Braun A5S1 Series User manual

A5S1
A5S1-Manual_EN_Rev01 2021_JAN_19 Page 1 of 37
Manual
Ex ia Sensors Series A5S1 (intrinsically safe)
(Original operating manual)
valid for versions
A5S1DD0 (1x speed, signal range 0 Hz…25 kHz)
A5S1DD3 (1x speed / 1x direction, signal range 0 Hz…25 kHz)
A5S1DD4 (2x speed, phase shifted, signal range 0 Hz…25 kHz)
A5S1DS0 (1x speed, signal range 0 Hz…12 kHz)
A5S1DS3 (1x speed / 1x direction, signal range 0 Hz…12 kHz)
A5S1DS4 (2x speed, phase shifted, signal range 0 Hz…12 kHz)
also valid for sensors with previous order code:
A5S10 to A5S13 (1x speed, signal range 0 Hz…12 kHz)
A5S14 to A5S17 (1x speed / 1x direction, signal range 0 Hz…12 kHz)
(valid from Serial-No. 1602050001)
A5S view
(version A5S1DS0M2210B48 shown)
Speed Sensors
for Hazardous Areas zone 0 resp. 1
based on Differential-Hall-Effect Principle
TÜV certified for IEC 61508:2010; SIL 3
DIN EN ISO 13849-1:2016; PL e; Kat. 3
DIN EN ISO 13849-2:2012; PL e; Kat. 3
IEC 62061:2015; SILCL 3

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Table of Contents
Contents Page
Table of Contents........................................................................................................................................................2
1General Information ...........................................................................................................................................3
1.1 List of Figures..............................................................................................................................................3
1.2 List of Abbreviations ....................................................................................................................................4
1.3 Application characteristics...........................................................................................................................5
1.4 Mounting of the Sensor ...............................................................................................................................5
1.4.1 Notes on Pole Wheel..........................................................................................................................6
1.4.2 Positioning of Sensor..........................................................................................................................6
1.4.2.1 Alignment of Sensor.......................................................................................................................6
1.4.2.2 Recommended Air Gap..................................................................................................................7
1.4.3 Maximum fastening torques / wrench sizes / thickness of BRAUN nuts.............................................7
1.5 Connection (pin assignment resp. wire assignment) ...................................................................................8
1.6 Arrangement of Pins in Sensor Plug ...........................................................................................................8
1.7 Signal Transmission ....................................................................................................................................9
1.8 Direction of rotation signal for sensor series A5S1DD3 / A5S1DS3 / A5S14 / A5S15 / A5S16 ..................10
1.9 Speed signal f2 (phase shifted) for sensor series A5S1DD4 / A5S1DS4 ..................................................10
1.10 Level and shape of the output signal.........................................................................................................11
1.11 Ordering Key for Sensors of A5S1… Series..............................................................................................12
1.11.1 Ordering Key old / current.................................................................................................................13
1.12 Safety Data................................................................................................................................................14
1.13 General Certificates / Approvals................................................................................................................14
1.13.1 Certification IEC 61508:2010; SIL 3..................................................................................................14
1.13.2 Certification DIN EN ISO 13849-1:2016; PLe; Kat. 3........................................................................14
1.13.3 Certification DIN EN ISO 13849-2:2012; PLe; Kat. 3........................................................................14
1.13.4 Certification IEC 62061:2015; SILCL 3 ..............................................................................................14
1.13.5 SIL 3 Certificate ................................................................................................................................15
1.13.6 EU Declaration of Conformity ...........................................................................................................16
2Hazardous protection ......................................................................................................................................17
2.1 Relevant technical Data for Hazardous Area.............................................................................................17
2.2 ATEX Certification of the Input Circuit .......................................................................................................17
2.3 Explosive relevant Certificates / Approvals................................................................................................17
2.3.1 ATEX ................................................................................................................................................17
2.3.2 IECEx ...............................................................................................................................................17
2.3.3 USA (NEC) and Canada (CEC)........................................................................................................17
2.3.4 EAC Ex.............................................................................................................................................17
2.3.5 ATEX EU Type Examination Certificate ............................................................................................18
2.3.6 IECEx Certificate of Conformity ........................................................................................................21
2.3.7 NEC/CEC Certificate of Conformity ..................................................................................................27
2.3.8 EAC Ex TR CU Certificate ................................................................................................................29
3Safety Notes for Installation and Operation...................................................................................................33
3.1 General Instructions ..................................................................................................................................33
3.2 EMI............................................................................................................................................................33
3.3 Safety note about metallic abrasion in the machine ..................................................................................33
3.4 Safety Notes on Installation.......................................................................................................................33
3.4.1 Initial Commissioning and Installation...............................................................................................33
3.5 Safety Notes on Operation ........................................................................................................................33
3.5.1 Machine Maintenance or Overhaul...................................................................................................33

