Siemens LDS 6 User manual

A5E00912721D-01 GN: 30490_CD_6C
Operating Instructions Edition 05/2007
Siemens Aktiengesellschaft
Automation and Drives
Industrial Automation Systems
Postfach 4848
90327 NÜRNBERG
GERMANY
LDS 6
In-situ Laser Gas Analyzer
Sensor CD 6C manual
www.siemens.com/processanalytics
gy gas analysis
A5E00912721-01
@A5E00912721@
A5E00912721

s
LDS 6
In-situ Laser Gas Analyzer
Sensor CD 6C manual
A5E00912721-01
Release 05/2007

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SIEMENS AG
A
utomation and Drives
Process Instrumentation © Siemens AG 2007
D-76181 Karlsruhe Subject to changes without prior notice
Siemens Aktiengesellschaft Order no. A5E00912721
Printed in Germany
AG 1004 De 0,05 90 PU

CONTENT
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Flange Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Process Flange and Purge Tube Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.3 Installation of Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.4 Measurement of Path Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 The Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Sensor Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 The Hybrid and Loop Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Cable Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.2 Identification of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 The Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.1 Installation of the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.2 Electrical and optical installation of CD 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1.3 Alignment of the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1.4 ATEX Transmitter and Receiver Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1.5 Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 CD 6C and cable overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.1.1 The Hybrid Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.1.2 The Loop Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.1.3 The CD 6C Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.1.4 The CD 6C Ex Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.1.5 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.1.1 Labels Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.1.2 Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.1.3 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.2 Repair/Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Appendix A: Toolkits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Flange Alignment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.2 Sensor Alignment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Appendix B: Gas Flow Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CD 6C – Water vapor sensor for LDS 6
Operating instructions A5E00912721-01 i

1
Introduction
Introduction
Purpose
The purpose of this manual is to provide support for Siemens ser-
vice technicians when installing, maintaining and servicing the
sensor CD 6C for the LDS 6 laser gas analyzer. This manual
describes the preparations, installation, maintenance and service
and trouble shooting. It also specifies the environmental condi-
tions 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 Guide-
lines” the instructions shall be followed in given order. The prepa-
ration checklist shall be used to check that all has been prepared
and considered at the measurement site before start of installa-
tion. To troubleshoot the system follow the work procedure and
instructions given in “Troubleshooting”. When a problem has
been located the chapter “Instructions for Maintenance and Ser-
vice” provides specific instructions on how to replace compo-
nents and maintain the set-up.
Chapter Overview
The service manual begins with a description of the sensor. In
the chapter “Technical Description” all parts of the sensor are
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 third 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 available tool kits.
Safety Guidelines
This manual contains notices which should be observed to
ensure personal safety, as well as to protect the product and the
connected equipment. These notices are marked as follows
according to the level of danger:
WARNING
Warning means that death or severe personal injury and/or substan-
tial damage to property may occur if the appropriate safety precau-
tions are not observed.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
1

Introduction
CAUTION
Caution means that slight personal injury or damage to property
can occur if the appropriate safety precautions are not observed.
NOTE
Note relates to important information on the handling of the prod-
uct or the respective part of the manual to which particular atten-
tion should be paid.
Qualified Personnel
Severe personal injury and/or extensive damage to property may
occur following unqualified installation or work on the device/
system or the failure to observe the warnings described in the
manual or on the device/system cabinet. Therefore only suitably
qualified personnel may install or work on it.
Persons considered as qualified in regards to the safety informa-
tion given in this manual and/or on the product itself are those
that:
•
are either configuring engineers familiar with the safety con-
cepts of automation technology; or
•
have been trained as operators in the use of automation tech-
nology equipment and are acquainted with the contents of
this manual which refer to operation; or
•
have been appropriately trained as commissioning and/or
maintenance personnel for such automation technology
equipment or are authorized to energize, ground and tag cir-
cuits and devices/systems in accordance to established safety
practices.
Units
The measurements in this manual are given in metric units and
in American units (in parenthesis).
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.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
2

2
Preparations for Installation
Preparations for Installation
This chapter provides pre-installation guidelines for the LDS 6
laser gas analyzer. The following requirements must be consid-
ered and the described preparations must be completed at the
measurement site before the installation of LDS 6 can be per-
formed.
2.1 Flanges
Before the gas analyzer and its sensors can be used, a pair of pro-
cess 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.
2.1.1 Flange Installation Requirements
The flanges should be welded to the wall of the furnace or fun-
nel.
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 varia-
tions 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. Remem-
ber 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.
2.1.2 Process Flange and Purge Tube Dimensions
The process flange dimensions should comply to the DIN stan-
dard (DN80/PN16) or the ANSI standard (ANSI 4”/150 lbf). The
process flange dimensions are shown in Figure 2.1 and Figure
2.2.
Customer process flanges are not supplied by Siemens.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
3

Preparations for Installation
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Figure 2.1 Dimensions of the water vapour flange (DN80/PN16).
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Figure 2.2 Dimensions of the flange ANSI 4”/150lbf.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
4

