Siemens SITRANS AS100 User manual

SITRANS
Acoustic Sensors
SITRANS AS100
Operating Instructions
04/2021
A5E31952194
-AC
Introduction
1
Installation
2
Mounting
3
Connecting
4
Applications
5
Specifications
6
Technical data and
dimensions
7
Product documentation and
support
A

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E31952194
Ⓟ
04/2021 Subject to change
Copyright © Siemens AG 2021.
All rights reserved
Legal information
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This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 3
Table of contents
1 Introduction ........................................................................................................................................... 4
2 Installation............................................................................................................................................. 5
3 Mounting ............................................................................................................................................... 7
4 Connecting .......................................................................................................................................... 11
5 Applications ......................................................................................................................................... 14
6 Specifications....................................................................................................................................... 18
7 Technical data and dimensions ........................................................................................................... 20
A Product documentation and support................................................................................................... 25
A.1 Product documentation ..................................................................................................... 25
A.2 Technical support .............................................................................................................. 26
Index .................................................................................................................................................... 27

SITRANS AS100
4Operating Instructions, 04/2021, A5E31952194-AC
Introduction
1
SITRANS AS100 Sensor
SITRANS AS100 is an acoustic sensor for flow detection. It monitors high frequency acoustic
emissions (sound waves) generated by:
•the friction and impact of solids flow in pipes, chutes, and conveyors
•cavitation occurring in pumps, pipes, and valves
•turbulence of gases or liquids leaking through valves and flanges
•friction and jarring of mechanical parts
Acoustic emissions travel readily through solid materials such as metal, but are strongly
attenuated when traveling through air. As such, the Sensor is immune to airborne
interferences and provides a non-invasive method of monitoring process activities.
The sensor can be configured electrically during wiring to operate in either low or high
sensitivity range mode. The high sensitivity range applies where highest signal levels vary up
to 40 dB. The low sensitivity range applies where highest signal levels vary between 28 and
68 dB.
SITRANS AS100 Sensor provides an analog output for use with the Sitrans Control Unit. The
Sensor may be operated independently from the Control Unit by providing an external
supply. The output is fed into a control panel, chart recorder, data logger, or programmable
logic controller with a suitable input.
SITRANS AS100 Sensor is primarily used for solids flow detection. However, this device can be
used in pump cavitation and fluid leak detection, provided sufficient noise levels are
generated.
Note
•
The SITRANS AS100 is to be used only in the manner outlined in this manual
•
This product is intended for use in industrial areas. Operation of this equipment in a
residential area may cause interference to several frequency based communications
Features
•non-invasive
•screw in, bolt on, weld, or bond in place
•analog output
•high and low sensitivity range of operation

SITRANS AS100
5Operating Instructions, 04/2021, A5E31952194-AC
Installation
2
Ideal Locations
•areas where the acoustic emission levels are highest and most consistent
•where the material impact is greatest
•areas closest to the point of leakage (e.g. valve body)
•closest point to source of cavitation (e.g. pump body)
Conditions to Avoid
•non-metallic surfaces, as these tend to attenuate acoustic emission levels
•pipes with non-metallic liners as these tend to attenuate acoustic emission levels
Conditions to Consider
•joints and interfaces attenuate the acoustic emission levels.
•minimal temperature variation where acoustic emission levels are weak.
•location should provide sufficient response time in alarm or control circuit. e.g. loss of
bearing lubrication, plug chute detection.

Installation
SITRANS AS100
6Operating Instructions, 04/2021, A5E31952194-AC
Solids Flow Sensing
Recommended
Not Recommended
Good friction between product and pip-
ing. Mount Sensor on the upstream side
of gasket for highest level of acoustic
emission activity.
Minimal amount of acoustic emission
activity due to limited friction between
product and
piping.

SITRANS AS100
7Operating Instructions, 04/2021, A5E31952194-AC
Mounting
3
Note
•
To ensure the most ideal location, test the SITRANS AS100 by clamping the Sensor to the
application, and running a trial period to determine the system's performance. The
acoustic emission level can be monitored by a voltmeter across the analog output. Refer
to Interconnection (Page 11).
•
Coating the contact surfaces with grease enhances the propagation of acoustic emissions
to the Sensor.
Mounting Method
Acoustic Coupling and Sensitivity
Clearance hole
Good
Drill and Tap
Good
Mounting Disc
Good
Extension Tab
Fair
Direct Mounting
Clearance Hole
Drill and Tap
Contact
Insert mounting post
through hole in device be-
ing monitored and fasten
with customer
supplied
washers and nut.
Screw mounting post into
threaded hole in device
being monitored.
Weld or bond mounting
post to device being
moni-
tored. When welding, first
remove the acoustic sensor
from the housing.
Note
To ensure proper coupling, the face of the Sensor nut must be tight to the application
surface.

