Operating Instructions Edition 11/2007 LDS 6 In-situ Laser Gas Analyzer gas g analysisy
Introduction 1 Preparations for Installation 2 In situ Laser Gas Analyzers LDS 6 Operating Instructions Installation Guidelines 3 Technical Description 4 Spare Parts List 5 Dimensional Drawings 6 Appendix A ESD guidelines B 11/2007 A5E01134377-02
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 Qualified Personnel Prescribed Usage Trademarks 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. 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. Note the following: Disclaimer of Liability 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. 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. 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: A5E01134377 P 02/2008 Copyright Siemens AG 2007. Technical data subject to change
Content 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...14 3.3 Alignment...15 3.4 ATEX considerations...20 3.5 Purging...21 4 Technical Description... 23 4.1 The Hybrid Cable...23 4.2 The Loop Cable...23 4.3 The CD 6 Sensor...24 4.4 High Pressure Flange...25 4.5 The Ex Sensor CD 6 Ex...26 4.6 Technical Specification...26 5 Spare Parts List... 29 5.1 Spare Parts...29 5.2 Repair/Upgrade...32 6 Dimensional Drawings... 33 6.1 Process Flange and Purge Tube Dimensions...33 6.2 Sensor dimensions...36 Operating Instructions, 11/2007, A5E01134377-02 3
Content A Appendix... 37 A.1 ATEX Set-up... 37 A.2 Purging of Optical Process Interface... 41 A.3 Gas Flow Calculations... 45 A.4 Tool kits... 46 B ESD guidelines... 49 B.1 ESD (ElectroStatic Discharge)... 49 4 Operating Instructions, 11/2007, A5E01134377-02
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). Operating Instructions, 11/2007, A5E01134377-02 5
Introduction 1.1 Introduction 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. 6 Operating Instructions, 11/2007, A5E01134377-02
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 as shown in the figure below. The flange must protrude at least 100 mm (4") from the wall and 0-30 mm (0-1.2") into the furnace/funnel. Figure 2-1 Sensor CD 6 mounted on a process flange 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. Operating Instructions, 11/2007, A5E01134377-02 7
Preparations for Installation 2.1 Flanges 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. Figure 2-2 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. 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. 8 Operating Instructions, 11/2007, A5E01134377-02
Preparations for Installation 2.1 Flanges 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 Figure 2-3 Customer flange alignment See also Tool kits (Page 46) Process Flange and Purge Tube Dimensions (Page 33) 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. Operating Instructions, 11/2007, A5E01134377-02 9
Preparations for Installation 2.2 Sensor Installation Requirements 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 36) 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. 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 prerequisites for installation of the cables. 10 Operating Instructions, 11/2007, A5E01134377-02
Preparations for Installation 2.3 The Hybrid and Loop Cables - Operating temp. -40 C/+80 C (-40 F/+176 F) Figure 2-4 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. Operating Instructions, 11/2007, A5E01134377-02 11
Preparations for Installation 2.4 Check list 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). 12 Operating Instructions, 11/2007, A5E01134377-02
Installation Guidelines 3 3.1 Installation This chapter provides instructions for the installation of the CD 6 sensor and its cables. The figure below shows the principle set-up of the LDS 6 central unit, sensors and cables. Figure 3-1 Principle set-up of an installation The installation of the sensors is very straightforward and can be performed by the customer. Note Do not install the sensors unless the purging media is accessible (for sensors that require purging). Never leave a sensor without purging since the wedge optics is easily damaged. At installation of the cross duct sensor, the fiber end and the photo-detector have to be aligned to the optical axis of the sensor pair. Note that each sensor has an optical axis of its own which is its axis of symmetry. Normally the process flanges are mounted with an angle error. The sensors are however, equipped with a flange pair with a spherical interface. This is used when the sensor pair is aligned to each other. In this way an angle error of up to ±2 on each side can be adjusted for. Installation of Sensors 1. Check that the flanges are installed properly, according to the instructions earlier in this manual. Operating Instructions, 11/2007, A5E01134377-02 13
