Vallen ISAFE3 Series, ISAS3, SISO3 Operation Manual

Intrinsically Safe Acoustic Emission Product Family:

Vallen ISAFE3

Operation Manual

Released September-2018

English (Original), Release 4, Last change: 2018-09-26, Pages: 58

Manufactured by

Vallen Systeme GmbH,

Schaeftlarner Weg 26A, 82057 Icking, Germany

Vallen Systeme GmbH Quality Assurance Certifications:
ISO9001:2015 by TÜV SÜD Reg. No. 12 100 9918 TMS

2014/34/EU (ATEX) Annex IV (ATEX Production) and EN 80079-34:2011

by TÜV SÜD, 0123 Certif. No. TPS 17 ATEX Q 55515 006

EC-Type Examination Numbers:

SISO3: TÜV-A 11ATEX0004X

ISAS3: TÜV-A 11ATEX0005X

Contact Address

Vallen Systeme GmbH
Schaeftlarner Weg 26a
D-82057 Icking
Germany

email: [e-mail]

http://www.vallen.de

Tel: [phone]
Fax: [phone]

Specifications are subject to change as product developments are made.
Comments and recommendations are appreciated and may be mailed to: [e-mail]

Copyright © 2018, Vallen Systeme GmbH

All rights reserved.
Electronic versions of this document may be read online, downloaded for personal use, or

referenced in another document as a URL to a Vallen website. No part of this specification may
be published commercially in print or electronic form, edited, translated, or otherwise altered
without the permission of Vallen.

Trademarks and Licenses

The hardware and/or software described herein are furnished under a license and may be used
or copied only in accordance with the terms of such license.

AMSY-5, AMSY-6, ASIP-2, VisualAE, VisualClass and VisualTR are trademarks of Vallen
Systeme GmbH.

Disclaimer

The material contained in this document is provided “as is” and is subject to being changed,

without notice, in future editions. Further, to the maximum extent permitted by applicable law,
we, Vallen Systeme GmbH, disclaim all warranties, either expressed or implied with regard to
this specification and any information contained herein, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose. We, Vallen Systeme GmbH,
shall not be liable for errors or for incidental or consequential damages in connection with the
furnishing, use, or performance of this document or any information contained herein.

We shall not be liable for any direct, indirect, consequential or incidental damage arising out of
the use or inability to use of the delivered equipment. We reserve the right to charge for any
efforts taken to remedy any problems for which we are not responsible.

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Purpose of this Document

This operation manual is to describe the features and the usage of ISAFE3 family products.
Further the manual outlines specifications and requirements to obtain and maintain intrinsic
safety.

Sections or sub-sections headed in italic font contain safety relevant information.
This manual does not describe the application of SISO3 in a zone 2 environment.

Contents:

1 Introduction ....................................................................................................................... 5

2 Safety Directions ............................................................................................................... 6

2.1 Intended Use .................................................................................................................. 6

2.2 Foreseeable misuse ....................................................................................................... 7

2.3 Safe operation of the sensor system ISAFE ................................................................... 7

2.4 Qualified or certified personnel ....................................................................................... 8

3 Sicherheitshinweise ......................................................................................................... 8

3.1 Bestimmungsgemäßer Betrieb ....................................................................................... 8

3.2 Vorhersehbare Falschanwendungen .............................................................................. 9

3.3 Sicherer Betrieb des AMSY-6 ....................................................................................... 10

3.4 Qualifiziertes oder zertifiziertes Personal ..................................................................... 11

4 Description of AE sensor system ISAFE3 .................................................................... 12

4.1 Members of ISAFE3 family ........................................................................................... 13

5 Signal Isolator SISO3...................................................................................................... 14

5.1 SISO3 Labeling ............................................................................................................. 15

5.1.1 Manufacturer and type: ........................................................................................ 15

5.1.2 ATEX / CENELEC label: ...................................................................................... 15

5.1.3 Front label ............................................................................................................ 16