Mounting
SITRANS AS100
8Operating Instructions, 04/2021, A5E31952194-AC
Accessory Mounting
Extension Tab
Mounting Disc
Screw Sensor into threaded hole of tab, and
fasten onto device being monitored.
Screw Sensor into disc, after welding or
bonding disc onto device being monitored.
Note
•
If welding, weld must be a continuous bead. Tacking does not provide
sufficient acoustical
coupling.
•
Do not arc weld on equipment connected to a SITRANS AS100. Remove the SITRANS
AS100 or disconnect electrically to avoid current flowing through the sensor.
•
If gluing, use Loctite 326 adhesive, or equivalent. Follow manufacturer’s instructions to
ensure proper adhesion.

Mounting
SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 9
Figure 3-1 Cable Gland (optional for use with ATEX II 2GD version)
①
Rubber component
②
Foil Jacket
③
Sleeve
④
Cable with outer jacket
The ATEX II 2GD version is supplied with an approved cable gland. Installation of glands/
conduit must conform to local governing codes.
1. Disassemble the cable gland and discard the plastic membrane inside.
2. Route the cable into the M20 section of the gland and thread it onto the housing.
3. Mark the cable 2” (50 mm) from the entry of the housing then remove the acoustic sensor
from the housing.
4. Remove the outer jacket of the cable from the acoustic sensor to the mark on the cable.
5. Reinstall the acoustic sensor into the housing and route the cable through the M20 section
and into the throat of the rubber component.
6. Peel back the foil jacket (on the cable) over the tapered steel (connected to the rubber
component).
7. Install the sleeve over the tapered steel part, and thread the remaining two parts of the
gland onto the cable.
8. Tighten the assembly to ensure a seal of the gland over the cable with outer jacket.

Mounting
SITRANS AS100
10 Operating Instructions, 04/2021, A5E31952194-AC
Temperature Considerations
WARNING
Temperature at Sensor must not exceed minimum or maximum ratings.
Ensure adequate isolation from hot surfaces
by providing additional spacing.
Tab acts as heat sink.
Note
For standard Temperature range model,
maximum temperature is 80°C.
Note
If the flange temperature is 100°C and the
ambient temperature is 20°C, the Sensor
temperature at the electroni
cs is below the
maximum rating.
*maximum range dependent on model.

SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 11
Connecting
4
SITRANS AS100 Standard Temperature Version (ST)
①
Vsup: 20 to 30 V DC supply input
②
Vsens: analog output 0.08 to 10 V DC nominal
③
shield--tied to Sensor casing
*Sensor range selection
high sensitivity range = red and green to Vsup +
low sensitivity range = red to Vsup + and green to Vsup -

Connecting
SITRANS AS100
12 Operating Instructions, 04/2021, A5E31952194-AC
Extended Temperature Version (ET)
①
Vsup: 20 to 30 V DC supply input
②
Vsens: Analog output 0.08 to 10 V DC nominal
③
shield--tied to Sensor casing
*Sensor range selection
high sensitivity range = red and orange to Vsup +
low sensitivity range = red to Vsup + and orange to Vsup -
Note
•
Connect shield to ground at one end only!
•
If Sensor mounting is grounded, leave cable shield disconnected
•
If Sensor mounting is not grounded, connect cable shield to ground
The longer the cable, the more susceptible it is to noise and earth loops. We recommended
using cable with heavy gauge conductors and good RF/electrical shielding (copper braid
rather than drain and foil). A proper junction box close to the sensor is an ideal location not
only to extend the cable, but to also to configure the wiring for high or low sensitivity range
operation.
This table provides a guideline for suitable wire gauges where distances are considerable.
Maximum distance between Sensor and supply (24V or Control Unit)
wire size
distance
AWG
mm
mm
2
*
meters
feet
24
7 x 0.20
0.22
500
1600
22
7 x 0.25
0.35
800
2600
20
10 x 0.25
0.5
1200
3900

Connecting
SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 13
* nominal wire size
Analog Output
The Sensor provides an analog output proportional to the level of acoustic emission activity.
As the level of acoustic emission activity is a relatively good indication of process or
mechanical activity, the output is suitable as an input to devices such as dataloggers chart
recorders and programmable logic controllers.
The output is 0.08 to 10V (nominal), dc coupled, short circuit protected with a 60 μs time
constant. The minimum load impedance is 100 KΩ. Refer to Installation. (Page 5)
Relative Sensitivity
The sensitivity of acoustic emission is affected by temperature. In most applications this is not
a concern when considering the much greater changes in signal level due to changes in flow.
However, it is important to be aware of the effect.
The sensitivity of the SITRANS AS100 Sensor decreases with increasing temperatures at a rate
of approximately 0.5% per degree Celsius.
For example, if the temperature of the standard Sensor increased from 20 °C to 50 °C, its
sensitivity would decrease by 15%. If the Sensor were to be used to monitor flow changes
over such a temperature range, you should set an associated alarm setpoint at least 30%
away from the normal operating level measured at 20 °C.

