas analyzer. This manual
describes the preparations, installation and maintenance. It also specifies the environmental
conditions and space requirements.
How to Use this Manual
All instructions in this manual are marked with the symbol to the left. In "Preparations for
Installation" and "Installation Guidelines" the instructions shall be followed in given order.
The preparation checklist shall be used to check that all has been prepared and considered
at the measurement site before start of installation.
Chapter Overview
The operating manual begins with a description of the sensor. In the chapter "Technical
Description" all parts of the sensor is described.
Before the sensors can be installed there are a few things that must be prepared at the
measuring site. For example, flanges have to be welded into the measuring site and
provisions for purging the sensor must be installed. This is described in the chapter
"Preparations for Installation".
The chapter "Installation Guidelines" gives instructions for the installation of sensors and
cables.
At the end of the manual there are some Appendices containing reference documents.
These documents provide information such as ATEX set-up and instructions for purging.
Units
The measurements in this manual are given in metric units and in American units (in
parenthesis).

Introduction
1.1 Introduction
Sensor CD 6C Operating Instructions
6 Operating Instructions, 12/2007, A5E00912721-02
Trademarks
The following names are registered trademarks of Siemens AG:
● LDS 6
● LDSComm
The remaining trademarks in this publication may be trademarks, whose use by third parties
for their own purposes could violate the rights of the owner.

Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 7
Preparations for Installation 2
2.1 Flanges
2.1.1 Flange Installation Requirements
Before the gas analyzer and its sensors can be used, a pair of process flanges should be
installed at the measurement site. The flanges must be installed at a safe and accessible
position to make installation and service easy to accomplish.
The flanges should be welded to the wall of the furnace or funnel.
The flange must protrude at least 100 mm (4") from the wall and 0-30 mm (0-1.2") into the
furnace/funnel.
There are applications where furnace walls move due to variations in temperature. If the
furnace walls move the sensors will be miss-aligned and the measurement interrupted. To
overcome this, the sensor can be fixed to a girder or other structure that is not influenced by
the temperature and the flexible metal tube is fitted between the process flange and the
sensor flange. Remember that the flanges fitted for the sensors must not deviate more than
±2°.
Note
It is very important that the flanges are mounted so that they are aligned. Otherwise the
measurements will not be correct.
See also
Process Flange Dimensions (Page 37)

Preparations for Installation
2.1 Flanges
Sensor CD 6C Operating Instructions
8 Operating Instructions, 12/2007, A5E00912721-02
2.1.2 Installation of Flanges
When welding the flange tubes it is recommended to have the Flange Alignment Kit. The
Flange Alignment Kit from Siemens consists of a light source, two flanges, an aiming tool, a
battery and a battery charger for the light source.
Make sure there is enough room for the sensor. Especially take into consideration that it
should be easy to mount or dismount and that the sensors lid should be able to open fully.
Safe working space around the sensors are also needed, guardrails, ladders, etc. The figure
below illustrates the process for installation of flanges.
Installation procedure
Alignment
kit flange
Halogen
light source
Process flange
to be aligned
Aiming tool
Alignment
kit flange
Figure 2-1 Installation of flanges
1. Weld the flange tubes loosely on each side of the wall. Do not weld them so hard that the
angle of the tubes can not be adjusted with a hammer.
2. Mount the light source on one flange and the aiming tool on the other flange.
3. Turn on the light source.
4. Adjust the focus on the aiming tool until the light spot from the light source is sharp.
5. Adjust the angle of the process flange tube, using for instance a rubber hammer, until the
light spot is centered on the cross hair on the aiming tool.
6. Weld the aligned flange tube permanently into this position.
7. Shift light source and aiming tool and repeat the procedure above for the opposite flange
until the other tube also is permanently welded.

Preparations for Installation
2.1 Flanges
Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 9
Note
It is important that the flanges are aligned from both sides. Therefore, remember to shift
light source and aiming tool and repeat the procedure from the other side as well. It is
also important that the sensor flanges are oriented in such a way that the spring loaded
bolts are located in the lower section of the flange.
Flange Alignment Deviation
When both flange-tubes are permanently fixed the deviation from the theoretical optical path
must not exceed ±2°. This is because the alignment flanges can be adjusted maximum ±2°.
See the figure below.
1
2
2°
Maximum deviation
min 150 mm Approx. 25-40 mm
(including insulation)
Wall thickness
Measurement A, to be measured after installation
Figure 2-2 Customer flange alignment
2.1.3 Measurement of Path Length
It is recommended that the open end of the purging tubes be the reference points from which
the path length is determined. When the flanges are permanently installed, measure the
distance between the outside of the flanges with an accuracy of at least ±10 mm (±0.4").
This distance is used to calculate the path length by subtracting the length of the flange
tubes and will later be used in the analyzer when it calculates the gas concentration. In the
area where the purging gas and the measurement gas are mixed there will be a zone of
uncertainty. This zone will depend on the purging flow and the flow of the measurement gas.

