Kistler 8852A Series User manual

Instruction
Manual
ATEX/CSA Hazardous
Area System:
AE-Piezotron®Sensor
Types
8852A...,
5125C0x1x,
5125C0x2x,
8152Cxxxxxx1,
8152Cxxxxxx2
ä
8852A_002-668e-05.16

Instruction
Manual
ATEX/CSA Hazardous
Area System:
AE-Piezotron®Sensor
Types
8852A...,
5125C0x1x,
5125C0x2x,
8152Cxxxxxx1,
8152Cxxxxxx2
ä
8852A_002-668e-05.16


Foreword
Foreword
8852A_002-668e-05.16
Thank you for choosing a Kistler quality product characterized
by technical innovation, precision and long life.
Information in this document is subject to change without notice.
Kistler reserves the right to change or improve its products and
make changes to the content without obligation to notify any
person or organization of such changes or improvements.
©2014 ... 2016 Kistler Group. All rights reserved. Except as ex-
pressly provided herein, no part of this manual may be repro-
duced for any purpose without the express prior written consent
of Kistler Group.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Fax +41 52 224 14 14
info@kistler.com
www.kistler.com
Page 1

8852A_002-668e-05.16Page 2
ATEX/CSA Hazardous Area System
Content
1. Introduction.......................................................................................................................................4
2. Important Information ......................................................................................................................6
2.1 For Your Safety.......................................................................................................................6
2.2 Precautions ............................................................................................................................7
2.3 Hazardous Area Certications................................................................................................7
2.4 Disposal of Electronic Equipment...........................................................................................8
2.5 Electromagnetic Compatibility................................................................................................9
2.6 Product Types ........................................................................................................................9
3. Product Description .......................................................................................................................11
3.1 Acoustic Emission (AE) as Measurands...............................................................................11
3.2 Acoustic Emission (AE) as Measurands...............................................................................11
3.3 AE-Piezotron®Sensor Type 8152C......................................................................................12
3.4 AE-Piezotron®Sensor Type 5125C......................................................................................13
4. Hazardous Area Installation ..........................................................................................................15
4.1 Suitable Safety Barriers for Zone 0 Installations ..................................................................16
4.2 Suitable Safety Barriers for Zone 2 Installations ..................................................................17
4.3 Parameter Values for Coupler Connections .........................................................................18
4.4 Wiring Details .......................................................................................................................20
4.5 Special Conditions for Safe Use...........................................................................................20
5. Mounting, Installation & Operation...............................................................................................21
5.1 Mounting the AE-Piezotron®Type 8152C... Sensors ...........................................................21
5.2 Mounting Techniques ...........................................................................................................21
5.2.1 Operation ................................................................................................................22
5.2.2 Filters ......................................................................................................................23
5.2.3 RMS (Root Mean Square) Converter .....................................................................24
5.2.4 Alarm Switch ...........................................................................................................24
6. Application Example ......................................................................................................................26
7. Calibration & Maintenance ............................................................................................................27
7.1 General.................................................................................................................................27
7.2 Care & Cleaning...................................................................................................................27
7.3 Calibration ............................................................................................................................27

Page 38852A_002-668e-05.16
Content
Total pages: 37
8. Storage & Transit Considerations.................................................................................................28
9. Warranty ..........................................................................................................................................29
10. CE Declaration of Conformity .....................................................................................................30
11. CSA Control Drawings .................................................................................................................36
11.1 Type 8852A... AE System...................................................................................................36