5.2 Specifications of SISO3 ................................................................................................ 16

5.2.1 Specifications with relevance to intrinsic safety (IS) ............................................ 16

5.2.2 Mechanical specifications .................................................................................... 16

5.2.3 Safety relevant electrical parameters: .................................................................. 17

5.2.4 Electrical specifications of signal line at BNC connector (to/from AE-system): ... 17

5.2.5 Electrical specifications of external intrinsically safe circuit ................................. 18

5.3 Modifying SISO3-gain ................................................................................................... 19

5.4 Environmental conditions for SISO3 ............................................................................. 21

6 Accessories for SISO3 ................................................................................................... 22

6.1 HISO3-08 ...................................................................................................................... 22

6.1.1 Mechanical specifications of HISO3-08 ............................................................... 23

6.2 HISO3-20 ...................................................................................................................... 23

6.2.1 Mechanical specifications of HISO3-20 ............................................................... 24

6.3 Cable entry instructions ................................................................................................ 25

6.3.1 Dismounting a SISO3 from DIN rail ..................................................................... 26

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7 ISAS3 Overview ............................................................................................................... 27

7.1 ISAS3 Labeling ............................................................................................................. 28

7.1.1 Manufacturer and type: ........................................................................................ 28

7.1.2 ATEX / CENELEC label: ...................................................................................... 28

7.2 Specifications ISAS3-xxx .............................................................................................. 29

7.2.1 Mechanical specifications .................................................................................... 29

7.2.2 Safety relevant electrical parameters: .................................................................. 30

7.2.3 Electrical specifications ........................................................................................ 30

7.2.4 Acoustic specifications ......................................................................................... 31

8 Accessories for ISAS3.................................................................................................... 32

8.1 Magnetic Holder MAG4IS ............................................................................................. 32

8.2 ISAS3-SpecMount ........................................................................................................ 33

8.3 ISAS3-SpecIP68 – oil resistant sealing of a cable-to-sensor transition against 12 bar

peak pressure ............................................................................................................... 34

8.3.1 Sealing Set Hardware: SS-OIL-5MM ................................................................... 34

8.3.2 Usage of Sealing Set SS-OIL-5MM ..................................................................... 34

8.4 Sealing the transition of a cable-in-a-tube to sensor against 12 bar peak pressure .... 36

9 Installation ....................................................................................................................... 37

9.1 General hints ................................................................................................................ 37

9.2 Sensor mounting – functional requirements ................................................................. 37

9.3 Cabling between sensor ISAS3 and SISO3 (Ex i) ........................................................ 37

9.4 Sensor installation - safety relevant requirements for EPL “Gb” and “Gc” (Earth

connection) ................................................................................................................... 38

9.5 Sensor installation - safety relevant requirements for EPL “Ga” (Earth connection).... 38

9.6 Functional verification ................................................................................................... 39

9.7 Maintenance ................................................................................................................. 39

9.8 Adjustment .................................................................................................................... 39

10 Product code overview................................................................................................... 40

11 Assembly instructions for SMA and BNC connectors ................................................ 41

12 Abbreviations .................................................................................................................. 45

13 Glossary ........................................................................................................................... 46

14 Standard compliance...................................................................................................... 48

15 Declaration of Conformity .............................................................................................. 49

16 EC Type Examination Certification ............................................................................... 51

17 2014/34/EU ATEX Certificate for Quality Assurance of Production .......................... 57

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1 Introduction

Note:

Indicates a note or comment

CAUTION:

This symbol indicates processes or procedures which must be performed carefully in order to
avoid problems.

DANGER:

This symbol indicates processes or procedures which must be performed carefully in order to
avoid danger of life.

