Siemens LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas Compact Operating Instructions

Continuous Gas Analysis In situ Laser Gas Analyzers LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas Compact Operating Instructions 1 1.1 Introduction Purpose of this documentation These instructions are a brief summary of important features, functions and safety information, and contain all information required for safe use of the device. It is your responsibility to read the instructions carefully prior to installation and commissioning. In order to use the device correctly, first review its principle of operation. The instructions are aimed at persons who mechanically assemble the device, connect it electrically, and start it up. To achieve optimum usage of the device, read the detailed version of the manual. 1.2 Intended use ● This device is used to quantitatively determine components in a gaseous probe. ● This device may only be used for the purposes specified in these instructions. ● Modifications to the device which are not expressly referred to in these instructions therefore result in an application which is not in accordance with the intended use. Such modifications to the device are then the exclusive responsibility of the user. 1.3 Range of application In these operating instructions, only versions approved for operation in hazardous areas in accordance with the EU directive 94/9/EC (ATEX) are described. All other analyzer versions are not considered here after. A complete LDS 6 system for use in hazardous areas consists of ● A central unit which must be placed outside the hazardous area ● A barrier box which must be placed outside the hazardous area ● A hybrid cable for the connection between central unit and barrier box ● 1 .. 3 transmitter sensor(s) CD 6 ● 1 .. 3 receiver sensor(s) CD 6 ● 1 .. 3 sensor connection cable(s) ● 1 .. 3 hybrid cable(s) for the connection between the barrier box and the sensor(s) ● A sensor alignment kit (optional) © Siemens AG 2013. All rights reserved A5E03314905-01, 04/2013 1 Table 1-1 Parts of the LDS 6 system approved for operation in hazardous areas Certificate Ex type of protection DEMKO 06 ATEX 139648 X IECEx UL 13.0029X and DEMKO 06 ATEX 139648 X IECEx UL 13.0029X and DEMKO 06 ATEX 139648 X IECEx UL 13.0029X and II (1) G [Ex op is T4 Ga] IIC Device MLFB No. LDS 6 central unit AD 4001-0xxx 7MB6121-1xxxx-xxxx Barrier box ADM 3040-3055 A5E00814175001 ... 006 Transmitter: CD 6 Ex CD 6 Ex HP Receiver: CD 6 Ex CD 6 Ex HP AD 4100-2080 7MB6122-1xxxx-xxxx II (1) D [Ex op is T135 °C Da] IIIC II (1) G [Ex ia op is T4 Ga] IIC II (1) D [Ex ia op is T135°C Da] IIIC II 1 G Ex ia op is IIC T4 Ga II 1 D Ex ia op is IIIC T135 °C Da AD 4100-2081 7MB6122-1xxxx-xxxx It is essential that you also observe the respective "Special conditions" of the certificates referred to in the table. These describe ● the fields of application, ● the requirements for operation in hazardous areas, ● other precautionary measures which are important for operation. 1.4 Set-up of an LDS 6 system for use in hazardous areas The figure below shows a schematic illustration of the set-up. Figure 1-1 Setup of an LDS 6 system for use in hazadous areas WARNING Unsafe connection Do only use sensor connection cable(s) and hybrid cable(s) delivered by Siemens. 2 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 1.5 Information on nameplates The following picture shows all information on a nameplate. ① ② ③ ④ ⑤ ⑥ Datamatrix code Warning! Observe operating instructions! Ex marking CE marking Manufacturer Country of origin Figure 1-2 ⑦ ⑧ ⑨ ⑩ ⑪ Ex data Serial number Product version Article number Product name Example of a nameplate of an LDS 6 component for use in hazardous areas Markings The central unit, the sensors and the barrier box are all marked according to the following pictures. Figure 1-3 Central unit nameplate LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 3 Figure 1-4 Receiver nameplate Figure 1-5 Transmitter nameplate Figure 1-6 Barrier box nameplate 4 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Manufacture date Figure 1-7 Example of a manufacture date (taken from the first nameplate in this paragraph) The date of manufacture is present coded in the serial number ⑦ of the nameplate. Details are shown in the following table. Year/fiscal year 2) Key 1) Month Key 1) 1970, 1990, 2010 A January 1 1971, 1991, 2011 B February 2 1972, 1992, 2012 C March 3 1973, 1993, 2013 D April 4 1974, 1994, 2014 E May 5 1975, 1995, 2015 F June 6 1976, 1996, 2016 H July 7 1977, 1997, 2017 J August 8 1978, 1998, 2018 K September 9 1979, 1999, 2019 L October 1980, 2000, 2020 M November N 1981, 2001, 2021 N December D 1982, 2002, 2022 P 1983, 2003, 2023 R 1984, 2004, 2024 S 1985, 2005, 2025 T 1986, 2006, 2026 U 1987, 2007, 2027 V 1988, 2008, 2028 W 1989, 2009, 2029 X 0, O 1) in compliance with DIN IEC 62 2) coding of the fiscal year is made using the key of the second named year: e. g. S for 2003/2004 etc. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 5 Warning note This warning note indicates that there is a hazard of potential electrostatic charges. Therefore it is mandatory to observe these instructions and the detailed manual. 1.6 Notes on warranty The contents of this manual shall not become part of or modify any prior or existing agreement, commitment or legal relationship. The sales contract contains all obligations on the part of Siemens as well as the complete and solely applicable warranty conditions. Any statements regarding device versions described in the manual do not create new warranties or modify the existing warranty. The content reflects the technical status at the time of publishing. Siemens reserves the right to make technical changes in the course of further development. 1.7 Checking the consignment 1. Check the packaging and the device for visible damage caused by inappropriate handling during shipping. 2. Report any claims for damages immediately to the shipping company. 3. Retain damaged parts for clarification. 4. Check the scope of delivery by comparing your order to the shipping documents for correctness and completeness. WARNING Using a damaged or incomplete device Danger of explosion in hazardous areas. ● Do not use damaged or incomplete devices. 1.8 Transportation and storage To guarantee sufficient protection during transport and storage, observe the following: ● Keep the original packaging for subsequent transportation. ● Devices/replacement parts should be returned in their original packaging. ● If the original packaging is no longer available, ensure that all shipments are properly packaged to provide sufficient protection during transport. Siemens cannot assume liability for any costs associated with transportation damages. CAUTION Insufficient protection during storage The packaging only provides limited protection against moisture and infiltration. ● Provide additional packaging as necessary. Special conditions for storage and transportation of the device are listed in "Technical data". 