SITRANS AS100
14 Operating Instructions, 04/2021, A5E31952194-AC
Applications
5
Pneumatic Conveyor
A tanker load of bulk solid material is being pneumatically conveyed into a silo. The Sensor
detects the acoustic emissions generated by the particles impacting against the pipe wall and
the output is used to activate the silo dust filter system.
Recommended location is any impact point along the line, such as an elbow.
Screw Conveyor Discharge
A fibrous material is being delivered to a pelletiser by means of a screw feeder. When loss of
flow is detected by the Sensor, an alarm in the control room informs the operator of a
possible blockage.
Recommended location is any point along the under side of chute, where there is friction due
to the flow of material.

Applications
SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 15
Diverter Gate
The process material is stored in a hopper and fed into the process through a diverter gate. A
Sensor mounted to each leg of the diverter indicates the presence or absence of flow in the
open leg. Low alarm gives early indication of problems in the diverter gate or slide gate, or of
blockage or material shortage in the hopper.
Leak detection

Applications
SITRANS AS100
16 Operating Instructions, 04/2021, A5E31952194-AC
Cavitation Monitoring
Install the SITRANS AS100 Sensor in B either A or B locations.
Machine Condition Monitoring
Install the SITRANS AS100 Sensor in either A or B locations.
Manufactured Date
To identify when the product was built use the tables below based on the serial number on
the product.
Serial Number Scheme
Compa-
ny/Plant
code
Separator
Year of
MFG.
Month of
MFG.
Day of MFG.
4 digit sequential # (0000 to 9999)
PBD
/
S
1
0
1
0
0
0
1
PBD
/
S
1
0
1
0
0
0
2
PBD
/
S
1
0
1
0
0
0
3

Applications
SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 17
Refer to following tables for encoding formats.
Encoding of Letters
Year of Manufacture (one character alpha entry)
Year
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
ALPHA
CODE
M N P R S T U V W X
Year
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
ALPHA
CODE
A
B
C
D
E
F
H
J
K
L
Month of Manufacture (one character alpha or numeric entry)
Jan.
Feb.
Mar.
Apr.
May
Jun.
Jul.
Aug.
Sept.
Oct.
Nov.
Dec.
1
2
3
4
5
6
7
8
9
0
N
D
Day of Manufacture (two character numerical entry)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

SITRANS AS100
18 Operating Instructions, 04/2021, A5E31952194-AC
Specifications
6
Model
•
standard
standard operating temperature range (see below)
•
extended
extended operating temperature range (see below)
Power
•
20 to 30 V DC
•
18 mA typical
Operating Temperature
•
standard
-20 to 80 °C (-4 to 176 °F)
1
•
extended:
-30 to 120 °C (-22 to 248 °F)
2
or
-40 to 125 °C (-40 to 257 °F)
3
Note
1
Available for CSA/FM Class II, ATEX versions
2
Available only for CSA Class II version
3Not available for hazardous rated versions
Relative Sensitivity
•
0.5% / °C of reading, average over the operating range
Output
•
analog, 0.08 to 10 V DC nominal, 100 KΩ minimum load impedance

Specifications
SITRANS AS100
Operating Instructions, 04/2021, A5E31952194-AC 19
Construction
•
housing
304 stainless steel
303 stainless steel (CSA/FM Class II, ATEX II 3D version)
aluminum (ATEX II 2GD version)
•
cable
standard: 4 m (13 ft) cable, PVC jacketed, 3 twisted pairs, 24 AWG, shield-
ed
extended: 4 m (13 ft) cable, thermoplastic elastomer jacketed, 6 conduc-
tor, 24 AWG conductor, shielded
Ingress Protection
•
IP68 (waterproof) The IP68 test was performed by immersing the enclosure in 1.8 m of
water for 30 minutes.
Weight
•
0.4 kg (1 lb.)
•
1.2 kg (2.65 lb.) (ATEX II 2GD version)
Approvals
General
CE, C-TICK, KCC
Hazardous
Europe:
ATEX II 2GD
•
Ex II 2G Ex d IIC T4 Gb
•
Ex II 2D Ex tb IIC T100 °C Db
•
DEKRA cert #: DEKRA 13ATEX0006 X
•
Standards: 60079-0 : 2009, EN 60079-1 : 2007 and EN 60079-31
: 2009
ATEX II 3D
US:
FM Class II, Div. 1, Groups E, F, G
Canada:
CSA Class II, Div. 1, Groups E, F, G
Russia
1Ex db IIC T4 Gb
Ex tb IIIC T100°C Db
Ex tc IIIC T100°C Dc

SITRANS AS100
20 Operating Instructions, 04/2021, A5E31952194-AC
Technical data and dimensions
7
SITRANS AS100 (ST and ET versions)
①
6 x 24 AWG cable
②
Mounting post, 17A/F nut and M10 thread