Preparations for Installation
2.2 Sensor Installation Requirements
Sensor CD 6C Operating Instructions
10 Operating Instructions, 12/2007, A5E00912721-02
2.2 Sensor Installation Requirements
The following requirements must be considered before installing the sensors at the
measurement site.
For systems with purging, do not install the sensors without access to purging air or steam.
Be sure to have sufficient space around the sensors, to ensure easy service. There must be
enough space to enable removing of the sensor lids and adjustment of the sensors.
See also
Sensor Dimensions (Page 39)
2.3 The Hybrid and Loop Cables
2.3.1 Cable Installation Requirements
The following requirements must be considered before installing the cables at the
measurement site.
The hybrid cables should be installed in a way that protects them from mechanical wear
such as sharp edges or moving parts. Operating temperature for the cables is -40 to +80°C
(-40 to + 176°F). Installation temperature for the cables is -20 to +80°C (-4 to + 176°F).
These temperatures refer to both ambient temperature and any parts the cables come in
contact with.
Always protect the single mode fiber (E2000 connector with green color) from dust. Cables
are supplied with a protective tube at each end and inside these a plastic protective cap for
the single mode fiber.
CAUTION
DO NOT remove the protective tube until the cable is installed and ready to be connected
to LDS 6 and sensors. DO NOT remove the plastic protective cap until the cable is routed
inside the LDS 6/sensor. The protective tubes should only be removed by authorized
personnel.

Preparations for Installation
2.3 The Hybrid and Loop Cables
Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 11
The bending radius of the cable may never be smaller than 100 mm (4"). If clamps are used
there must be a minimum of 0.5 mm (0.02") clearance between cable and clamp or use
rubber coated clamps. Take extra care of hybrid cables for HCl systems since the cables are
very sensitive to the wavelength used in these systems. The figure below shows the pre-
requisites for installation of the cables.
approx. 50 cm (20")
Protection tube for the cables (one in each end).
NOTE! DO NOT remove the protective tube
until the cable is installed and ready to
be connected to LDS 6 and sensors.
The cable end protection should only be
removed by authorized personnel.
If clamps are used there must be min 0.5 mm (1/64")
clearence between cable and clamps
However it is recomended to protect the cables
into a metallic tube. Proper size of this tube is 75 mm (3").
Environment requirements:
- Installation temp. -20°C/+80°C (-4°F/+176°F)
- Max tensile strength 500 N (112 lbs)
- Impact resistance 200 N/cm (115 lbs/")
- Min. bend radius 10 cm (4")
Minimum radius = 10 cm (4")
- Operating temp. -40°C/+80°C (-40°F/+176°F)
Figure 2-3 Cable handling
2.3.2 Identification of Cables
All cables are marked with identification tags, as follows:
HXXXA or HXXXB, where H means Hybrid cable, is used for all types of systems except
oxygen. XXX is the serial number for the cable and A/B depends on the direction in which
the cable is oriented. Before cables are shipped from Siemens they are tested in both
directions A to B and B to A. It does not matter which way the cable is installed. Hybrid
cables are installed between the LDS 6 and the transmitter sensor.
OXXX are hybrid cables for oxygen systems only and are installed between the LDS 6 and
the transmitter sensor.
LXXX are loop cables and are the same for all systems. Loop cables are installed between
the transmitter sensor and the receiver sensor.
CAUTION
Make sure the operating and installation temperatures for the hybrid and loop cables are
not exceeded.

Preparations for Installation
2.4 Check list
Sensor CD 6C Operating Instructions
12 Operating Instructions, 12/2007, A5E00912721-02
2.4 Check list
Go through the following points before beginning the installation of the LDS 6 laser gas
analyzer to make sure all preparations are completed.
● The flanges shall be welded to the wall of the furnace or funnel and properly aligned from
both sides.
● Make sure that the positions of the flanges are stable. The flanges fitted for the sensors
must not deviate more than ±2°.
● Make sure that the flanges protrude at least 100 mm (4") from the wall and 0-30 mm (0-
1.2") into the furnace or funnel.
● There must be enough room for the sensors to allow easy access for maintenance and
service.
● Make sure the path length is measured properly.
● Make sure that the environment where the central unit is to be installed has the right
temperature conditions.
● Make sure there is enough space to allow free airflow around the central unit (500
mm/20" behind, 50 mm/2" above and 30 mm/1.2" below).
● Make sure the operating and installation temperatures for the hybrid and loop cables are
not exceeded.
● Make sure the process flange has an inner diameter which allows the purging tube to be
adjusted ±2 deg. (The outer diameter is 44.5 mm for the 400 purging tube and 54 mm for
the 800 and 1200 mm purging tubes).

Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 13
Installation Guidelines 3
3.1 Installation
This chapter provides instructions for the installation of the CD 6C sensors and cables. The
figure below shows the principle set-up of the LDS 6 central unit, sensors and cables.
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Figure 3-1 Principle set-up of an installation

Installation Guidelines
3.1 Installation
Sensor CD 6C Operating Instructions
14 Operating Instructions, 12/2007, A5E00912721-02
Installation of the sensors
It is necessary to remove the air moisture inside the sensor heads. The transmitter and
receiver sensor heads are delivered from the factory with readily mounted nitrogen purge
connections:
Nitrogen inlet (1), purging tube (2) and the check valve (3), see Figure 3.2 "Sensor mounting
– bottom view". The high pressure window can be purged using the check valve input (7).
If required, purging of the dry nitrogen into the process is possible. This is done by
connecting the purge nitrogen inlet (5) both to the transmitter and receiver side. A use of
check valve is highly recommended to prevent the process gas from leaking into the nitrogen
net in case of a sudden drop in the nitrogen supply net. As standard this input is delivered
with a plug.
1
2
5
3
7 6
4
Figure 3-2 Sensor mounting – bottom view
1. Purging input – sensor body.
2. Purging bypass.
3. Lens.
4. Adjustment screws.
5. Wedge window.
6. Purging output – sensor body (through check valve).
7. Purging input – process. (only if process purging is applied)

Installation Guidelines
3.1 Installation
Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 15
The installation process should follow these steps.
1. Unpack the transmitter and receiver and connect them to customer flanges using
provided M16 screws. Orientation of both the receiver and transmitter flanges has to be
such so that the check valve (3) faces downwards.
2. Align the sensor.
3. Reconnect the transmitter and receiver heads after the alignment procedure is
completed.
4. Make the electrical connections.
5. Connect the nitrogen inlet (1) both on the transmitter and receiver side to the customer
dry nitrogen net.
6. Check that all the parts are in place and the connections are tightened properly,
especially the parts being removed during the alignment procedure.
7. Open the nitrogen supply to the sensors.
8. Allow the entire system to dry down after installation. Depending on installation type it can
take from an hour up to several hours to remove residual moisture from the sensors and
customer interface.
Note
The recommended nitrogen flow rate to each sensor is 10 liter/min. The absolute
minimum rate is 6 liter/min otherwise the measurement value might be faulty.

Installation Guidelines
3.2 Electrical connections
Sensor CD 6C Operating Instructions
16 Operating Instructions, 12/2007, A5E00912721-02
3.2 Electrical connections
Transmitter
Install the cables, hybrid and loop cable, at the transmitter sensor. Cables are fixed in the
sensor with gaskets. Always use lubricant on the gaskets before installing, otherwise these
will be very difficult to remove later. Multi-mode fiber (SMA connector) and 24 V are just
connected straight through to the receiver.
Note
Always protect the single-mode fiber (E2000 connector) from dust. Do not remove the plastic
vial until the cable is firmly secured in the sensor.
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Figure 3-3 Connections in the transmitter
Receiver
Install the loop cable in the receiver sensor. Cables are fixed with gaskets. Always use
lubricant on the gaskets before installing, otherwise they will be very difficult to remove later.
Connect the multi-mode fiber to the sensor-board as shown below.
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Figure 3-4 Connections in the receiver

Installation Guidelines
3.3 Alignment
Sensor CD 6C Operating Instructions
Operating Instructions, 12/2007, A5E00912721-02 17
3.3 Alignment
In addition to the standard sensor alignment kit used with the CD 6 sensors, two alignment
adaptors are provided. The adapter marked with a blue line is used to align the receiver
sensor.
Blue line
Figure 3-5 CD 6C alignment kit
Align the sensors in the following steps:
After switching off the sensor purging, remove the sensor purging tube at the transmitter
side:
Transmitter side
Figure 3-6 Removal of the sensor purging tube

Installation Guidelines
3.3 Alignment
Sensor CD 6C Operating Instructions
18 Operating Instructions, 12/2007, A5E00912721-02
Release the transmitter lock ring using the supplied tool and remove the sensor:
Transmitter side
Figure 3-7 Removal of the transmitter lock ring
Figure 3-8 Removal of the sensor at the transmitter side