6 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 2 Safe use of the device Unless otherwise stated all safety-related information in this document applies to all components of the system, i.e. to the central unit, the barrier box, the sensors, and the connections. This device left the factory in good working condition. In order to maintain this status and to ensure safe operation of the device, observe these instructions and all the specifications relevant to safety. Observe the information and symbols on the device. Do not remove any information or symbols from the device. Always keep the information and symbols in a completely legible state. WARNING Loss of explosion protection properties The test certificate for your explosion-proof device only applies to the original configuration as well as to the installation and connection according to the switching and piping plans of Siemens. If one or more components are changed, the explosion protection properties of your device are abolished. WARNING Improper device modifications Danger to personnel, system and environment can result from modifications to the device, particularly in hazardous areas. ● Only carry out modifications that are described in the instructions for the device. Failure to observe this requirement cancels the manufacturer's warranty and the product approvals. WARNING Dust layers above 5 mm Danger of explosion in hazardous areas. Device may overheat du to dust build up. ● Remove any dust layers in excess of 5 mm. WARNING Loss of safety of device with type of protection "Intrinsic safety Ex i" If the device has already been operated in non-intrinsically safe circuits or the electrical specifications have not been observed, the safety of the device is no longer ensured for use in hazardous areas. There is a danger of explosion. ● Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe circuit. ● Observe the specifications for the electrical data on the certificate and in Chapter "Technical data (Page 35)". 2.1 Requirements for special applications Due to the large number of possible applications, each detail of the described device versions for each possible scenario during commissioning, operation, maintenance or operation in systems cannot be considered in the instructions. If you need additional information not covered by these instructions, contact your local Siemens office or company representative. Note Operation under special ambient conditions We highly recommend that you contact your Siemens representative or our application department before you operate the device under special ambient conditions as can be encountered in nuclear power plants or when the device is used for research and development purposes. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 7 2.2 Safety information The device complies with the applicable safety standards. If the handling instructions and safety information are observed, no dangers exist when using the device which could endanger the health of personnel or result in damage to property. You will find the safety information: ● In these operating instructions and in the (detailed) operating instructions of the device ● On the device ● On the device components Electric safety WARNING Improper power supply Observe the specifications of the examination certificate valid in your country. Check whether the available power supply is compliant with the power supply specified on the nameplate and specified in the examination certificate valid in your country. WARNING Unsuitable accessories for the hazardous area The use of the alignment kit (optional) for aligning the sensors is not covered by the certificate for the use of the analyzer in hazardous areas. The use of the verification kit (optional) for verifying or calibrating the sensors is not covered by the certificate for the use of the analyzer in hazardous areas. ● These devices must only be used in an atmosphere without any risk of explosion (hot work permit)! The following safety note applies to the barrier box and the sensors. WARNING Opening device in energized state Danger of explosion in areas subject to explosion hazard. Only open the device in a de-energized state. ● Check prior to commissioning that the cover, cover locks, and cable inlets are assembled in accordance with the directives. Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in an energized state in dustfree hazardous areas when all necessary measures for explosion protection are ensured. Note The equipment does not provide 500 V insulation between intrinsically-safe circuits and ground as required by EN/IEC 60079-11 Clause 6.3.13. Materials in the sensor pair WARNING Impact or friction of device enclosure The device enclosure contains aluminium and is considered to constitute a potential risk of ignition by impact or friction. The user must take precautions to avoid any ignition hazard caused by impact or friction due to the content of light metals in the sensor enclosures. The sensor pair (transmitter and receiver) is built mainly using stainless or surface treated steel and an aluminum alloy (content of aluminum >85 %; content of magnesium, titanium and zirconium <0.7 %). The O rings and gaskets used are made of FKM (fluorocarbon elastomer) or FFKM (perfluoro elastomer) and graphite. The process interface consists of either (when using pressure-resistant window flanges) a borosilicate glass or (when using standard flanges with a wedge window module) a quartz or borosilicate glass wedge window. If the gas purging of the sensor will fail the O-rings will be the limiting component for the temperature. For their maximum temperature refer to Technical data (Page 35). 8 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Pressure safety For pressure specifications refer to the Technical data (Page 35). WARNING Damaged optics The high pressure glass in the sensors must not be subject to any mechanical impact which might cause damage to the glass (scratch, gash etc.). Only use a soft cloth for cleaning of the glass. Make sure that it is safe to dismount the sensor before cleaning. WARNING Malfunction of sealing Make sure all plugs and tube fittings are sealed with the enclosed pipe thread sealant. Instructions given on the sealant tube must be carefully followed. See also Technical data (Page 35) Installing/mounting (Page 11) Laser safety The analyzer is classified as a class 1 laser product. The emitted laser light is invisible (near infrared) and not hazardous to the unprotected eye. The analyzer has warning labels at appropriate positions according to EN 60825-1. WARNING Maintenance during continued operation in a hazardous area There is a danger of explosion when carrying out repairs and maintenance on the device in a hazardous area. ● Isolate the device from power. - or ● Ensure that the atmosphere is explosion-free (hot work permit). 