IEC 60417-5017

Protective ground

2014/34/EU

Explosion protection label

2014/34/EU Appendix X

Sign of conformity

This user manual is part of the AE-sensor system ISAFE, consisting of AE-sensor ISAS3, signal
isolator SISO3 and (optional) the HISO3 box to accommodate the signal isolator(s). Please
read this document carefully before putting the AE-sensor system into operation. Make sure that
an operation manual is always accessible to operators throughout the lifetime of the product.

Following symbols are used throughout the user manual:

Following symbols can be found on the equipment

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2 Safety Directions

DANGER:

Make sure that ATEX zone rating of components complies with the ATEX zone rating of the area
where components are installed.

DANGER:
Make sure that the AE-sensor ISAS3 is properly grounded to test object.

DANGER:

Make sure that the system is properly installed before it is taken into operation.

The ISAFE sensor system, consisting of ISAS3, SISO3 and (optional) HISO3, has been
produced and tested in compliance with standards and codes listed in section 14 of this User
Manual. It has been shipped in safety related flawless condition. The user has to follow the
notes and consider warning notes within this operation manual to ensure safe operation.

2.1 Intended Use

The AE-sensor system ISAFE3 is part of an Acoustic Emission measurement system, such as
the AMSY-6. ISAFE3 consists of AE-sensor ISAS3 and signal isolator SISO3.

The AE-sensor ISAS3 picks up surface movements on a test object and converts them into AC
voltage. ISAS3 can be installed in an explosion hazardous area that requires Equipment
Protection Level (EPL) Ga, Gb or Gc only. For the relation between EPL and zones see
EN 60079-14:2008/5.4.

SISO3 has to be located in a non-hazardous area and interfaces the intrinsically safe circuit with
the AE system.

The sensor ISAS3 can be immersed into a liquid, usually water or oil, if the cable-to-case
transition is properly sealed as described in chapter 8.3. The liquid shall have a chemical
composition that does not degrade the wetted materials. These materials are specified in
chapters 7.2.1 (case, O-ring) and 8.3.1 (heat shrink and clamps). The maximum peak pressure
(12 bar) and ambient temperature range (-20 °C to +60 °C) must not be exceeded. ISAS3 must
be safely and reliably fastened as outlined in chapter 8.1 and 8.2 ensuring good acoustic
contact to the test object. For cabling and earthing see chapter 9. The cable from SISO3 to
ISAS3 must comply with the environmental conditions or be properly protected. The cable must
be installed and connected while the environment of ISAS3 is non-hazardous.

Signal isolator SISO3 must be installed in an environment of pollution degree 2 or 1; this could
be inside a closed cabinet or an enclosure, see chapter 5.4 to 6.2. For pollution degree see
glossary. Temperature inside the cabinet or enclosure must not exceed the temperature range
of -20 °C to +60 °C.

For the additional requirements on EPL "Ga" see EN 60079-14:2008/12.3.
The individual application of ISAFE3 must ensure that the output of the sensor system is

properly converted to digital data and properly processed. The sensor system allows for a
computer controlled sensor coupling test by sending artificial AE with one sensor, to be picked
up by one or more neighboring sensor(s). This feature helps to identify a loss of coupling quality
or sensor sensitivity.

ISAFE3 shall be installed and operated by qualified personnel only. Correct operation of the AE­sensor system according to specification shall be verified in regular intervals by qualified
personnel.

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2.2 Foreseeable misuse

Do not install/operate the AE-sensor ISAS3 in mines.
Do not expose the AE-sensor ISAS3 to environment with temperature exceeding 60°C or on

test objects with surface temperature higher than 60°C.
Do not expose the AE-sensor ISAS3 to ambient pressure higher than 12 bar.
Do not install/operate the signal isolator SISO3 in an explosion hazardous area.
Do not install/operate the signal isolator SISO3 in an environment with temperature exceeding

60°C.
Do not install/operate the signal isolator SISO3 in an environment of pollution degree 3 or

larger. For pollution degree see glossary. Do not install/operate the AE-sensor system ISAFE3 if
any of its components (ISAS3, SISO3, HISO3 or cables) show any visible defect.