Installation Guidelines 3.2 Electrical connections 2. Mount the sensors, receiver and transmitter, with gaskets on the flanges and cross tighten the bolts. 3.2 Electrical connections Installation of Transmitter Sensor Install the cables, hybrid and loop cable, at the transmitter sensor according to Figure 3.2. 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 fastened in the sensor. Figure 3-2 Connections in the transmitter Installation of Receiver Sensor 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. Figure 3-3 Connections in the receiver 14 Operating Instructions, 11/2007, A5E01134377-02
Installation Guidelines 3.3 Alignment 3.3 Alignment Mount the sensors, receiver and transmitter, with gaskets on the flanges and cross tighten the bolts. Align the sensors in the following steps: Roughly align the adjustable flange so that the two discs are parallel. Receiver side Figure 3-4 Remove the receiver sensor box Release the receiver lock ring furthest from the process use the supplied tool and remove the receiver sensor. Operating Instructions, 11/2007, A5E01134377-02 15
Installation Guidelines 3.3 Alignment Receiver side Figure 3-5 Mount flash light Fasten the supplied alignment plate. It screws on easily with the help of an O-ring. The alignment plate is included in the supplied alignment kit, Order No. A5E00253142. Turn the flashlight on and mount it on the alignment plate. In dusty environments or long path-lengths use a stronger light source such as a 55 W/12 V lamp, an option supplied by Siemens. Transmitter side Figure 3-6 Remove the launcher Remove the optical fiber launcher on the transmitter end. 16 Operating Instructions, 11/2007, A5E01134377-02
Installation Guidelines 3.3 Alignment Transmitter side Figure 3-7 Align the transmitter Mount the cross-hair and align the transmitter with the two hexagonal socket screws, by tightening and loosening them until the light dot is centered in the inner ring of the cross-hair. Operating Instructions, 11/2007, A5E01134377-02 17
Installation Guidelines 3.3 Alignment Transmitter side Figure 3-8 Center the light dot The light dot should have a perfect round shape. If the light dot is oval or scattered it might be necessary to adjust the welded flanges or remove any objects that might be blocking the light-path. Transmitter side Figure 3-9 Mount the flash light in the transmitter Move the flashlight to the transmitter and replace the cross-hair with it. 18 Operating Instructions, 11/2007, A5E01134377-02
Installation Guidelines 3.3 Alignment Receiver side Figure 3-10 Align the receiver Remove the alignment plate and remount the receiver sensor. Tighten the quick coupling firmly. Remove the detector card and replace it with the cross-hair. Align the receiver with the two hexagonal socket screws, by tightening and loosening them until the light-dot is centered on the cross-hair. Note The stability of the sensor alignment depends on the stability of the construction to which the customer s flange is mounted. If the incinerator wall or smoke duct is subject to movements due to, for instance, thermal changes CD 6 will need repeated realignment. This can be avoided by mounting the sensor pair on an external, more stable base, like a concrete or steel support. Operating Instructions, 11/2007, A5E01134377-02 19
Installation Guidelines 3.4 ATEX considerations 3.4 ATEX considerations A hybrid cable is used to connect the transmitter sensor to the barrier. Connecting Transmitter Sensor to Barrier 1. Cut off the pre-mounted phoenix contact at the hybrid cable. 2. Insert the hybrid cables (one for each channel) in the feed through at the top of the barrier box. Fasten each cable with a gasket. 3. Connect each hybrid cable to the Surge Protection Devices SD32X (yellow). - (brown cable) shall be connected to inlet number 4 and + (green cable) to inlet number 5. 4. Connect the hybrid cable to the transmitter sensor. Connecting Receiver to Transmitter Sensor For ATEX versions of the LDS 6 the receiver sensor are premounted with special ATEX electronics and surge protection. The green phoenix contact mounted on the sensor card is already connected with a red wire for +24 V and a black wire for GND. Two additional wires should be connected to the phoenix connector. These wires come from the loop cable. 1. Connect the green wire next to the red one (for 24 V) on the phoenix contact. 2. Connect the brown wire next to the black one (for GND) on the phoenix contact. Connect the sensor housings, on both the transmitter and the receiver side, to earth using the premounted 2 meters earth cable (yellow-green). AD_4100-2080_Transmitter_Ex_Std_CD6 and AD_4100-2081_Receiver_Ex_Std_CD6 in Appendix A shows the transmitter and receiver sensors. All ATEX devices are labelled. See also ATEX Set-up (Page 37) 20 Operating Instructions, 11/2007, A5E01134377-02