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 4
Thank you for choosing a quality product from Kistler. Please
read through this manual thoroughly to enable you to fully
exploit the various features of your product.
To the extent permitted by law Kistler accepts no liability if
this instruction manual is not followed or products other than
those listed under Accessories are used.
These instructions describe the AE-Piezotron®Sensor for
Hazardous areas Types 8152Cxxxxxx1 or 8152Cxxxxxx2
and the AE-Piezotron®Coupler for Hazardous areas
Types 5125C0x1x or 5125C0x2x, installed with intrinsically
safe barriers as part of a Type 8852A… AE System.
Performance features at a glance:
Acoustic emission measuring chain
Standard ATEX Zone 0 or ATEX Zone 2 versions available
High sensitivity and wide frequency range from
50 ... 900 kHz (depending on sensor type chosen)
Insensitive to electric and magnetic noise elds
Robust, for industrial use (IP65)
High operating temperature range: –55 ... 165 °C
[–67 ... 330 °F]
Ground isolated; prevents ground loops
Conforming to ä
Kistler offers a wide range of products for use in measuring
technology:
Piezoelectric sensors for measuring force, torque, strain,
pressure, acceleration, shock, vibration and acoustic
emission
Strain gage sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems, as well as
software for specic measurement applications
Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions
for the application elds engines, vehicles, manufacturing,
plastics and biomechanics sectors.
Our product and application brochures, in addition to our
detailed data sheets, will provide you with an overview of our
product range. All unit measurements provided are listed in
order of meters, followed by inches [in brackets].
1. Introduction

8852A_002-668e-05.16
Introduction
Page 5
If you require additional assistance beyond what can be loca-
ted online or in this manual, please contact Kistler‘s extensive
support organization or visit us online at www.kistler.com.

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 6
2. Important Information
The instruments are CE-compliant within the meaning of EU
Directive 2004/108/EC and conform to the EMC standard
EN 61326-1:2013; compliance is required with the correspon-
ding installation notes. All equipment is tested and has left
the factory in a perfect, safe condition. In order to maintain
this condition and ensure safe operation, compliance is requi-
red with the instructions and warning notes contained within
this manual or imprinted on the product itself.
Compliance with local safety regulations, which may apply
to the use of power line operated electrical and electronic
equipment, is strongly recommended.
It is essential for your to review the following information,
which is intended to ensure your personal safety when
working with acoustic emission sensors and contribute
toward a long-fault-free service life.
2.1 For Your Safety

8852A_002-668e-05.16
Important Information
Page 7
2.3 Hazardous Area Certications
Zone 0:
Type 8152C… AE sensor for Zone 0 is marked Ex ia IIC
T6/T5/T4/T3 Ga, Ex ia IIIC T85C°/T100C°/T135C/T185C° Da
(–55°C<Ta<60°/75°/110°/165°C) for Europe (ATEX) and Ex
ia IIC T6/T5/T4/T3 Ga (–55°C<Ta<60°/75°/110°/165°C) for
North America (CSA).
Consult the EC Type Examination Certicate
Baseefa12ATEX0216X and CSA Certicate of Compliance
2605763 included in Section 10 of this Instruction
Manual for specic instructions related to the Zone 0
certication. Type 5125C… AE Coupler for Zone 0 is
marked Ex ia IIC T4/T6 Ga (–40°C<Ta<80°/75°C), Ex ia
IIIC T90°C Da (-40°C<Ta<80°C) for Europe (ATEX) and
Ex ia IIC T6...T4 Ga (–40°C<Ta <75°C ... 80°C), Ex ia IIIC
T90°C Da (–40°C<Ta<80°C) for North America (CSA).
2.2 Precautions
Compliance with the following precautionary measures is
vital to ensure safe and reliable operation:
Check all equipment packaging for transporation damage.
Report any damage to the transporter and to Kistler.
The equipment should be used only under the specied ope-
rating conditions and must be protected against excessive
dust and mechanical stress (shock, vibration, etc.).
Avoid high atmospheric humidity, which can lead to conden-
sation during changes in temperature.
If there is evidence that safe operation is no longer possib-
le, the instrument must be powered off and rendered safe
against accidental start-up. Safe operation is no longer pos-
sible when the product
▪ shows visible signs of damage
▪ is no longer operating
▪ has been subjected to prolonged storage under unsuitable
conditions