Preparations for Installation
2.1.3 Installation of Flanges
When welding the flange tubes it is recommended to have the
Flange Alignment Kit (see Appendix G). The Flange Alignment
Kit from Siemens consists of a light source, two flanges, an aim-
ing 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 work-
ing space around the sensors are also needed, guardrails, lad-
ders, etc. The sensor dimensions are described in 2.2 “The Sen-
sors” on page 8.Figure 2.3 illustrates the process for installation
of flanges.
Installing the Flanges
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Figure 2.3 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 (as illustrated in Figure 2.3).
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 centred 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 per-
manently welded.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
5

Preparations for Installation
NOTE
It is important that the flanges are aligned from both sides. There-
fore, 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 Figure 2.4.
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Figure 2.4 Customer flange alignment
The Flange Alignment Kit also provides information on how to
measure the deviation (the error angle) using the flange align-
ment tools. This is described in a graph that shows the error
angle as a function of the light spot distance from the centre (see
Figure 2.5 on next side).
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
6

Preparations for Installation
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Figure 2.5 The error angle
2.1.4 Measurement of Path Length
It is recommended that the open end of the purging tubes are
the reference points from which the path length is determined.
When the flanges are permanently installed, measure the dis-
tance between the outside of the flanges (measurement A in Fig-
ure 2.4) with an accuracy of at least ±10 mm (±0.4”). This dis-
tance is used to calculate the path length (by subtracting the
length of the flanges from A) and will later be used in the ana-
lyzer 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.This is further
described in Appendix B.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
7

Preparations for Installation
2.2 The Sensors
The following requirements must be considered before installing
the sensors at the measurement site.
2.2.1 Sensor Installation Requirements
For systems with purging, do not install the sensors without
access to purging air. 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 sen-
sors. Figure 2.6 shows the dimensions of the sensors.
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Figure 2.6 The dimensions of the sensors
1. High pressure flange.
2. Sensor purging check valve.
3. Process purging check valve. (only if process purging is applied)
2.3 The Hybrid and Loop Cables
The following requirements must be considered before installing
the cables at the measurement site.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
8

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Preparations for Installation
2.3.1 Cable Installation Requirements
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 tempera-
ture and any parts the cables come in contact with.
Always protect the single mode fibre (E2000 connector with
green colour) from dust. Cables are supplied with a protective
tube at each end and inside these a plastic protective cap for the
single mode fibre.
NOTE
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/sen-
sor. The protective tubes should only be removed by authorized per-
sonnel.
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 sys-
tems. Figure 2.7 shows the pre-requisites for installation of the
cables.
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Figure 2.7 Cable handling
2.3.2 Identification of Cables
All cables are marked with identification tags, as follows:
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
9

Preparations for Installation
HXXXA or HXXXB, where H means Hybrid cable. 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 Sie-
mens 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.
LXXX are loop cables and are the same for all systems. Loop
cables are installed between the transmitter sensor and the
receiver sensor.
2.4 Checklist
Go through the following points before beginning the installa-
tion 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 fun-
nel 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 fun-
nel.
•
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 have 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.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
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3
Installation Guidelines
Installation Guidelines
This chapter provides instructions for the installation of the CD
6C sensors and cables. Figure 3.1 below shows the principle set-
up of the LDS 6 central unit, sensors and cables.
N2purging intake
LDS 6
Hybrid Cable
Sensor
(transmitter)
Sensor
(receiver)
Measurement
Volume
Loop Cable
N2purging intake
(for process, if applicable)
(for sensor head)
Figure 3.1 Principle set-up of an installation
3.1 The Sensors
3.1.1 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 connec-
tions:
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).
NOTE
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 recom-
mended 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.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
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Installation Guidelines
1
2
6
7
43
5
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)
The installation process should follow these steps.
1. Unpack the transmitter and receiver and connect them to cus-
tomer 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. Follow the sensor alignment procedure for CD 6C sensors, se
3.1.3 “Alignment of the Sensors” on page 14.
3. Reconnect the transmitter and receiver heads after the align-
ment procedure is completed.
4. Connect the fiber and electrical cables according to 3.1.2
“Electrical and optical installation of CD 6C” on page 13. Do
not touch the alignment screws (4).
CD 6C – Water vapor sensor for LDS 6
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Installation Guidelines
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 measure-
ment value might be faulty.
3.1.2 Electrical and optical installation of CD 6C
Transmitter
Install the cables, hybrid and loop cable, at the transmitter sen-
sor. Cables are fixed in the sensor with gaskets. Always use lubri-
cant on the gaskets before installing, otherwise these will be very
difficult to remove later. Multi-mode fibre (SMA connector) and
24 V are just connected straight through to the receiver.
NOTE
Always protect the single-mode fibre (E2000 connector) from dust.
Do not remove the plastic vial until the cable is firmly fastened 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.
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
13

Installation Guidelines
Connect the multi-mode fibre to the sensor-board as shown in
Figure 3.4.
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Figure 3.4 Connections in the receiver
3.1.3 Alignment of the Sensors
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 purg-
ing tube at the transmitter side:
CD 6C – Water vapor sensor for LDS 6
A5E00912721-01
14