Installation Guidelines 3.5 Purging 3.5 Purging Protecting the Optical Surfaces The wedge windows are in many applications exposed to very rough environments and will get stained very quickly if no measures are taken. Three existing methods to keep the wedge windows in good shape are: Instrument air purging Purging with air blower Steam purging These methods are further described in Appendix. Purging can be divided into purging of optical process interface and purging of sensors. Purging of Optical Process Interface Wedge optics can be purged with instrument air purging, elevated instrument air purging, air blower purging and steam purging. Always install the purging before the sensors are installed to avoid damage to the optics during the rest of the installation process. The figure below shows the principle set-up for purging. For optimal performance use sensors equipped for the specific purging type, supplied from Siemens. Sensor Purging In oxygen applications it might be necessary to purge boxes and lens tubes with an oxygen free gas, such as nitrogen. Any oxygen free gas can be used for this purpose. However, when explosive gases are used the Ex sensor must be used. Purging with oxygen free gas is also necessary when performing water vapor measurements. The sensors for sensor purging supplied by Siemens include a needle valve and a check valve (see the figure below). Purging Set-up Follow the procedure to mount the purging connectors: Remove the four plugs from the wedge tube. Mount the valves and 6 mm tube according to the figure. Operating Instructions, 11/2007, A5E01134377-02 21
Installation Guidelines 3.5 Purging Figure 3-11 Sensor purging set-up Note When using a plastic tube, be sure to use the rigid metal insert. See also Purging of Optical Process Interface (Page 41) Gas Flow Calculations (Page 45) 22 Operating Instructions, 11/2007, A5E01134377-02
Technical Description 4 4.1 The Hybrid Cable The hybrid cable is constructed for very harsh environments and consists of two optical fibers, one for transmission of the laser light to the measurement volume (single-mode fiber) and one for the return of the detected signal (multi-mode fiber). Two twisted electrical wires are used for powering the electronics in the sensor (24 VDC). Twisted pair Multi mode fiber Single mode fiber Figure 4-1 The hybrid cable 4.2 The Loop Cable The loop cable connects the transmitter sensor to the receiver sensor. This cable is a hybrid cable that does not contain the single-mode fiber. Operating Instructions, 11/2007, A5E01134377-02 23
Technical Description 4.3 The CD 6 Sensor 4.3 The CD 6 Sensor The cross duct sensor, CD 6 (shown in the figure below) is designed for in situ measurements. It consists of a transmitter and a receiver creating a single path measurement situation. The beam diameter is expanded to about 25 mm in order to improve performance in high dust load (>1 g/m 3 ) applications. 4 4 4 4 4 4 4 4 4 4 Figure 4-2 Sensor CD 6 - dismantled 1. Alignment screws. 2. Purge tube. 3. Purge flange. 4. Wedge module, including wedge window. 5. Lock rings (2 pc.). 6. Lens tube. 7. Sensor housing. 8. Needle valve with fittings. 9. Cable feed through - the transmitter has two (for hybrid cable and loop cable) and the receiver has one (for loop cable). 10. Ground mount. The transmitter includes a lens and a connection for the optical fiber located in the focal plane of the lens. The receiver contains a lens and the sensor electronics. The sensor electronics consist of the detector module and the sensor card. The powering of the sensor electronics is performed with a twisted pair copper cable delivering 24 VDC. The detector card is a detector with pre-amplifier and the sensor card consists of driver electronics for the optical return signal and DC/DC-converter. 24 Operating Instructions, 11/2007, A5E01134377-02
Technical Description 4.4 High Pressure Flange The laser light is coupled from the optical fiber in the transmitter to its lens and passes through a wedge tube (for protection of the lens) and then through the measurement volume. The lens in the receiver (also protected with a wedge module) focuses the incoming laser light on the detector where it is converted to an electrical signal. This signal is amplified and converted to an optical signal and returned to the central unit. The mounting of the sensor requires a flange with the dimensions DN65/PN6 or ANSI 4"/150 lbf. 4.4 High Pressure Flange In some applications - like AP where oxygen is measured up to 5 bars - a high pressure window is needed to seal the process. These windows can be purchased as spare parts and they exist in 3 versions namely, DN65/PN6, ANSI 4"/150lb and a special version that will adapt the DN65/PN6 flange on the sensor to a DN80/PN16 flange on the process - se the figure below. Figure 4-3 High pressure window with DN80/PN16 towards the process and DN65/PN6 towards the sensor Operating Instructions, 11/2007, A5E01134377-02 25