2.3 Safe operation of the sensor system ISAFE

Set up

Please follow the mounting instructions of section 9. Make sure that you have the permission of
the operator of the object under test to carry out the work as described in the mounting
instructions.

Power supply connection

The signal isolator receives DC-power over the combined signal/power cable from the AE
system. Use only Vallen-provided cables or cables that have been approved by Vallen Systeme
to connect a signal isolator to a signal processor providing 28 VDC power supply.

Install all cables in a safe way, avoiding stumbling and stepping on the cable. Please note the
specified bending radius for each cable.

Ground connection

Make sure that each AE-sensor is grounded properly. Use a cable as short as possible with
cross section of at least 4 mm². Make sure that each AE-sensor is grounded before it goes into
operation.

Damage

Do not apply power to a signal isolator if it is obvious that a component of the AE-sensor system
is damaged. In such a case make sure that it cannot be used by any other person.

Environmental conditions

Only use AE-sensor system ISAFE3 in environments that comply with environmental conditions
specified in the given specification. Please make sure that dust or any fluid cannot enter the
signal isolator. The HISO3 box was developed to protect the SISO3 (IP54).

Repairs

Only qualified personnel (see section 2.4) may open and repair equipment. Only replacement
parts may be used that comply with the safety regulations of the equipment. Before removing
cover parts make sure that no power is applied to the equipment.

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Cleaning

Note:

This section contains the German translation of “Safety Directions”

GEFAHR:

Stellen Sie sicher, dass die ATEX Einstufung der Komponenten der ATEX Zoneneinstufung des
Installationsortes entspricht.

GEFAHR:

Stellen Sie sicher, dass der Sensor ISAS3 ordnungsgemäß geerdet wurde bevor dieser
betrieben wird.

GEFAHR:

Stellen Sie sicher, dass das AE-Sensor System ordnungsgemäß installiert wurde bevor es in
Betrieb genommen wird.

Do not use abrasive or solvents for cleaning. Make sure that liquid cannot enter the equipment.
For cleaning purposes a soft dry cloth is sufficient. In case of heavy stains use a moist cloth with
a mild rinsing agent.

2.4 Qualified or certified personnel

Qualified personnel are characterized that they

 have an appropriate technical education
 know regulations concerning employment protection and on-the-job safety
 recognize safety of used equipment
 know operation manual of used equipment

Furthermore to qualification mentioned above certified personnel hold a valid certification
according to ISO 9712, ASNT or any other comparable standard or standardization
organization.

3 Sicherheitshinweise

Das AE-Sensor System, bestehend aus ISAS3, SISO3 und (optional) HISO3, ist gemäß den
Standards und Richtlinien in Kapitel 14 des vorliegenden User Manuals gebaut und geprüft. Es
hat das Werk in sicherheitstechnisch einwandfreiem Zustand verlassen. Um einen gefahrlosen
Betrieb sicherzustellen, muss der Anwender die Hinweise und Warnvermerke beachten, die in
dieser Gebrauchsanweisung enthalten sind.

3.1 Bestimmungsgemäßer Betrieb

Das AE-Sensor System ISAFE3 ist Teil eines Schallemissionsmessgeräts, wie zum Beispiel
das AMSY-6. ISAFE3 besteht aus den Sensoren ISAS3 und dem Signalisolator SISO3.

ISAS3 nimmt Oberflächenbewegungen von Testobjekten auf und wandelt diese in AC­Spannung um. ISAS3 Sensoren können in explosionsgefährdeten Bereichen installiert werden,
in denen das Geräteschutzniveau Ga, Gb oder Gc gefordert ist. Für die Zuordnung zwischen
Geräteschutzniveau und Zonen beachten Sie bitte EN 60079-14:2008/5.4.