2.3 Qualified personnel for hazardous area applications Qualified personnel for hazardous area applications Persons who install, assemble, commission, operate and service the device in a hazardous area must have the following specific qualifications: ● They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures, aggressive and hazardous media. ● They are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems. ● They are trained or instructed in maintenance and use of appropriate safety equipment according to the pertinent safety regulations. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 9 2.4 Laws and directives Observe the test certification, provisions and laws applicable in your country during connection, assembly and operation. These include, for example: ● National Electrical Code (NEC - NFPA 70) (USA) ● Canadian Electrical Code (CEC) (Canada) Further provisions for hazardous area applications are for example: ● IEC 60079-14 (international) ● EN 60079-14 (EC) 2.5 Conformity with European directives The CE marking on the device symbolizes the conformity with the following European directives: Electromagnetic compatibility EMC 2004/108/EC Directive of the European Parliament and of the Council on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC. Low voltage directive LVD 2006/95/EC Directive of the European Parliament and of the Council on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits. Atmosphère explosible ATEX 94/9/EC Directive of the European Parliament and the Council on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres. The applicable directives can be found in the EC declaration of conformity of the specific device. 10 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 3 3.1 Installing/mounting Safety notes Note Material compatibility Siemens can provide you with support concerning selection of sensor components wetted by process media. However, you are responsible for the selection of components. Siemens accepts no liability for faults or failures resulting from incompatible materials. Note Use in a domestic environment This is a Class A Group 1 equipment intended for use in industrial areas. In a domestic environment this device may cause radio interference. WARNING Incorrect mounting at Zone 0 Danger of explosion in hazardous areas. ● Ensure sufficient tightness at the process connection. ● Observe the standard IEC/EN 60079-14. WARNING Exceeded maximum permissible operating pressure Danger of injury or poisoning. The maximum permissible operating pressure depends on the device version. The device can be damaged if the operating pressure is exceeded. Hot, toxic and corrosive process media could be released. ● Make sure that the device is suitable for the maximum permissible operating pressure of your system. Refer to the information on the nameplate and/or in "Technical data (Page 35)". WARNING Exceeded maximum ambient or process media temperature Danger of explosion in hazardous areas. Device damage. ● Make sure that the maximum permissible ambient and process media temperatures of the device are not exceeded. Refer to the information in Chapter "Technical data (Page 35)". WARNING Unsuitable connecting parts Danger of injury or poisoning. In case of improper mounting hot, toxic and corrosive process media could be released at the connections. ● Ensure that connecting parts (such as flange gaskets and bolts) are suitable for connection and process media. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 11 Electric Safety WARNING Unsafe connection Do only use sensor connection cable(s) and hybrid cable(s) delivered by Siemens. Special conditions for safe operation Before taking into operation, the user shall make an analysis of compliance between sealing and enclosure materials versus media and temperature for the intended mounting position. This is to ensure that normal atmospheric conditions, as per IEC/EN 60079-26, are maintained inside the devices. WARNING Impact or friction of device enclosure The device enclosure contains aluminium and is considered to constitute a potential risk of ignition by impact or friction. The user shall take precautions to avoid any ignition hazard caused by impact or friction due to the content of light metals in the sensor enclosures. Take care that in ATEX/IEC Ex zone 0 and Ex zone 1 installations the total lengths of the hybrid cable and sensor connection cable between barrier box and receiver shall not exceed 250 m. The requirements to IEC/EN 60079-14 must be considered. Do not use longer cable lengths than necessary for a good signal quality and to prevent excess inductance. According to IEC/EN 60079-14 intrinsically-safe conductors must only be installed such that neither electric nor magnetic fields have any influence on these conductors. For this reason they must be placed in a way that they cannot generate electric or magnetic fields themselves, e.g. by coiling them up to more than one loop. CAUTION Hot surfaces resulting from hot process media Danger of burns resulting from surface temperatures above 70 °C (155 °F). ● Take appropriate protective measures, for example contact protection. ● Make sure that protective measures do not cause the maximum permissible ambient temperature to be exceeded. Refer to the information in Chapter "Technical data (Page 35)". 3.2 Site requirements As required by IEC/EN 60079-25, a site risk analysis has to determine possible measures to exclude any dangers from overvoltage. For zone 1 and 2, the surge protection of the CD 6 sensor can be used for this purpose. For zone 0, a separate surge protection must be implemented outside zone 0. 3.2.1 Central unit and barrier box WARNING Insufficient air circulation Risk of fire. The device may overheat or start burning in case of insufficient air circulation. ● Ensure sufficient air circulation in the room. Refer to the information in Chapter "Technical data (Page 35)". CAUTION Direct sunlight Device damage. The device can overheat or materials become brittle due to UV exposure. ● Protect the device from direct sunlight. ● Make sure that the maximum permissible ambient temperature is not exceeded. Refer to the information in Chapter "Technical data". 