Technical Description 4.5 The Ex Sensor CD 6 Ex 4.5 The Ex Sensor CD 6 Ex The sensor is also available in an Ex-version - se also separate user manual. This has very low power electronics - intrinsically safe - and an IP65 enclosure. For further information regarding the Ex option please refer to the separate ATEX manual. See also ATEX Set-up (Page 37) 4.6 Technical Specification The Hybrid Cable Two optical fibers and two electrical wires for 24 VDC are housed in one cable. (The loop cable interconnecting the sensor pair does not contain the single mode fiber). Item Connector SM fiber Connector MM fiber Jacket material Dimension Ambient temperature - installation Ambient temperature - storage and operation Length (distance between central unit and sensor) Minimum bend radius Impact resistance Max tensile strength Specification E2000 angle polished SMA Green, oil resistant polyurethane Diam.: <8 mm. Length: up to 1000 m -20 to +80 C (-4 to +176 F) -40 to +80 C (-40 to +176 F) Maximum 1000 m. Longer is possible if a splicing box is used. 10 cm 200 N/m 500 N The Sensor The cross duct sensor, CD 6 (a sensor for measuring through a gas channel) is designed for in situ measurements. It consists of a transmitter and receiver creating a single path measurement situation. The beam diameter is expanded to about 25 mm in order to improve performance in high dust load (>1 g/m3) applications. The transmitter includes a lens and a connection for the optical fiber located in the focal plane of the lens. The receiver contains a lens, a detector with preamplifier, driver electronics for the optical return signal, and a 24 VDC to ±15 VDC DC/DC-converter. The laser light is coupled from the optical fiber in the transmitter to the transmitter lens and passes through the measurement volume. The lens in the receiver focuses the incoming laser light on the detector where it is converted to an electrical signal. This signal is amplified and converted to an optical signal and returned to the central unit LDS 6. 26 Operating Instructions, 11/2007, A5E01134377-02
Technical Description 4.6 Technical Specification Item Dimension, sensor box Dimension, purging tube Weight Power supply Power consumption Degree of protection EMC - Electromagnetic compatibility Electrical safety Fuse rating Permissible ambient temperature (Operation) Permissible ambient temperature (Storage and transport) Permissible ambient humidity Sensor/process interface Measurement path length Temperature Pressure Dust load Detection limit Accuracy Specification Ø: 163 mm, D: 105 mm L: 400, 800 or 1200 mm, OD: 44 mm, ID: 40 mm. Custom length of up to 1300 mm is also available. 2 x 11 kg (24 lb) Integrated in the central unit. External supply may be used: 18 V - 36 V DC. Approx. 2 W IP65 according to EN60529. Conforms to standard requirements of NAMUR NE21 (08/98). According to EN 61010-1, over voltage test category II. Central unit power supply, 1 A, poly switch. -30 to +70 C (-22 to +158 F) -40 to +70 C (-40 to +158 F) < 95% relative condensing, non-condensing DN65/PN6 and ANSI 4"/150 lb 1-12 m depending on measuring conditions (dust load). Application specific: -5 to +1300 C (+23 to +2370 F) Ambient ± 50 hpa Depending on particle size distribution and optical path length. Depending on gas, path length, temperature, pressure and gas. 2% of measured value or the detection limit. The highest of these values applies. CD 6Ex The spec for the Ex sensor CD 6Ex differs from the CD 6 in some aspects. Item Ex class Power supply Power consumption Permissible ambient temperature (Operation) Specification Ex-protected version according to {Ex} II 1G D T135 EEx ia IIC T4 IP65 According to the intrinsically-safe standards (EN 50020 or DIN EN 50020, and IEC 60079-11 or EN 60079-11). Max. 0.58 W -30 to +60 C (-22 to +140 F). Operating Instructions, 11/2007, A5E01134377-02 27
Spare Parts List 5 5.1 Spare Parts CD 6 exists in two versions as a consequence of a major upgrade. Three of the CD 6 spare parts are affected by the change and will consequently exist in two different versions. The "Sensor electronic" spare parts consist of one detector and one detector PCB (A5E00681433) respectively. The PCB is not affected by the modification but the detector is different. This spare parts list corresponds to the technical state of February 2007. Labels Detectors All detectors have the following label where the detector A5E-number indicates if a sensor is to be used with a Version 2 Central unit. Besides the example in the picture below also A5E1033996 (HCl) and A5E1030124 (CD 6C) are used with version 2. Ordering Instructions All orders should specify the following: 1. Quantity. 2. Product description. 3. Order number. 4. MLFB number and serial number of the instrument to which the spare part will be used. Operating Instructions, 11/2007, A5E01134377-02 29