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4Technical Specifications..................................................................................................................................34
4.1 Conformity to Standards............................................................................................................................34
4.2 Power Supply ............................................................................................................................................34
4.3 Signal Output.............................................................................................................................................34
4.4 Speed (Frequency-) Range.......................................................................................................................34
4.5 Signal Transmission ..................................................................................................................................34
4.6 Electrical Protective Measures ..................................................................................................................34
4.7 Connection ................................................................................................................................................34
4.8 Permissible Ambient Temperature.............................................................................................................34
4.9 Installation Dimensions .............................................................................................................................35
4.10 Cable diameters of BRAUN Cables...........................................................................................................35
4.11 Weight .......................................................................................................................................................35
5Accessories (optional).....................................................................................................................................35
6Useful Lifetime, Proof Test Interval and replacement of A5S sensors ........................................................35
7Dimensions at different Connection Types....................................................................................................36
8Revision Notes .................................................................................................................................................37
1 General Information
1.1 List of Figures
Figure 1: Adjustment to the profile edges ......................................................................................................... 5
Figure 2: Alignment of sensor........................................................................................................................... 6
Figure 3: Information on profile size..................................................................................................................7
Figure 4: SIL 3 Certificate ............................................................................................................................... 15
Figure 5: EU Declaration of Conformity .......................................................................................................... 16
Figure 6: ATEX EU Type Examination Certificate part 1................................................................................. 18
Figure 7: ATEX EU Type Examination Certificate part 2................................................................................. 19
Figure 8: ATEX EU Type Examination Certificate part 3................................................................................. 20
Figure 9: IECEx Certificate of Conformity part 1............................................................................................. 21
Figure 10: IECEx Certificate of Conformity part 2............................................................................................. 22
Figure 11: IECEx Certificate of Conformity part 3............................................................................................. 23
Figure 12: IECEx Certificate of Conformity part 4............................................................................................. 24
Figure 13: IECEx Certificate of Conformity part 5............................................................................................. 25
Figure 14: IECEx Certificate of Conformity part 6 ............................................................................................. 26
Figure 15: NEC/CEC Certificate of Conformity part 1 ....................................................................................... 27
Figure 16: NEC/CEC Certificate of Conformity part 2 ....................................................................................... 28
Figure 17: EAC Ex TR CU Certificate part 1..................................................................................................... 29
Figure 18: EAC Ex TR CU Certificate part 2..................................................................................................... 30
Figure 19: EAC Ex TR CU Certificate part 3..................................................................................................... 31
Figure 20: EAC Ex TR CU Certificate part 4..................................................................................................... 32
Figure 21: Dimensions at different connection types ........................................................................................ 36

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1.2 List of Abbreviations
Abbreviation
Meaning
altern.
alternative
API
Technical standards of the "American Petroleum Institute"
A5S
BRAUN GmbH Sensor series
ATEX
stands for ATmosphère Explosibles (meaning the ATEX EU directives for explosion protection)
DIN
German Institute for Standardisation (Deutsches Institut für Normung)
EMC
Electro magnetic compatibility
EN
European Norm
Ex ia
Type of protection "Intrinsically Safe", approval for hazardous areas zone 0 resp. 1
F/R
Forward/Reverse (Forward/Backward)
IEC
International Electrotechnical Commission
incl.
inclusive
IPxx
Ingress Protection Number xx according to DIN EN 60529
ISO
International Organization for Standardization
max.
maximum
min.
minimum
MTTFd
Mean Time To Failure dangerous
n
Short term for Speed
NEMAx
National Electrical Manufacturers Association Number x
Nm
Newton meter
PELV
Protective Extra Low Voltage
PFDavg
Probability of Failure on Demand average
RPM
Revolutions Per Minute
sec
second
SELV
Safety Extra Low Voltage
SILx
Safety Integrity Level x
TMR
Triple Modular Redundant
Ub
+ supply voltage
UL
Underwriter Laboratories
Vdc or
V dc
Volt direct current

