Siemens AS 100, sitrans Instruction Manual

Instruction Manual April 2005

sitrans

AS 100

Safety Guidelines: Warning notices must be observed to ensure personal safety as well as that of

others, and to protect the product and the connected equipment. These warning notices are
accompanied by a clarification of the level of caution to be observed.

Qualified Personnel: This device/system may only be set up and operated in conjunction with this

manual. Qualified personnel are only authorized to install and operate this equipment in accordance with
established safety practices and standards.

Unit Repair and Excluded Liability:

• The user is responsible for all changes and repairs made to the device by the user or the user’s
agent.

• All new components are to be provided by Siemens Milltronics Process Instruments Inc.

• Restrict repair to faulty components only.

• Do not reuse faulty components.

Warning: This product can only function properly and safely if it is correctly transported, stored,

installed, set up, operated, and maintained.

Note: Always use product in accordance with specifications.

Copyright Siemens Milltronics Process

Disclaimer of Liability

Instruments Inc. 2005. All Rights Reserved

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Inc. will not be responsible for the contents of partial or
whole reproductions of either bound or electronic
versions.

While we have verified the contents of this
manual for agreement with the
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The contents of
this manual are regularly reviewed and
corrections are included in subsequent
editions. We welcome all suggestions for
improvement.

Technical data subject to change.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

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1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [e-mail]

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© Siemens Milltronics Process Instruments Inc. 2005

Table of Contents

General Information ........................................................................................................... 1

SITRANS AS 100 Sensor ......................................................................................................................1

Features .....................................................................................................................................................1

Specifications ......................................................................................................................2

Outline and Dimensions .................................................................................................... 4

Installation ........................................................................................................................... 6

Ideal Locations .........................................................................................................................................6

Conditions to Avoid .................................................................................................................................6

Conditions to Consider ...........................................................................................................................6

Mounting ............................................................................................................................. 7

Temperature Considerations ................................................................................................................8

Interconnection ................................................................................................................... 9

SITRANS AS 100 Standard Temperature Version (ST) .................................................................9

Extended Temperature Version (ET) ..................................................................................................9

Analog Output ........................................................................................................................................10

Relative Sensitivity ................................................................................................................................10

Applications ....................................................................................................................... 11

Pneumatic Conveyor ............................................................................................................................11

Screw Conveyor Discharge ................................................................................................................11

Diverter Gate .......................................................................................................................................... 11

i

ii

General Information

SITRANS AS 100 Sensor

SITRANS AS 100 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 AS 100 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 AS 100 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.

Features

• non-invasive

• screw in, bolt on, weld, or bond in place

• analog output

• high and low sensitivity range of operation

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 1

Specifications

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

•extended:

1

-20 to 80 °C (-4 to 176 °F)

-30 to 120 °C (-22 to 248 °F)2 or

-40 to 125 °C (-40 to 257 °F)

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

Construction

• housing 304 stainless steel
303 stainless steel (hazardous rated version)

• cable standard: 4 m (13 ft) cable, PVC jacketed, 3 twisted pairs, 24 AWG,
shielded
extended: 4 m (13 ft) cable, thermoplastic elastomer jacketed, 6
conductor, 24 AWG conductor, shielded

1.

Class II and ATEX II versions available

2.

Class II version available

Page 2 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

Ingress Protection

• IP 68 (waterproof) The IP 68 test was performed by immersing the enclosure in 1.8m of

water for 30 minutes.

Weight

• 0.4 kg (1 lb.)

Approvals

•General CE

• Hazardous Europe: ATEX II 3D
US: FM Class II, Div. 1, Groups E, F, G
Canada: CSA Class II, Div. 1, Groups E, F, G

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 3

Outline and Dimensions

SITRANS AS 100 (ST and ET Versions)

17mm

(0.7")

67mm

(2.7")

36mm

(1.4")

6 x 24 AWG cable

mounting post, 17A/F
nut and M10 thread

8mm
(0.3")

44mm

(1.8")

SITRANS AS 100 (Class II Rated ST and ET Versions)

6 x 24 AWG cable

½" NPT
(CSA and FM approvals)
or
M20 (ATEX approval)
female conduit fitting

82mm

(3.2")

32mm

(1.3")

36mm

(1.4")

Page 4 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

mounting post, 17A/F
nut and M10 thread

8mm
(0.3")

44mm

(1.8")

Accessories

Extension Tab (optional)

10mm

(0.4")

30mm

(1.2")

Mounting Disc (optional)

15mm

(0.6")

SITRANS AS 100 mounting hole
M10 thread

15mm

(0.6")

85mm

(3.3")

bolt hole,

14mm

(0.55")Ø

15mm

(0.6)

30mm (1.2")Ø

Note: Both Tab and Disc are 304SS.