Spare Parts List 5.1 Spare Parts Spare Parts List All spare parts are identified by an order number. For example the order number A5E00338487 corresponds to a Window module, quartz. Spare parts cables Product description Standard Hybrid Cable LW 5 m in case Standard Hybrid Cable LW 10 m in case Standard Hybrid Cable LW 25 m in case Standard Hybrid Cable LW 40 m in case Standard Hybrid Cable LW 50 m in case Standard Hybrid Cable SW 5 m in case Standard Hybrid Cable SW 10 m in case Standard Hybrid Cable SW 25 m in case Standard Hybrid Cable SW 40 m in case Standard Hybrid Cable SW 50 m in case Standard Loop Cable 5 m in case Standard Loop Cable 10 m in case Standard Loop Cable 25 m in case Hybrid cable SW 2m Hybrid cable LW 2m Hybrid Cable LW Customized Length (please specify length in order) Hybrid Cable SW Customized Length (please specify length in order) Loop Cable Customized length (please specify length in order) Order no. A5E00818626001 A5E00818626002 A5E00818626003 A5E00818626004 A5E00818626005 A5E00818619001 A5E00818619002 A5E00818619003 A5E00818619004 A5E00818619005 A5E00818640001 A5E00818640002 A5E00818640003 A5E00814073 A5E00814171 A5E00856746 A5E00856745 A5E00856744 Spare parts CD 6 Product description Window module, quartz Window module engine, no purging Purg. tube 400mm, sintered filter Purg. tube 400mm fan adapter Purg. tube 800mm, sintered filter Purg. tube 800mm, fan adapter Purg. tube 1200mm, sintered filter Purg. tube 1200mm, fan adapter Sensor box Transmitter LW Sensor box Transmitter SW Sensor box Receiver SW Sensor box Receiver LW Order no. A5E00338487 A5E00338490 A5E00858612 A5E00858615 A5E00858611 A5E00858614 A5E00338496 A5E00858580 A5E00902914 A5E00902916 A5E00902917 A5E00902918 30 Operating Instructions, 11/2007, A5E01134377-02
Spare Parts List 5.1 Spare Parts Product description Barrier box 1 channel Barrier box 2 channels Barrier box 3 channels High pres. w. f. SS2343 DN65/PN6 High pres. w. f. SS2343 DN80/PN16 High pres. w. f. SS2343 ANSI 4" Becker Air blower 115 V Becker Air blower 230 V Alignment kit Window module, Quartz, ATEX CD 3002 Roxtec Gasket for Sensor Roxtec Gasket for ATEX Box Order no. A5E00902922 A5E00902926 A5E00902927 A5E00534662 A5E00534663 A5E00534664 A5E00829150 A5E00829151 A5E00253142 A5E00338594 A5E00853911 A5E00979661 Please note that three of the LDS 6 sensor electronic spare parts are version dependent. (The PCB:s are not affected but detector electronics are different). Spare parts sensors electronics Product description Sensor electronic LW InGaAs (Ver. 1) Sensor electronic LW InGaAs NEL (Ver. 2) Sensor electronic LW Ge, HCl only (Ver. 1) Sensor electronic LW Ge, HCl only NEL (Ver. 2) Sensor electronic SW, O2 only Sensor electronic ATEX SW Sensor Electronic ATEX HCl Sensor Electronic ATEX HF Sensor el. ATEX NH3, CO, CO2 Sensor Electronic lppm H2O (Ver. 1) Sensor Electronic lppm H2O NEL (Ver. 2) Sensor Electronic lppm H2O ATEX Order no. A5E00338540 A5E01090409 A5E00338552 A5E01090413 A5E00338533 A5E00338563 A5E00853896 A5E00853905 A5E00338572 A5E00854159 A5E01090420 A5E00924868 Operating Instructions, 11/2007, A5E01134377-02 31
Spare Parts List 5.2 Repair/Upgrade 5.2 Repair/Upgrade Faulty equipment should be sent to the repair department with details of the fault and its origin. When ordering replacement equipment, please specify the serial number of the original equipment. Your will find the serial number on the rating plate on the central unit. Address of the responsible repair location, your contact, list of spare parts etc. can all be found on Internet: http://www.siemens.com/automation/service&support or http://www.automation.siemens.com/partner 32 Operating Instructions, 11/2007, A5E01134377-02
Dimensional Drawings 6 6.1 Process Flange and Purge Tube Dimensions The process flange dimensions should comply to the DIN standard (DN65/PN6) or the ANSI standard (ANSI 4"/150 lbf). The process flange dimensions are shown in Figure 2.2 and Figure 2.3. Customer process flanges are not supplied by Siemens. For engine DeNox applications the mounting of the sensor requires a specially designed flange and a special motor wedge (both delivered by Siemens). The standard purge tube from Siemens is 400 mm (the tube protrudes 370 mm into the process from the flange surface). 900 mm and 1200 mm tubes can be supplied as an option. If the purge tube is shorter than the flange tube there could be a build up of dust in front of the purge tube that eventually blocks the light-beam. CAUTION The 800 and 1200 mm purging tubes have a larger outer diameter. If long tubes for the process flanges are used (because of thick process walls) it si important to makes sure that the ±2 deg adjustment can be maintained. Operating Instructions, 11/2007, A5E01134377-02 33