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 8
2.4 Disposal of Electronic Equipment
Do not discard old electronic equipment in municipal trash.
For disposal at end of life, please return this product to the
nearest authorized electronic waste disposal service or
contact your Kistler sales ofce for disposal instructions.
Consult the EC Type Examination Certicate
Baseefa12ATEX0136X and CSA Certicate of Compliance
2605764 included in Section 10 of this Instruction Manual for
specic instructions related to Zone 0 Certication.
Zone 2:
The Type 8152C… AE sensor for Zone 2 is marked Ex nA
IIC T6/T5/T4/T3 Gc, (–55°C<Ta<60°/75°/110°/165°C) for
Europe (ATEX) and Ex nA IIC T6/T5/T4/T3 Gc (–55°C<Ta
<60°/75°/110°/165°C) for North America (CSA).
Consult the Type Examination Certicate
Baseefa12ATEX0217X and CSA Certicate of Compliance
2605763 included in Section 10 of this Instruction Manual for
specic instructions related to the Zone 2 Certication.
The AE-Piezotron Coupler Type 5125C… is CE-compliant
according to the conformity declaration in Section 11 of this
instruction manual.
The 5125C… AE Coupler for Zone 2 is marked Ex nA IIC
T4/T6 Gc (–40°C<Ta<80°C/75°C) for Europe (ATEX) and Ex
nA IIC T6 ... T4 Gc (–40°C<Ta <75°C ... 80°C) is marked for
North America (CSA).
Consult the EC Type Examination Certicate
Baseefa12ATEX0138X and CSA Certicate of Compliance
2605764, included in Section 10 of this instruction manual for
specic instructions related to the Zone 2 Certication.
Installations for Zone 2 require that the user supply a
surge protective device in the power connection between the
Type 5125C0XXX (located in the Hazardous area) and the
power supply (located in the Safe area). This protective de-
vice must limit the peak input voltage to less than 140 % of
the maximum rated input voltage. A Zener IS barrier with a
maximum fault voltage less than 36 V, at fuse operation, is
suitable for this purpose.

8852A_002-668e-05.16
Important Information
Page 9
2.5 Electromagnetic Compatibility
The Type 8852A… AE System meets the EMC regulations:
EN 61326-1:2013.
Connections in explosive environments and differences in
ground potential when connecting the cable can produce
sparking.
With normal coaxial connections, as used with most
piezoelectric sensors, the shield utilizes a signal return lead
with connections over long distances. Therefore, different
ground potentials can produce equalizing currents in the
cable shield. In this case, it may be necessary to forgo
grounding at both ends to prevent ground loops. Using an
additional equipotential bonded lead, with a sufciently
large cross-sectional area and the lowest possible internal
resistance, may also provide a solution.
The intrinsically safe Type 5125C0XXX Coupler contains
oating circuitry, which makes shields of little use since they
cannot be grounded. Effective suppression of electromagnetic
interference is gained by installing the supplied ferrite chokes
on Power, RMS and 4 ... 20 mA connections, as shown in
Fig. 4, Fig. 5, and Fig. 7. A fourth choke is supplied for use on
the sensor connection.
Use an unshielded, twisted pair, certied for the Hazardous
area application, with a round jacket of an external diameter
of 5 mm [0.20 in], to t the cable glands (see Section 4.5)
2.6 Product Types
This instruction manual summarizes ATEX/CSA Hazardous
area Acoustic Emission System Type 8852A…, which
includes the AE sensor Type 8152C… and coupler
Type 5125C…

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 10
Type 8152Cxxx0001/2 ATEX AE-Sensor with polyurethane cable
Type 8152Cxxxxxx1/2 ATEX AE-Sensor with steel braid conduit
Type 5125C0XXX ATEX AE-Coupler
Fig. 1: Type 8852A... AE ATEX System for Hazardous Areas

8852A_002-668e-05.16
Product Description
Page 11
3. Product Description
3.1 Acoustic Emission (AE) as Measurands
Acoustic emissions (AE), also called “sound emissions”,
involve phenomena in which short, acoustic pulses are
emitted as a result of deformation processes or crack
propagation in a material. A common example of this is what
is known as "tin cry", which occurs during the deformation
of tin by hammering or bending. The acoustic pulses emitted
are so strong that they can be heard by the human ear.
Normally, the effects which lead to acoustic emissions
have a much lower intensity. This means that very sensitive
measuring instruments must be used in order to "hear" these
acoustic emissions. Highly sensitive piezoelectric sensors,
such as Type 8152C…, can demonstrate that almost all
materials (i.e. metals, ceramics, glass, and compound
materials) emit acoustic emissions under stress.
Acoustic emissions always occur in a solid when elastic
energy is suddenly released. Such energy releases can have
a wide variety of causes:
a) Plastic deformation, i.e. sliding processes (displacement
motion) or twinning, such as in the case of “tin cry”
b) Phase conversions, particularly those which occur rapidly,
i.e. martensitic conversions
c) Crack formations and crack propagation or fracture
processes
d) Friction processes in a crack or between two other
materials.
The causes can therefore be microscopic or submicroscopic
dimensions (a … b), as well as macroscopic dimensions
(c … d).
3.2 Acoustic Emission (AE) as Measurands
A number of variants are included under the Kistler
Type 8852A… Acoustic Emission System, based on a
selection of sensitivities, lter characteristics and cable
lengths accommodating the needs of various applications.
Below is the detail code of the Type number:

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 12
The Kistler Type 8852A… acoustic emission measuring
system for hazardous locations contains three parts. Please
refer to Fig. 4 and Fig. 5, the Type 5125C… system block
diagrams, to assist in visualizing the following explanation.
3.3 AE-Piezotron®Sensor Type 8152C...
The AE sensor consists of the sensor case, the piezoelectric
measuring element and the integral impedance converter.
The measuring element of piezoelectric ceramic is mounted
on a thin steel diaphragm. Its structure determines the
sensitivity and frequency response of the sensor.
The diaphragm, which is welded into the case, has a slightly
protruding coupling surface allowing the surface to be
pressed with an accurately dened force during mounting.
This ensures constant and reproducible coupling of the
AE transmission into the sensing element. The measuring
element is acoustically insulated by the specic design
of the sensor case and is well-protected against external
interference. The Kistler AE-sensors have a very high
sensitivity to surface (Rayleigh) and longitudinal waves over
a wide frequency range. Type 8152C… covers the frequency
range of 100 … 900 kHz.
A miniature impedance converter is incorporated in the
AE-sensor, allowing a low impedance voltage signal to
become available at the output. The power supply and signal
processing are provided by the AE-coupler Type 5125C….
Connecting cables do not need to be highly insulating or low
noise.
The Type 8152C… AE-sensor is available in a simple cable
with pigtails or a cable with exible conduit protection. The
maximum cable length for use in hazardous areas is 20 m
[65 ft].
TYPE 5125C0XXX VARIANT/
RMS TIME CONSTANT/GAIN TYPE

8852A_002-668e-05.16
Product Description
Page 13
CUSTOMER SUPPLIED LENGTH OF CABLE TO 20 m [65 ft]
CUSTOMER SUPPLIED LENGTH OF ARMOR TO 20 m [65 ft]
FLEXIBLE CONDUIT PROTECTION
7/16-20 UNF FEMALE FLARED JIC END TO MATE WITH TYPE 5125C
OR TO BE USED WITH ADAPTOR CONVERTING TO
M13 x 1.0 MALE THREAD OR ¼” MALE NPT
AND INTEGRAL IMPEDANCE CONVERTER
PIGTAIL END
TRIAXIAL PFA CABLE
25 mm [0.98 in]
23.5 mm [0.9 in]
Ø14.2 mm [0.56 in]
16 mm [0.6 in]
23.5 mm [0.9 in]
SENSOR CASE
CUSTOMER SUPPLIED LENGTH OF CABLE TO 20 m [65 ft]
PIGTAIL END
TRIAXIAL PFA CABLE
DIAPHRAGM & COUPLING SURFACE INTERNAL HOUSING CONTAINING
PIEZOELECTRIC MEASURING ELEMENT
AND INTEGRAL IMPEDANCE CONVERTER
Ø8.9 mm [0.35 in]
16 mm [0.6 in]
25 mm [0.98 in]
Fig. 2: AE Sensor Type 8152C... with pigtail (above) and
exible conduit (below)
3.4 AE-Piezotron®Sensor Type 5125C...
The Type 5125C… AE coupler serves multiple functions in
the system. The coupler supplies constant-current power for
the IEPE amplier contained in the sensor. While the constant
current ows though the cable to the sensor, the sensor
bias voltage varies in response to the acoustic wave signal
produced by the ceramic transducer element. The coupler
chooses the signal from the bias voltage and amplies it by
unity, x10 or x100 as appropriate to the application. Next, the
coupler applies high-pass and low-pass ltering in order to
remove that frequency content which is of no interest and
measures the RMS level of the resultant signal. Finally, the
RMS level is converted to a representative DC level.
The coupler outputs available to the user system are the DC
representation of RMS level, a 4-20 mA representation of
RMS level and a switch closure adjustable for RMS level, for
alarm purposes.