12 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 3.2.2 Sensors CAUTION External stresses and loads Damage to device by severe external stresses and loads (e.g. thermal expansion or pipe tension). Process media can be released. ● Prevent severe external stresses and loads from acting on the device. 3.3 Safe installation Approval The concept of the Ex approval is that the central unit is not modified, and that special ATEX-approved cables and bushings are used, and that a special Ex sensor pair (CD 6 Ex) is used in the hazardous zone. In addition to this an explosion protection barrier is added before entry into the hazardous zone. An absolute condition for the approval is that the equipment is set up according to the system drawing in section Connection diagrams (Page 27). The Ex-relevant ingress protection (IP65) comprises the entire area marked with a dashed line in the following figure. Figure 3-1 Ex-relevant IP area LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 13 DANGER Danger of explosions To surely avoid a penetration of explosive dust or gas into the Ex-relevant ingress protection area even without purging in action seal this area using dummy plugs or a check valve and needle valve. WARNING Ingress of dust and humidity To prevent ingress of dust and humidity the owner must assure that the ambient temperature of the Ex-relevant ingress protection area does not exceed the values specified in Chapter Technical data (Page 35). Liability Following commissioning, the total responsibility lies with the owner. 3.4 Sensor installation The installation of the Ex sensors can be performed by personnel qualified for hazardous area applications observing fully the instructions given in the certificate(s) and the operating instructions. NOTICE Incorrect mounting The device can be damaged, destroyed, or its functionality impaired through improper mounting. ● Before installing ensure there is no visible damage to the device. ● Make sure that process connectors are clean, and suitable gaskets and glands are used. ● Mount the device using suitable tools. Refer to the information in Chapter "Technical data (Page 35)", for example installation torques requirements. WARNING Open cable inlet or incorrect cable gland Danger of explosion in hazardous areas. ● Close the cable inlets for the electrical connections. Only use cable glands or plugs which are approved for the relevant type of protection. NOTICE Damage to optics Do not install the sensors unless the purging media is accessible (for sensors that require purging). Never leave a purged sensor with the purging switched off since the wedge optics are easily damaged. Device position The device may be mounted in any direction. When mounting the sensors the large springs of the alignment flanges must face downwards. Proceed as follows: 1. Check that the flanges are installed properly. 2. Mount the receiver and transmitter, both with gaskets on the flanges and cross-tighten the bolts. 3. Align the sensors as described in section 'Sensor alignment' of the detailed operating instructions. Note The stability of the sensor alignment depends on the stability of the construction to which the process flange is mounted. If the operation site is subject to movements due to, for instance, thermal changes the sensors will need repeated realignment. This can be avoided by mounting the sensor pair on an external, more stable base, such as concrete or steel support. 14 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 3.5 Installation of the barrier box When the LDS 6 sensors are used in explosive areas a barrier must be installed between the central unit and the sensor pair. The barrier and the central unit must be installed in a safe environment. Technical specifications for the connections are given on the barrier box and the surge protection. For wall mounting the barrier box is equipped with 4 mounting brackets as shown in the following figure. 1 2 3 Wall mounting bracket Sealing washer M8 hexagon bolt, 9 Nm tightening torque A wall mounting kit is part of the delivery. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 15 4 Electric connections WARNING Unsafe connection Do only use sensor connection cable(s) and hybrid cable(s) delivered by Siemens. 4.1 Safety notes WARNING Unsuitable cables and/or cable glands Danger of explosion in hazardous areas. ● Only use suitable cables and cable glands complying with the requirements specified in Chapter "Technical data". ● Tighten the cable glands in accordance with the torques specified in Chapter "Technical data". ● When replacing cable glands use only cable glands of the same type. ● After installation check that the cables are seated firmly. WARNING Dangerous contact voltage Danger of electric shock in case of incorrect connection. ● For the electrical connection specifications, refer to the information in Chapter "Technical data (Page 35)". ● At the mounting location of the device observe the applicable directives and laws for installation of electrical power installations with rated voltages below 1000 V. WARNING Missing PE/ground connection Danger of electric shock. Depending on the device version, connect the power supply as follows: ● Power plug: Ensure that the used socket has a PE/ground conductor connection. Check that the PE/ground conductor connection of the socket and power plug match each other. ● Connecting terminals: Connect the terminals according to the terminal connection diagram. First connect the PE/ground conductor. WARNING Improper power supply Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using direct current instead of alternating current. ● Connect the device in accordance with the specified power supply and signal circuits. The relevant specifications can be found in the certificates, in Chapter "Technical data (Page 35)" or on the nameplate. WARNING Lack of equipotential bonding Danger of explosion through compensating currents or ignition currents through lack of equipotential bonding. ● Ensure that the device is potentially equalized. Exception: It may be permissible to omit connection of the equipotential bonding for devices with type of protection "Intrinsic safety Ex i". 