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 5

SITRANS AS 100 mounting hole
M10 thread

Installation

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.

Solids Flow Sensing

Recommended

Good friction between product and
piping. Mount Sensor on the
upstream side of gasket for highest
level of acoustic emission activity.

Not Recommended

Minimal amount of acoustic emission
activity due to limited friction
between product and piping.

Page 6 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

Mounting

Notes:

• To ensure the most ideal location, test the SITRANS AS 100 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 on page

•9.

• 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
Insert mounting post through hole in
device being monitored and fasten
with customer-supplied washers
and nut.

Drill and Tap
Screw mounting post into threaded hole in
device being monitored.

Note: To ensure proper coupling, the face of the Sensor nut must be tight to the

application surface.

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 7

Accessory Mounting

Extension Tab
Screw Sensor into threaded hole of tab,
and fasten onto device being monitored.

Notes:

• If welding, weld must be a continuous bead. Tacking does not provide
sufficient acoustical coupling.

• Do not arc weld on equipent connected to a SITRANS AS 100. Remove the
SITRANS AS 100 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.

Temperature Considerations

Warning: Temperature at Sensor must not exceed minimum or
maximum ratings.

Mounting Disc
Screw Sensor into disc, after welding or
bonding disc onto device being monitored.

20 ºC

Ensure adequate isolation from hot
surfaces by providing additional
spacing.

Note: for standard Temperature

range model, maximum
temperature is 80 °C.

*maximum range dependent on model.

Page 8 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

100 ºC

< 80 ºC

65 ºC

>80 ºC

Tab acts as heat sink.

Note: If the flange temperature is 100 °C
and the ambient temperature is 20 °C,
the Sensor temperature at the
electronics is below the maximum
rating.

Interconnection

SITRANS AS 100 Standard Temperature Version
(ST)

red
blk

grn*
blk

wht
blk

shield--tied to Sensor casing

*Sensor range selection

high sensitivity range = green to Vsup +
low sensitivity range = green to Vsup -

Extended Temperature Version (ET)

red
blk

org
grn*

yel
brn

shield--tied to Sensor casing

or

or

+

-

+

-

+

-

+

-

20 to 30 V

Vsup:

DC supply
input

Vsens:

analog output

0.08 to 10 V DC
nominal

20 to 30 V

Vsup:

DC supply
input

Vsens:

analog output

0.08 to 10 V DC
nominal

Notes:

• 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.

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 9

*Sensor range selection

high sensitivity range = orange to Vsup +
low sensitivity range = orange to Vsup -

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

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

mm2 *

meters feet

* 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 on page 6 or
Interconnection on page 9.

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 AS 100 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.

Page 10 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

Applications

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.

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.

7ML19985DM02 SITRANS AS 100 – INSTRUCTION MANUAL Page 11

Leak Detection

Cavitation Monitoring

A

B

Machine Condition Monitoring

B

B

A

A

Install the SITRANS AS 100 Sensor
in either A or B locations.

Install the SITRANS AS 100 Sensor
in either A or B locations.

Page 12 SITRANS AS 100 – INSTRUCTION MANUAL 7ML19985DM02

Index

A

Accessories 5
Accessory Mounting 8
Analog Output 10
Applications
Approvals 3
AS100 (Class II Rated ST and ET Versions) 4
AS100 (ST and ET Versions)
AS100 Standard Temperature Version (ST) 9
Avoid 6

11

4

C

Construction 2

D

Direct Mounting 7
Diverter Gate 11

E

Extended Temperature Version (ET) 9
Extension Tab 8

F

Features 1

G

General Information 1

I

Ideal Location 6
Ingress Protection 3
Installation
Interconnection 9

6

L

Leak Detection 12

M

Model 2
Mounting
Mounting Disc

7

8

O

Operating Temperature 2
Output

2

P

Pneumatic Conveyor 11
Power 2

R

Relative Sensitivity 10

S

Screw Conveyor Discharge 11
Solids Flow Sensing
Specifications

6

2

T

Temperature Considerations 8
The Senaco AS100 Sensor 1

W

Weight 3
wire gauges

10

Notes

www.siemens.com/processautomation

Siemens Milltronics Process Instruments Inc.
1954Technology Drive, P.O. Box 4225
Peterborough, ON, Canada K9J 7B1
Tel: [phone] Fax: [phone]
Email: [e-mail]

Siemens Milltronics Process Instruments Inc. 2005

Subject to change without prior notice

Rev. 2.1

*7ml19985DM02*

Printed in Canada