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 14
System power for the AE coupler is supplied as 15 VDC
nominal, at 26 mA maximum. Maximum voltage supplied to
the coupler in intrinsically safe applications may not exceed
26 VDC.
TYPE 8152C SENSOR TERMINATION
0 = 12 mm [0.47 in] CABLE GLAND
1 - CONDUIT ADAPTOR
133 mm [5.2 in]
27 mm [1.06 in]
105 mm [4.1 in]
144 mm [5.67 in]
12 mm [0.47 in] CABLE GLAND PLUG
2 x 20 mm [0.79 in] CABLE GLAND
#6-32 GROUND STUD
TYPE 8152C SENSOR
TERMINATION ‘0’ SHOWN
12 mm
[0.47 in]
21 mm [0.83 in]
TYPE 8152C SENSOR
TERMINATION ‘0’ SHOWN
86 mm
[3.39 in]
45 mm
[1.77 in]
46 mm
[1.8 in]
120 mm [4.72 in]
29 mm
[1.14 in]
45 mm
[1.77 in]
38 mm
[1.5 in]
Fig. 3: AE Coupler

8852A_002-668e-05.16
Hazardous Area Installation
Page 15
4. Hazardous Area Installation
Installation of Type 5125C0XXX in a hazardous area location
must be in accordance with the requirements of DIN EN
60079-14 and IEC 60079-14.
Installation in Zone 0 requires that the user supply Intrinsic
Safety Barrier Devices between the Type 5125C0XXX
acoustic emission coupler, which is located within the Hazard
area and the control system, located in the "Safe" area.
Component
Variable Type
Max.
Allowable
Capacitance
In Cable (nF)a
Ci
(nF)
Max.
Allowable
Capacitance
In Cable (μH)a
Li
(μH)
li
(mA)
Max.
Supply
Voltage
(VDC)
P Max.
(W)
5125C01XX 17,4 130 194 150 84 26 1.2
5125C02XX 17,4 130 194 150 84 26 1.2
5125C03XX 17,4 130 194 150 84 26 1.2
5125C04XX 17,4 130 194 150 84 26 1.2
5125C05XX 17,4 130 194 150 84 26 1.2
5125C06XX 17,4 130 194 150 84 26 1.2
a) Comprising four (4) cables of length 30 m each
Table 1: Ci, Li, li, & Li/Ri Values
Installation in Zone 2 requires that the user supply a sur-
ge protective device in the power connection between
Type 5125C0XXX acoustic emission coupler, which is loca-
ted within the Hazardous area while the power supply is loca-
ted in the Safe area. This protection device must limit the
peak input voltage to a value less than 140 % of the maxi-
mum rated input voltage. A Zener IS barrier with a maximum
fault voltage less than 36 V at fuse operation is suitable for
this purpose.

8852A_002-668e-05.16
ATEX/CSA Hazardous Area System
Page 16
Fig. 4: Type 5125C... System Block Diagram for Zone 0
4.1 Suitable Safety Barriers for Zone 0 Installations
Power Supply, J7-1 w/rt 2: See Table 2 for Entity
Parameters
Galvanic: Turck IM72-11-Ex/L
Zener: Turck MTL7722+
RMS 0-10V DC Analog, J11-1 w/rt 2: See Table 3 for Entity
Parameters
Galvanic: Turck IM31-11-Ex-U
Zener: Turck MTL7722+
RMS 4-20mA Analog, J11-3 w/rt 4: See Table 4 for
Entity Parameters
Galvanic: Turck IM3-11-Ex-I
Alarm Switch, J8-1 w/rt 2: See Table 5 for Entity Parameters
Galvanic: Turck IM1-12Ex-R
Zener: Turck MTL7710+

8852A_002-668e-05.16
Hazardous Area Installation
Page 17
4.2 Suitable Safety Barriers for Zone 2 Installations
Power Supply, J7-1 w/rt 2: See Table 2 for Entity
Parameters
Zener: Turck MTL 7722+
Kistler Type 5252A2
Fig. 5: Type 5125C... System Block Diagram for Zone 2
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4
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