16 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 WARNING Unprotected cable ends Danger of explosion through unprotected cable ends in hazardous areas. ● Protect unused cable ends in accordance with IEC/EN 60079-14. WARNING Improper laying of shielded cables Danger of explosion through compensating currents between hazardous area and the non-hazardous area. ● Only ground shielded cables that run into the hazardous area at one end. ● If grounding is required at both ends, use an equipotential bonding conductor. WARNING Insufficient isolation of non-intrinsically safe and intrinsically safe circuits Danger of explosion in hazardous areas. ● When connecting intrinsically safe and non-intrinsically safe circuits ensure that isolation is carried out properly in accordance with IEC/EN 60079-14. ● Make sure that you observe the device approvals applicable in your country. Central unit NOTICE Condensation in the device Damage to device through formation of condensation if the temperature difference between transportation or storage and the mounting location exceeds 20 °C (68°F). ● Before taking the device into operation let the device adapt for several hours in the new environment. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 17 4.2 Connecting the sensors Connecting the transmitter sensor Install the cables, hybrid and sensor connection cable, at the transmitter sensor according to the figure below. 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 the power supply are just connected straight through to the receiver. Note During installation make sure that the ambient temperature is always within the range specified in section Hybrid and sensor connection cables (Page 36). 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 4-1 Transmitter connections Figure 4-2 Transmitter sensor 18 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Installing the receiver sensor Install the sensor connection cable in the receiver sensor according to the figure below. 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 in the figure below. Figure 4-3 Receiver connections ● Insert the receiver detector and fix it by rotating it 90 degrees. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 19 ● Fasten the detector card. ● Cut off the pre-mounted connector from the sensor connection cable. 20 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Connect the sensor connection cable and the cables from the surge protection according to the following figure (red to green and black to brown). Before connecting, fit the sleeving provided over the green and brown wires ① and make sure that the end of the sleeving is as close as possible to the connector. Fix the wire group to the pre-mounted edge clip using the attached cable tie ②. Connect the grounding cable to the sensor house with the corresponding screw ③. Carefully fold the ribbon cable and fix it to the pre-mounted edge clip using the attached cable tie ④. Make sure that the ribbon cable is not in contact of the conductive part of the PCB. Handling of entry seal gaskets used with CD 6 sensors. The sensor connection and hybrid cables connected to the CD 6 sensors are fitted with entry seal gaskets. To make sure the sensors are sealed appropriately, the gaskets must be correctly installed. When the gaskets are delivered together with the cables they are fitted in the protection tubes. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 21 When mounting the gaskets in the sensor, please proceed as follows: ● Once the sensors are mounted, remove the cables and gaskets from the protection tubes by unscrewing the fixing screws. 22 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 ● Lubricate the gaskets with the supplied lubricant. Make sure both inside and outside surfaces are lubricated. ● Carefully insert the cable and gasket into the sensor. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 23 ● Fixing: Tighten the fixing screws evenly with 1 Nm until the gasket seals. Grounding of sensors Figure 4-4 CD 6 sensor (transmitter or receiver) for use in hazardous areas Barrier box Connecting central unit to barrier box 1. The central unit and the barrier box are connected with a 2 meter long hybrid cable. This cable consists of two optical fibers and one standard twisted pair for the low voltage power. This cable is connected to the bottom of the barrier box when delivered. 2. Connect the hybrid cable to the central unit using the standard procedure. Ex transmitter and receiver sensors A hybrid cable is used to connect the transmitter sensor to the barrier box. 24 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Connecting transmitter sensor to barrier box 1. Cut off the fitted connector from the end of the hybrid cable at the barrier side. 2. Insert the hybrid cables (one for each channel) through the openings at the top of the barrier box. Fasten each cable with a gasket. 3. Connect each hybrid cable to the surge protection device. Minus (brown cable) shall be connected to terminal number 4 and plus (green cable) to terminal number 5. 4. Connect the hybrid cable to the transmitter sensor. WARNING Sparkovers To prevent sparkovers in a multi-channel barrier box that is equipped with one surge protection device for each channel the distance between each other must be >2 mm. Figure 4-5 Connections inside the barrier box LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 25 Connecting receiver to transmitter sensor The connector mounted on the sensor card is already connected with a red wire for + and a black wire for –. Two additional wires should be connected to the connector. These wires come from the sensor connection cable. A detailed connection information can be obtained from section Connection diagrams (Page 27). 1. Connect the green wire next to the red wire on the connector. 2. Connect the brown wire next to the black wire on the connector. 3. Connect the sensor housings, on both the transmitter and the receiver side, to earth using the pre-mounted 2 meter potential equalizing cable (yellow-green). 26 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 4.3 Connection diagrams System layout Figure 4-6 System drawing A5E00908323A LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 27 Barrier box circuit diagram CD 6 receiver circuit diagram 28 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 5 5.1 Commissioning General safety notes The following safety notes apply to the central unit. WARNING Humid environment Danger of electric shock. ● Avoid working on the device when it is energized. ● If working on an energized device is necessary, ensure that the environment is dry. ● Make sure when carrying out cleaning and maintenance work that no moisture penetrates the inside of the device. WARNING Dusty environment Danger of electric shock. ● Avoid working on the device when it is energized. ● If working on an energized device is necessary, ensure that the environment is clean. ● Make sure when carrying out cleaning and maintenance work that no dust penetrates the inside of the device. CAUTION Dangerous voltage at open device Danger of electric shock when the enclosure is opened or enclosure parts are removed. ● Before you open the enclosure or remove enclosure parts, de-energize the device. ● If maintenance measures in an energized state