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1.3 Application characteristics
Speed sensors for applications such as turbines, compressors, expanders, etc. in hazardous
areas of zones 0 resp. 1. The sensors are approved as intrinsically safe equipment with
protection class Ex ia IIC, temperature class T4 (at Ta = -40 ° C to +125 ° C) or temperature
class T6 (at Ta = -20 ° C to + 40 ° C). The power supply must comply with the regulations for this
(see chapter 4.2 "Power supply" or Chapter 3 "Safety instructions"). Safety classification up to
SIL 3 / IEC 61508:2010 resp. DIN EN ISO 13849-1:2016 PL e Kat. 3, DIN EN ISO 13849-2:2012
PL e Kat. 3 and IEC 62061:2015; useable in applications up to SILCL 3 as speed sensors.
Their low end of 0 Hz allows monitoring the machine down to zero speed. They are contact-free,
wear-free, maintenance-free and unsusceptible versus external magnetic stray fields and
machine vibration.
Sensors A5S1DD0 and A5S1DS0 and A5S10…13 for detection of rotational speed
Single Channel, the output provides the rotational speed as a single-track frequency signal.
Sensors A5S1DD3 and A5S1DS3 and A5S14…17 for detection of rotational speed and
direction of rotation
Dual Channel, 1 track = rotational speed as frequency, 1 track = F/R status as binary signal.
Sensors A5S1DD4 and A5S1DS4 for detection of rotational speed and direction of
rotation with two phase-shifted speed signals
Dual Channel, the output provides the rotational speed as a twin-track frequency signal (phase
shifted). Suitable for external direction detection with enhanced safety.
1.4 Mounting of the Sensor
The sensor should be mounted in radial direction so that it points to the axis of rotation of the
rotating profile. An arrangement parallel to the axis of rotation for frontal scanning is also
possible. Then, a possible axial displacement in the machine must be considered. All our
information applies to radial scanning.
For mounting, it is best to have the same thread in the fixed part. The sensor is then fixed in the
correct position with the supplied nut.
The mounting may be made flush in any material; several sensors can also be placed close to
each other.
Mounting preferably in radial
direction and in alignment
with the profile
Figure 1: Adjustment to the profile edges
rotation of
target
wrench planes at rear or front end
of sensor
profile
edge
Adjustment to the profile edges
Slots for positioning with
NPT at rear end

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Figure 2: Alignment of sensor
1.4.1 Notes on Pole Wheel
The pole wheel must be made of ferromagnetic steel. Non-ferrous material, stainless steel or
plastics do not work.
The grooves / bolts of the pole wheel must be equidistant; otherwise the speed signal will be
unsteady.
The pole wheel should have no damage or burrs; otherwise the speed signal can become
unsteady. If there is any damage, increasing the gap in the air can eliminate a possible fault
(double pulses).
1.4.2 Positioning of Sensor
1.4.2.1 Alignment of Sensor
The sensor must be aligned with the flanks of the profile to be scanned. It is correctly installed if
the two planes at the end of the sensor (which also serve as wrench planes for screwing in)
point in the direction of the profile or perpendicular to the profile edges (for example the tooth
flanks of a gear).
A deviation of up to ± 20 ° is permitted.
Correct alignment of the sensor
Incorrect alignment of the sensor