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Der SISO3 wird außerhalb des Gefahrenbereichs installiert und verbindet den eigensicheren
Schaltkreis mit dem AE System.

Der ISAS3 kann in Flüssigkeiten (normalerweise Wasser oder Öl) eingetaucht werden, wenn
die Kabelverbindung ordnungsgemäß abgedichtet wurde (siehe Kapitel 8.3). Die Flüssigkeit darf
das Material, mit dem es in Kontakt kommt, nicht angreifen oder verändern. Die relevanten
Materialien sind in Kapital 7.2.1 (Gehäuse, O-Ring) und 8.3.1 (Schrumpfschlauch und
Klammern) aufgeführt. Ein Maximaldruck von 12 bar und ein Umgebungstemperaturbereich
von -20 °C bis +60 °C darf nicht überschritten werden. Der ISAS3 muss sicher befestigt werden,
wie beschrieben in Kapitel 2.3 und 9.2, damit eine gute akustische Ankopplung gewährleistet
ist. Bitte beachten Sie auch Kapitel 9 zum Thema Anschluss und Erdung des Systems. Die
Kabel vom SISO3 zu dem ISAS3 Sensor müssen für die vorhandenen Umwelteinflüsse
spezifiziert sein oder ausreichend geschützt werden. Die Kabel müssen mit dem ISAS3
verbunden werden, solange dieser sich noch nicht in einem Gefahrenbereich befindet.

Der Signalisolator SISO3 darf nur in einer Umgebung mit Verschmutzungsgrad 2 oder niedriger
installiert werden. Dieses kann ein geschlossener Schrank oder ein Gehäuse sein (siehe Kapitel

6.1 bis 6.2). Die Innentemperatur des Schranks oder des Gehäuses darf nicht außerhalb eines
Bereichs von -20 °C bis +60 °C liegen.

Weitere Angaben zum Geräteschutzniveau „Ga“ finden Sie in der Norm EN 60079­14:2008/12.3.

Bei der individuellen Anwendung des ISAFE3 muss sichergestellt werden, dass das
Sensorsignal korrekt in digitale Daten umgewandelt wird und weiterverarbeitet werden kann.
Das Sensorsystem ermöglicht eine automatische Ankopplungsüberprüfung, bei der ein Sensor
ein künstliches AE Signal generiert, welches von den benachbarten Sensoren aufgenommen
werden kann. Mit dieser Funktion können, mit Hilfe einer Software, Änderungen in der
Ankopplung jedes Sensors an dem Prüfobjekt automatisch ermittelt werden.

Das AE-Sensor System darf nur durch qualifiziertes Personal (siehe Abschnitt 3.4) installiert
und betrieben werden. Die korrekte Funktionsweise des AE-Sensor Systems muss in
regelmäßigen Abständen durch qualifiziertes Personal geprüft werden.

3.2 Vorhersehbare Falschanwendungen

Installieren und betreiben Sie das AE-Sensor System ISAFE3 nicht in Bergwerken.
Installieren und betreiben Sie den AE-Sensor ISAS3 nicht in Umgebungen oder an Oberflächen

deren Temperatur 60°C überschreiten.
Installieren und betreiben Sie den AE-Sensor ISAS3 nicht in Umgebungsdrücken über 12 bar.
Installieren und betreiben Sie den Signalisolator SISO3 nicht in explosionsgefährdeten

Bereichen.
Installieren und betreiben Sie den Signalisolator SISO3 nicht in Umgebungen, deren

Temperatur 60 °C überschreitet.
Installieren und betreiben Sie den Signalisolator SISO3 nicht in Umgebungen mit

Verschmutzungsgrad über 2.
Betreiben Sie das AE-Sensor System nicht, wenn Komponenten davon (ISAS3, SISO3, HISO3

oder Kabel) offensichtliche Schäden aufweisen.