are necessary, observe the particular precautionary measures. Have maintenance work carried out by qualified personnel. The following safety notes apply to all system components, i. e., central unit, barrier box, and sensors. WARNING Dangerous contact voltage Danger of injury through dangerous contact voltage when the device is open or not completely closed. The degree of protection specified on the nameplate or in Chapter "Technical data (Page 35)" is no longer guaranteed if the device is open or not properly closed. ● Make sure that the device is securely closed. The following safety note applies to the barrier box and the sensors. WARNING Loss of explosion protection Danger of explosion in hazardous areas if the device is open or not properly closed. ● Close the device as described in Chapter "Installing/mounting (Page 11)". LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 29 The following safety notes apply to the sensors. WARNING Hot surfaces Danger of burns resulting from hot surfaces. ● Take corresponding protective measures, for example by wearing protective gloves. WARNING Alignment of sensors in a hazardous area Prior to operation align the sensors as described in the detailed analyzer manuals. For a correct alignment the Siemens sensor alignment kit must be used. The sensor alignment kit is not certified for use in a potentially explosive atmosphere. ● When aligning the sensors make sure that there is no potentially explosive atmosphere (hot work permit)! 5.2 Sensor side purging NOTICE Failure of purging gas supply When the process purging is connected to the sensor purging, it may be necessary to use non-return valves to ensure that no process gas can enter the purging gas line in the event of failure of the purging gas supply. This applies especially in the case of cascaded sensor and process purging where there is otherwise the danger that, for example, corrosive process gases could enter the sensor enclosure. 5.3 Process side purging With this option a needle valve is supplied with the analyzer which must be mounted on the process interface. WARNING Damage due to overpressure Observe that the use of this needle valve opens up into the process. The process must be permanently monitored if it is under pressure. If any danger for personnel or equipment can arise from the over pressurized process we recommend to mount a check valve on the process interface to prevent flow out from the process. Make sure that under no circumstances the process gas will intrude into the purging system. This applies particularly to a cascaded sensor and process purging which otherwise may lead to ingress of corrosive process gases. NOTICE Damage to the optics Always install the purging system before you install the sensors to avoid damage to the optics during the rest of the installation process. For optimal results use sensors equipped for the specific purging type, supplied by Siemens AG. 30 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 6 Service and maintenance 6.1 Safety notes The following safety note applies to the barrier box and the sensors. WARNING Impermissible repair of explosion protected devices Danger of explosion in areas subject to explosion hazard. ● Repair must be carried out by Siemens authorized personnel only. WARNING Commissioning and operation with pending error If an error message appears, correct operation in the process is no longer guaranteed. ● Check the gravity of the error ● Correct the error ● If the error still exists: – Take the device out of operation. – Prevent renewed commissioning. WARNING Electrostatic charge Danger of explosion in hazardous areas if electrostatic charges develop, for example, when cleaning plastic enclosures with a dry cloth. ● Prevent electrostatic charging in hazardous areas. WARNING Improper connection after maintenance Danger of explosion in areas subject to explosion hazard. ● Connect the device correctly after maintenance. ● Close the device after maintenance work. Refer to Chapter "Installing/mounting (Page 11)". NOTICE Penetration of moisture into the device Device damage. ● Make sure when carrying out cleaning and maintenance work that no moisture penetrates the inside of the device. The following safety notes apply to the sensors. WARNING Hot, toxic or corrosive process media Danger of injury during maintenance work. When working on the process connection, hot, toxic or corrosive process media could be released. ● As long as the device is under pressure, do not loosen process connections and do not remove any parts that are pressurized. ● Before opening or removing the device ensure that process media cannot be released. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 31 WARNING Maintenance during continued operation in a hazardous area There is a danger of explosion when carrying out repairs and maintenance on the device in a hazardous area. ● Isolate the device from power. - or ● Ensure that the atmosphere is explosion-free (hot work permit). CAUTION Hot surfaces Danger of burns during maintenance work on parts having surface temperatures exceeding 70 °C (158 °F). ● Take corresponding protective measures, for example by wearing protective gloves. ● After carrying out maintenance, remount touch protection measures. 6.2 Service instructions The following sections give step-by-step instructions for maintenance and service tasks for the sensors. Cleaning the optical parts of the cross duct sensors If the transmission for a channel drops below the level set by the user, the transmission alarm will be activated. This means that the sensors for this channel are in need of service (cleaning of the optical surfaces and aligning the sensors). Before the sensors are removed make sure that no purging is active. Preparations WARNING Danger of burns Due to hot process gases and/or purging media the sensors and their environment can become very hot. This applies particularly when steam is used for purging since overheated steam is not visible! Before you start cleaning the optical parts of the sensor make sure that ● no purging is under way ● no hazardous or hot gases can escape from the process ● you are sufficiently protected against hot surfaces on and around the sensor, e.g. by using protective gloves Failure to do so may result in severe burns! Cleaning of the process interface window on the process side 1. Demount the process interface, also demount the purging tube if applicable. WARNING Dangerous or pressurized process Before you start demounting the process interface make sure that the process conditions are safe, e.g. there are no more pressure or dangerous substances on the process side. 2. Remove all dust particles using pressurized air or flushing water. 