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Figure 3: Information on profile size
D
W
T
Profile size of a
grooved wheel
D = min. 3 mm
W = min. 3 mm
T = min. 5 mm
1.4.2.2 Recommended Air Gap
The recommended air gap between the sensor front surface and the rotating part must be
observed. It increases with the size of the profile: For cams or milled grooves with their width,
distance and depth, for a gear with its module (= diameter / number of teeth). The field between
grooves or cams must be at least as large as the specified width (W), the depth D = at least 3
mm. Thickness of a gear or length (T) of a milled recess of at least 5 mm (plus a possible axial
displacement).
The guideline values given below for the profile size (D / W / T) of a rotor are the minimum
dimensions, they may be exceeded in any direction. However, the maximum permissible air gap
between the sensor and the pole wheel will not increase.
Air gap in dependency of profile size
A5S1DS0
A5S1DD0
A5S10 … A5S13
A5S1DS3 and DS4
A5S1DD3 and DD4
A5S14 … A5S17
Module of a
gear wheel
Diametrical Pitch
approx.
min. width W of a
groove wheel
Recommended
air gap
Recommended
air gap
m1
25.40 mm
3 mm
0.5 –0.8 mm
--
m1.5
16.93 mm
3 mm
0.5 –1.0 mm
--
m2
12.70 mm
3 mm
0.8 –1.5 mm
0.3 –0.8 mm
m3
8.47 mm
3 mm
0.8 –2.0 mm
0.3 –1.2 mm
m4
6.35 mm
3 mm
1.0 –2.5 mm
0.5 –1.5 mm
1.4.3 Maximum fastening torques / wrench sizes / thickness of BRAUN nuts
Nut
Maximum
fastening torque
wrench size
thickness
(+/- 0.5 mm)
M12 x 1
12 Nm
WS 19
6 mm
M14 x 1
25 Nm
WS 22
4 mm
M14 x 1.5
25 Nm
WS 22
7 mm
3/4“-16
25 Nm
WS 28
10 mm
M16 x 1
35 Nm
WS 24
8 mm
M18 x 1
50 Nm
WS 26
9 mm
3/4“-20
50 Nm
WS 24
6 mm
M18 x 1.5
50 Nm
WS 26
9 mm
5/8“-18
50 Nm
WS 24
10 mm
M22 x 1
75 Nm
WS 30
6 mm

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1.5 Connection (pin assignment resp. wire assignment)
All sensors described here can have different dimensions and different connection types.
For the connections applies to the different types:
Assignment
with plug
pin no.
with open cable ends of
BRAUN cables
wire color
Signal output 1:
(speed signal f1)
4
white
Common zero
3
green
+ sensor supply Ub
1
brown
Signal output 2:
(speed signal f2 resp.
rotation direction signal)
2
red (at Teflon® cable)
resp.
yellow (at PVC cable)
Screen (not connected to
sensor housing)
black
1.6 Arrangement of Pins in Sensor Plug

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1.7 Signal Transmission
The possible transmission distance is essentially determined by the highest occurring signal
frequency, the properties of the transmission line and the input of the connected receiving
device.
When connected to our Isolating Barrier D461R1…, a signal frequency of 25000 Hz can be
safely transmitted over a distance of up to 500 m. If the signal frequency is lower, a corres-
pondingly longer transmission distance applies. The cable is based on a 3-core or 4-core
shielded version LiYCY or LiTCT with 3x0.5 mm2or 4x0.5 mm2, as supplied by us (R <36 Ohm /
km, C <150 pF / m).
The signal frequency in Hz is calculated with a uniformly divided profile by:
Number of poles x speed / 60.
For narrow poles, the effective frequency must be set higher in accordance with the relationship
between pole and gap.
Important in the transmission:
A continuous good shielding must be provided. The shield must be connected directly to a shield
rail on the receiving side. Never transmit multiple signals under one common screen!
Lay transmission line separately from sources of interference.

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1.8 Direction of rotation signal for sensor series A5S1DD3 / A5S1DS3 / A5S14 /
A5S15 / A5S16
The sensor indicates the direction of rotation by a constant signal, which is either high or low
depending on the direction (see below for level values). The change is instantaneous as soon as
a pole pitch (e.g., 1 tooth) has passed the sensor. At standstill, the last reported direction is
retained. A hysteresis in the direction change or the combination with a speed lower limit must
be implemented in the connected evaluation unit.
The assignment between the signal level and the direction of rotation results from the installation
position of the sensor. For the purpose of predetermination, a mark o is placed on the type strip
of the sensor. If the profile wheel rotates clockwise in the viewing direction to this mark, the
output has high level, otherwise low level.
Relationship between mark and direction signal
o mark visible and rotation in clockwise direction = direction output high
o mark visible and rotation in counterclockwise direction = direction output low
o mark not visible: output inverse to above
1.9 Speed signal f2 (phase shifted) for sensor series A5S1DD4 / A5S1DS4
The sensor provides two phase shifted frequency signals f1 and f2:
Relationship between mark and phase position
o mark visible and rotation in clockwise direction: f1 is ahead
o mark visible and rotation in counterclockwise direction: f2 is ahead
o mark not visible: phase position inverse to above
wrench plane
o mark
wrench plane
o mark