Dimensional Drawings 6.1 Process Flange and Purge Tube Dimensions 4 x Ø14 mm Ø65 mm Ø130 mm Ø160 mm Figure 6-1 Dimensions of the flange DN65/PN6. 34 Operating Instructions, 11/2007, A5E01134377-02
Dimensional Drawings 6.1 Process Flange and Purge Tube Dimensions 8 x Ø(for 5/8" bolt) Ø4" Ø7½" Ø9" Figure 6-2 Dimensions of the flange ANSI4"/150 lbs. Operating Instructions, 11/2007, A5E01134377-02 35
Dimensional Drawings 6.2 Sensor dimensions 6.2 Sensor dimensions Ø163 370 (770, 1170) 395 105 Figure 6-3 The dimensions of the sensor 36 Operating Instructions, 11/2007, A5E01134377-02
Appendix A A.1 ATEX Set-up ATEX Set-up This appendix provides illustrations of the ATEX set-up for the LDS 6 laser gas analyzer. This set-up is used for measurements in explosive areas. Figure A-1 ATEX Barrier Operating Instructions, 11/2007, A5E01134377-02 37
Appendix A.1 ATEX Set-up Figure A-2 ATEX Transmitter Sensor Figure A-3 ATEX Receiver Sensor 38 Operating Instructions, 11/2007, A5E01134377-02
Appendix A.1 ATEX Set-up Figure A-4 ATEX Set-up Operating Instructions, 11/2007, A5E01134377-02 39
Appendix A.1 ATEX Set-up Figure A-5 ATEX Set-up Description 40 Operating Instructions, 11/2007, A5E01134377-02
Appendix A.2 Purging of Optical Process Interface A.2 Purging of Optical Process Interface This appendix gives information on purging of optical process interfaces and gas flow calculations for purging. There are four different types of optical process interface purging; instrument air purging, elevated flow instrument air purging, purging with air blower and steam purging. Instrument Air Purging This is the standard solution to keep the wedge windows free from contamination. It requires an inlet flange with sintered filter for instrument air or gas, to create an air-flow in front of the wedge windows and into the process, see the figure below. The instrument air purging is not recommended for O2 applications. The instrument air should have a pressure of 2-6 bar and be oil free. The sensor is supplied with a inlet connector for semi-rigid tube with an inner diameter of 4 mm (0.16") and an outer diameter of 6 mm (0.24"). As a rule of thumb, a pressure of 2 bar generates an air flow of 40 l/min, 4 bar generates 80 l/min and 6 bar generates 120 l/min (when the needle valve is fully opened). Figure A-6 Instrument Air Purging Elevated Flow Instrument Air Purging The elevated flow instrument air purging is a type of instrument air purging but without the needle valve (the needle valve limits the flow to maximum 120 l/min). This purging type allows the flow to be up to 500 l/min, at an upstream pressure of 6 bar. Sensors for elevated flow instrument purging from Siemens are equipped with fan adapter, see the figure below. Operating Instructions, 11/2007, A5E01134377-02 41
Appendix A.2 Purging of Optical Process Interface Figure A-7 Elevated flow instrument air purging Note Measures should be taken to minimize the consumption of the instrument air. Therefore a pressure regulator should be used at the instrument air connection point to facilitate adjustment of the flow if no flow regulation is applied. If very high air flows (>100 l/min.) are needed, an air blower should be used. As an option a needle valve can be supplied and used instead to give an adjustable air flow of approx. 0-120 l/min. (with 6 bar G instrument air). Purging with Air Blower In applications with high dust load or high process flow purging with an air blower must be considered. The air speed when standard instrument air purging is used is too low to prevent build-up of dust in the flange tubes. The Siemens standard air blower solution provides an air flow of up to about 850 l/min. Air blower can be purchased from Siemens as an accessory. The figure below illustrates the air blower sensor, including purging flange. When using the sensors for air blower purging (including fan adapter) supplied from Siemens, and a maximum hose length of 2 m, purge flow at 20 mbar counter pressure will be 850 l/min. The purging gas flow calibration has greater impact on the measurement readings for long measuring path lengths than for short path lengths. For assistance to calculate and calibrate the purging gas flow, contact a service manager at Siemens. 42 Operating Instructions, 11/2007, A5E01134377-02
Appendix A.2 Purging of Optical Process Interface Figure A-8 Purging with air blower Steam Purging If overheated steam (absolutely dry steam) is available at the sensor site, it is possible to use steam purging to keep the wedge windows clean, see the figure below. This has some advantages. One is when oxygen is measured. Since steam is free of oxygen it will not interfere with the measurements and consequently, when water is measured this becomes a disadvantage. When oxygen is measured, N2 purging (or any other gas that is free of oxygen) of the sensor housing might also be necessary to obtain maximum performance. An additional advantage is that the high temperature of the steam prevents condensation of salt on the optical surfaces. Steam purging requires sensors for steam purging supplied from Siemens, which include fan adapter. Figure A-9 Steam purging Operating Instructions, 11/2007, A5E01134377-02 43