3. Clean the optical surface with a soft cloth. Water with a small amount of soap or a mild detergent also works fine in many cases. Start the cleaning process at the center and work with circular movements towards the rim. 4. To remount the process interface, refer to section Sensor installation (Page 14). Also a new alignment of the sensors has to be carried out. 32 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Cleaning of lens or the process interface window on the sensor side 1. Release the clamp ring using an appropriate tool. 2. Remove the sensor. 3. Clean the optical sufaces from dust particles using pressurized air or flushing water. 4. Clean the optical surfaces with a soft cloth. Water with a small amount of soap or a mild detergent also works fine in many cases. Start the cleaning process at the center and work with circular movements towards the rim. 5. When remounting the sensor, make sure that the guide pin fits the hole on the purging flange. Screw on the lock ring and tighten it gently with the tool. If this operation is performed properly, it will not affect the alignment of the sensor. Note Any work with the optical lens requires utmost care. The lens is anti-reflection coated and thus very susceptible to scratches! Replacing the sensor electronics When performing service on the cross duct sensor electronics you must be ESD protected. Use a wrist strap and ground it somewhere close to the sensor. Put the strap around your arm. To replace the sensor electronics proceed as follows: 1. Remove the lid of the sensor by rotating the lid counter-clockwise. 2. Disconnect the connector between the sensor card and the sensor connection cable. 3. Remove the two screws holding the card using a TORX 20 screwdriver. 4. Carefully remove the card. 5. Replace the sensor electronics (detector module and/or sensor card). 6. Mount the two screws holding the card. 7. Connect the connector as described in section Connecting the sensors (Page 18). 8. Remount the lid by rotating it clockwise. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 33 7 Decommissioning WARNING Incorrect disassembly The following dangers may result through incorrect disassembly: - Injury through electric shock - Danger through emerging media when connected to the process - Danger of explosion in hazardous area In order to disassemble correctly, observe the following: ● Before starting work, make sure that you have switched off all physical variables such as pressure, temperature, electricity etc. or that they have a harmless value. ● If the device contains dangerous media, it must be emptied prior to disassembly. Make sure that no environmentally hazardous media are released. ● Secure the remaining connections so that no damage can result if the process is started unintentionally. Devices identified by this symbol may not be disposed of in the municipal waste disposal services under observance of Directive 2002/96/EC and / or Directive 2006/66/EC. Waste electronic and electrical equipment and waste industrial batteries can be returned to the supplier within the EC or to a locally approved disposal service. Observe the specific regulations valid in your country. Enclose the bill of lading, return document and decontamination certificate in a clear plastic pouch and attach it firmly to the outside of the packaging. Any devices/replacement parts which are returned without a decontamination declaration will be cleaned at your expense before further processing. For further details refer to the operating instructions. 34 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 8 Technical data 8.1 Central unit The following tables comprise all technical characteristics relevant for the use of the LDS 6 system in hazardous areas. General Concentration units ppmv, % vol., mg/Nm3 EU, mg/Nm3 US Display Digital concentration display (5 digits with floating decimal point) Laser protection class Class 1, safe to the eye Design, enclosure Degree of protection IP20 according to EN 60529 Dimensions 177 x 440 x 380 mm (7 x 17 5/16 x 15") Weight Approx. 13 kg (28.7 lbs.) Mounting horizontal Electrical characteristics Power supply 100 ... 240 V AC, 50 ... 60 Hz, automatically adapted by the system; with a 3-channel central unit, an additional external power supply +24 V DC, 50 VA is included in the scope of delivery Power consumption 50 W EMC According to EN 61326 and standard classification of NAMUR NE21 Electric safety According to EN 61010-1, overvoltage classification II Fuse specifications 100 ... 240 V: T2.5L250V Electrical inputs and outputs Number of measurement channels 1 ... 3, optional Analog outputs 2 per channel, 4 ... 20 mA, floating, ohmic resistance max. 750 Ω Analog inputs 2 per channel, designed for 4 ... 20 mA, 50 Ω Binary outputs 6 per channel, with changeover contacts, configurable, 24 V AC/DC/1 A, floating Binary inputs 6 per channel, designed for 24 V, floating, configurable Communication interface Ethernet 10BaseT (RJ-45) Climatic conditions Ambient temperature - during operation - during transportation and storage 5 ... 45 °C (41 ... 113 °F) -40 ... +70 °C (-40 ... +158 °F) Atmospheric pressure 800 ... 1 100 hPa (12 ... 16 psi) Humidity <85 % relative humidity, non-condensing LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 35 8.2 CD 6 sensor for use in hazardous areas CD 6 for use in hazardous areas Specification Dimension, sensor L: 450 mm (17 3/4"), Ø: 163 mm (6 7/16"), flange diameter DN80/PN16: 200 mm (7 7/8") or ANSI 4"/150 lbs.: 230 mm (9") Dimension, purging tube L: 400, 800 or 1 200 mm (15 3/4, 31 1/2 or 47 1/4"), Ø: 44 mm (1 3/4") Weight 2 x 11 kg (24 lbs.) Power supply According to the intrinsically-safe standards (IEC/EN 60079-11) Power consumption Max. 0.6 W Degree of protection IP65 according to EN 60529 EMC - Electromagnetic compatibility According to EN 61326 and standard classification of NAMUR NE21 Electrical safety According to EN 61010-1, overvoltage classification II. Permissible ambient temperature (operation) for -20 ... +60 °C (-4 ... +140 °F) the components of the Ex-relevant IP area (see Safe installation (Page 13)) Permissible ambient temperature (storage and transport) -30 ... +70 °C (-22 ... +158 °F) Atmospheric pressure 800 ... 1100 hPa (12 ... 16 psi) Maximum allowable work pressure (MAWP) for pressure-resistant window flange 1.6 MPa (232 psi) at 20 °C (68 °F) for standard flange 1 050 hPa (15 psi) at 20 °C (68 °F) Permissible ambient humidity <95 % relative humidity, non-condensing Sensor/process interface DN65/PN6 and ANSI 4"/150 lbs.; DN80/PN16 (only as pressure-resistant variant) Measurement path length 0.3 ... 12 m (1 ... 