Appendix A.2 Purging of Optical Process Interface Steam Purging Installation When steam is used there are a couple of important issues to consider. Figure A-10 Saturated pressure region 1. The steam must be kept overheated at all times and condensation in the tubes or on the optical surfaces must be prevented. When uncertainty regarding the steam quality (the dryness of the steam) exists, a steam trap is recommended. This accessory can be purchased from Siemens. It can also be recommended to isolate the steam tubing and to keep the tube as short as possible (place the trap as close to the sensors as possible). The curve in the figure above shows four regions in the pressure/temperature diagram for steam (the figure gives approximate figures). The steam installation should be designed so that the operating point just before the sensor connection at all times falls inside the Safe region. In the border between the Minimum in safe region and the Saturation line the steam is saturated and condensation will most certainly occur when the steam is passing the steel filter due to a power loss of roughly 50 W (the power needed to keep the sensor at elevated temperature). In the top region there is a risk of destroying the gaskets in the sensor. The margin illustrated in the figure should be such that changes in ambient temperature, changes in the power loss in the steel filter, etc. does not move the steam parameters to the saturation line when passing the steel filter in the sensor. 2. The Cv through the sintered steel filter is 0.39 and the flow through this filter will be 300 std ltr/min if the inlet pressure is 4 bar and the temperature is 165 C (329 F). This flow is adequate for most applications but when necessary, the pressure can be increased to prevent dust from building up in the sensor air buffer tube. The flow is proportional to the inlet pressure according to the figure above. 3. The steam system must be installed and certified by authorized personnel. 4. All exposed hot surfaces must be protected and properly labeled. 44 Operating Instructions, 11/2007, A5E01134377-02
Appendix A.3 Gas Flow Calculations Note If the steam quality turns out to be too poor the steam tubing must be isolated or the steam must be heated. Do not isolate the sensor since this may damage the electronics in the receiver due to overheating. A cold start of the steam system requires a tapping the valve just before the sensor to drain the system from water. A.3 Gas Flow Calculations Gas flow calculations are slightly complex because gases are compressible fluids whose density changes with pressure. In this application we are dealing with choked flow. The outlet pressure is less than one half of the inlet pressure and the gas reaches sonic velocity in the valve. A further decrease in outlet pressure does not increase the flow. The flow (q) of instrument air at P1 = 6000 hpa and T1 = 25 C (77 F) through the needle valve when it is fully opened would then be a little more than 110 Nltr/min. The figure below shows the flow (q) as a function of the up-stream pressure (P1). There are two parameters in the diagram, the process pressure (Pp) and the temperature of the purge gas which is assumed to be air. The diagram shows the flow through a system with a total Cv of 0.1. The flow increases linearly with Cv. q = the flow rate on the low pressure side [Nltr/min.] Cv= the flow coefficient (0.1 for the needle valve in our standard sensor) P1 = the inlet absolute pressure [hpa] Gg = the gas specific gravity (air = 1.0) T1 = the upstream temperature [ C] Pp = process pressure (1023 hpa) 140 120 T 1 = 25 C q (Cv = 0.1) [Nltr/min] 100 80 60 40 20 P p = 2026 hpa P p = 1013 hpa P p = 3039 hpa T 1 = 100 C 0 0 1 2 3 4 5 6 7 P 1 [x1013 hpa] Figure A-11 Purge air flow rate Operating Instructions, 11/2007, A5E01134377-02 45
Appendix A.4 Tool kits A.4 Tool kits Siemens provide toolkits to be used for installation, maintenance and service of the LDS 6 laser gas analyzer. These toolkit are described in this appendix. Flange Alignment Kit The Flange Alignment Kit (shown below) is intended for use when installing the two opposite process flanges on the measurement volume. It consists of a light source, two alignment flanges, an aiming tool, a battery for the light source and a battery charger. The light source is a halogen lamp with a wide beam angle and can consequently be mounted on non aligned process flanges (which will be the case when the first flange is aligned). 5 3 2 1 4 Figure A-12 The Flange Alignment Kit 1. Light source 2. Alignment flanges 3. Aiming tool 4. Battery 5. Charger The Flange Alignment Kit also contains a description of how to use the kit and t graph that shows how to measure the error angle to see if the flanges are properly aligned. The graph (shown below) shows the angle error as a function of the light spot distance from the centre at the limits of the focal distance setting of the tool. 46 Operating Instructions, 11/2007, A5E01134377-02
Appendix A.4 Tool kits It shows that the ±2 deg demand is met if the spot is inside the fifth ring on the aiming tool in other words if the spot is inside a circle with a 5 mm radius. 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0 1 2 3 4 5 6 7 8 9 Figure A-13 Graph showing the reading of angle error Sensor Alignment Kit The Sensor Alignment Kit (shown below) is used for installation and re-alignment of the sensors. The kit includes five tools, described in the table below, and an instruction for alignment of the sensors. The instruction is found on the inside of the case. 1. Hook spanner 2. Allen keys, 3 mm and 6 mm 3. Alignment flange 4. Light source 5. Lubricant, copper based Operating Instructions, 11/2007, A5E01134377-02 47
Appendix A.4 Tool kits Figure A-14 CD 6C alignment kit 48 Operating Instructions, 11/2007, A5E01134377-02
ESD guidelines B B.1 ESD (ElectroStatic Discharge) ESD is the rapid, spontaneous transfer of electrostatic charge induced by a high electrostatic field. Electrostatic damage to electronic devices can occur at any point from manufacture to field service. Damage results from handling the devices in uncontrolled surroundings or when poor ESD control practices are used. Generally damage is classified as either a catastrophic failure or a latent defect. The symbol to the left indicates an ESD protected area, where all workspaces are ESD protected and all personnel must wear wrist straps. This symbol will be used in this chapter to indicate that a service task requires ESD protection. A catastrophic failure means that exposure to an ESD event has caused an electronic device to stop functioning. Such failures usually can be detected when the device is tested before shipment. A latent defect, on the other hand, is more difficult to identify. It means that the device has only been partially degraded from exposure to an ESD event. Latent defects are extremely difficult to prove or detect using current technology, especially after the device is assembled into a finished product. Note Usually, the charge flows through a spark between two objects at different electrostatic potentials as they approach one another. It is of utmost importance that ESD protective procedures are used during service in the field. The components used in SITRANS SL have all been protected from ESD through the whole production chain. Ground Everything Effective ESD grounds are of critical importance in any operation, and ESD grounding should be clearly defined and regularly evaluated. According to the ESD Association Standard ANSI EOS/ESD all conductors in the environment, including personnel, must be bonded or electrically connected and attached to a known ground, bringing all ESD protective materials and personnel to the same electrical potential. This potential can be above a "zero" voltage ground reference as long as all items in the system are at the same potential. It is important to note that non-conductors in an Electrostatic Protected Area (EPA) cannot lose their electrostatic charge by attachment to ground. Operating Instructions, 11/2007, A5E01134377-02 49
ESD guidelines B.1 ESD (ElectroStatic Discharge) Wrist Straps In many facilities, people are one of the prime generators of static electricity. Therefore, wrist straps must be used while carrying out maintenance and service on the SITRANS SL, to keep the person wearing it connected to ground potential. A wrist strap consists of the cuff that goes around the person's wrist and the ground cord that connects the cuff to the common point ground. Work Surface An ESD protective work surface is defined as the work area of a single individual, constructed and equipped to limit damage to ESD sensitive items. The work surface helps to define a specific work area in which ESD sensitive devices may be safely handled. The work surface is connected to the common point ground by a resistance to ground of 106 Ohms to 109 Ohms. This is done by using a soft bench mat, which is connected to ground, on the work surface. All equipment must be connected to grounded outlets and all personnel must wear wrist straps connected to the bench mat using a cord. Bench mat, wrist strap and lightweight cord can be provided from Siemens Laser Analytics in the ESD kit. 50 Operating Instructions, 11/2007, A5E01134377-02