39 ft) depending on measuring conditions (dust load) Dust load Depending on particle size distribution and optical path length 8.3 Hybrid and sensor connection cables General Configuration hybrid cable Two optical fibers and two twisted copper wires in one cable for 24 V DC. Single-mode optical fiber configured at both ends with E2000 angle connectors. Multimode optical fiber configured at both ends with SMA connectors. For installations in Ex zones non-intrinsically-safe cables have to be spatially separated from intrinsically-safe lines Cable sheath Oil-resistant polyurethane Dimensions - Diameter - Length <8 mm (5/16"), total length of the hybrid cable and sensor connection cable must not exceed 250 m (820 ft) in Ex zone 0 and Ex zone 1 installations and not exceed 700 m (2 300 ft) in Ex zone 2 and non Ex installations. For lengths >500 m (1 640 ft), an external power supply must be additionally ordered. Impact resistance 100 N/cm Maximum tensile strength 200 N (45 lbf) Minimum bending radius 12 cm (4 3/4") Climatic conditions Ambient temperature -40 ... +80 °C (-40 ... +176 °F) during operation, transport and storage -5 ... +50 °C (23 ... 122 °F) during installation Rel. humidity <95 % relative humidity, above dew point 36 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 8.4 Barrier box Design, enclosure Degree of protection IP45 according to EN 60529 Dimensions (without wall mounting kit) 400 x 240 x 155 mm (15 3/4 x 9 1/2 x 6 1/8") Weight (fully equipped) Approx. 6.8 kg (15 lbs.) Permissible ambient temperature (operation) -20 ... +60 °C (-4 ... 140 °F) 8.5 Purging Conditions of purging media For purging the sensor side nitrogen, and for non-oxygen applications also instrument air are permissible as purging media. Nitrogen, steam, air and gases which are not subject to the pressure equipment directive Cat. 2 are permissible as purging gases for the process side. Purging with instrument air, nitrogen Maximum flow of sensor purging 5 l/min (1.32 US gal/min) Maximum overpressure in the sensor <500 hPa (7.25 psi) Quality - Instrument air - Nitrogen free of oil and water Purity better than 99.7 %. For oxygen measurements, an oxygen content <0.01 % is recommended in the purging gas (optical path length ≥1 m (3 ft), min. 5 % oxygen in the process gas) Maximum flow rate for process purging 500 l/min (132 US gal/min) Dew point Benchmark: ≤-10 °C (14 °F), condensation on the optics must be avoided Blower purging Maximum counter pressure 40 hPa (0.6 psi) Maximum flow rate 850 l/min (224.5 US gal/min) Power consumption 370 W Degree of protection (fan) IP54, cover required to protect against rain Steam purging Steam conditioning Overheated Maximum temperature 240 °C (464 °F) Minimum pressure >4 000 hPa (58 psi) Maximum pressure 16 000 hPa (232 psi), refers to a volume flow of approx. 1 100 l/min (291 US gal/min) 9 Product information on the internet The instructions are also available on the internet as a part of the range of technical documentation, online catalogs, and the online ordering system for process analytics products and systems Processanalytics (http://www.siemens.com/processanalytics) Here you will find: ● Products & solutions, including our newsletter containing up-to-date information on your products. ● Electronic trading over the Internet. ● Support with e.g. certificates, brochures and catalogs. LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 37 A Abbreviations List of abbreviations Abbreviation / symbol Explanation ″ Inch - 1″ ≙ 25.4 mm < Less than > Greater than ≤ Less than or equal to ≥ Greater than or equal to ± Plus-minus, more or less ≙ Corresponds to % Per cent % vol Per cent by volume ° Degrees °C Degrees celsius - 1°C ≙ 1.8 °F °F Degrees fahrenheit - 1°F ≙ 0.555... °C A Ampere AC Alternating Current ANSI American National Standards Institute ATEX Explosive atmospheres (French: Atmosphères Explosibles) CE European Community (French: Communautée Européenne) CH Channel cm Centimeter CO Carbon monoxide CO2 Carbon dioxide DC Direct Current DIN German Standardization Institute (German: Deutsches Institut für Normung) DN Diameter nominal DP Distributed Peripheral I/O EC European Community EEC European Economic Community e. g. For example (from Latin: exempli gratia) EMC Electromagnetic compatibility EN European Standard (German: Europäische Norm) EPA Electrostatic Protected Area ESD Electrostatic Discharge EU European Union Ex Explosive atmosphere FFKM Perfluoro elastomer FKM Fluorocarbon elastomer ft foot, feet - 1ft ≙ 30.48 cm 38 LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 Abbreviation / symbol Explanation H2 Hydrogen (molecular formula) H2O Water (vapor) HCl Hydrogen chloride HF Hydrogen fluoride hPa hectoPascal i. e. This means (from Latin: id est) IEC Internation Electrotechnical Committee I/O Input/Output IP Ingress protection kg Kilogram kHz Kilohertz kPa Kilopascal l/min Liters per minute, a flow unit lb(s). Pound(s), 1 lb ≙ 454 g lbf Pound-force, a unit for powers, 1 lbf ≙ 4.45 N LVD Low Voltage Directive m Meter mA Milliampere MAWP Maximum allowable work pressure max. Maximum MCERTS Monitoring Certification Scheme (of the Environment Agency of England & Wales) mg/Nm3 Milligrams per normal cubic meter (at 0 °C and 1.013 hPa) mH Millihenry(s) min. Minimum MLFB Machine-readable product number (German: Maschinenlesbare Fabrikatenummer) mm Millimeter mm² Square millimeters MPa Megapascal N Newton N2 Nitrogen (molecular formula) NAMUR Standards working committee for measuring and control technology in the chemical industry. NC, n. c. Not connected nF Nanofarad(s) NFPA National Fire Protection Association NH3 Ammonia Nm Newtonmeter, a measure of torque No. Number O2 Oxygen (molecular formula) PE Protective Earth (terminal) PN Pressure nominal ppm Parts per million ppmv Parts per million (by volume) psi pounds per square inch - 1 psi ≙ 69 hPa PUR Polyurethane, a plastic LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas A5E03314905-01, 04/2013 39 Abbreviation / symbol Explanation RH Relative humidity RJ-45 A cable connector plug type Rx Receive (Rx) identifies a receiver s, sec. Second SMA Sub Miniature A, an optical fiber connector type TÜV Technical Inspection Association (German: Technischer Überwachungs-Verein) Tx Transmit (Tx) identifies a transmitter US gal/min US gallons per minute, a flow unit, 1 US gal/min ≙ 3.8 l/min UV Ultraviolet V Volt VA Volt-ampere VDI German Engineers Association (German: Verein Deutscher Ingenieure) W Watt(s) Δ Difference (Greek letter delta) Ω Ohm(s) (Greek letter omega) Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG LDS 6/CD LDS 6/CD 6 Operating Instructions for use of the device in hazardous areas6 Operating Instructions for use of the device in hazardous areas A5E03314905, 04/2013 40 A5E03314905-01, 04/2013