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3.3 Sicherer Betrieb des AMSY-6

Aufstellen

Folgen Sie den Aufbauanweisungen des Kapitel 9. Stellen Sie sicher, dass Sie eine Bewilligung
des Betreibers der zu prüfenden Anlage haben, um die Ausrüstung gemäß der
Aufbauanweisung zu installieren.

Anschlussleitungen

Der Signalisolator wird über ein kombiniertes Signal/Spannungs-Kabel vom AE System mit
Gleichspannung versorgt. Verwenden Sie nur Kabel von Vallen Systeme oder Kabel die von
Vallen Systeme zur Verwendung freigegeben wurden, um den Signalisolator an die 28 VDC
Spannungsversorgung anzuschließen.

Verlegen Sie die Leitungen so, dass niemand darauf treten oder darüber stolpern kann.
Beachten Sie den minimalen Biegeradius des jeweiligen Kabels.

Erdung

Stellen Sie vor der Inbetriebnahme sicher, dass jeder AE-Sensor fachgerecht geerdet ist. Der
Sensor stellt dazu ein Erdungsgewinde samt Schraube zur Verfügung. Das verwendete Kabel
muss einen Querschnitt von mindestens 4 mm² besitzen. Stellen Sie sicher, dass der Sensor
geerdet ist bevor er in Betrieb genommen wird.

Beschädigungen

Stellen Sie sicher, dass der Signalisolator nicht mit Spannung versorgt wird, wenn eine
Komponente des AE-Sensor Systems sichtbare Beschädigungen aufweist. Sichern Sie in einem
solchen Fall das AE-Sensor System vor Inbetriebnahme durch Dritte ab.

Umgebungsbedingungen

Das AE-Sensor System darf nur unter solchen Umgebungsbedingungen eingesetzt werden, die
im vorliegenden Operation Manual spezifiziert sind. Achten Sie darauf, dass keine
Fremdmaterialien, wie Staub oder Flüssigkeit, in die Geräteöffnungen des Signalisolators
SISO3 gelangen können. Für den Schutz der SISO3s wurde die HISO3 box entwickelt (IP54).

Reparaturen

Reparaturen dürfen nur von qualifiziertem Personal (siehe Abschnitt 3.4) ausgeführt werden. Es
dürfen nur solche Ersatzteile verwendet werden, die die Sicherheitsbestimmungen des Gerätes
nicht verändern. Vor dem Öffnen des Gerätes muss sichergestellt sein, dass keine
Versorgungsspannung anliegt.

Reinigung

Verwenden Sie für die Reinigung kein Scheuerpulver und keine lack- oder kunststofflösende
Reinigungsmittel. Lassen Sie keine Flüssigkeiten in das Gerät und den Anschlüssen eindringen.
Zur Reinigung der Gehäuseoberfläche ist ein trockenes Tuch ausreichend. Bei starker
Verschmutzung kann ein feuchtes Tuch verwendet werden, das in Wasser mit mildem
Spülmittel getaucht und gut ausgewrungen wurde.

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3.4 Qualifiziertes oder zertifiziertes Personal

Qualifiziertes Personal sind Personen die

 eine entsprechende technische Ausbildung haben
 die Regeln zu Arbeitsschutz und Arbeitssicherheit kennen
 die Sicherheit der Messausrüstung erkennen
 die Bedienungsanleitung der Messausrüstung kennen

Darüber hinaus sind zertifizierte Personen im Besitz einer gültigen Zertifizierung gemäß
ISO 9712, ASNT oder vergleichbarer Standards oder Standardisierungseinrichtungen.

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4 Description of AE sensor system ISAFE3

Figure 4-1 Block diagram of an ISAS3 sample setup

Acoustic Emission has been proven to be a powerful tool for integrity testing and leak detection
especially for applications of the oil and gas industry. Working in the environment of gas and oil
often requires special safety measures for the equipment to prevent accidental ignition of
flammable gases or fluids. Especially AE sensors which are installed in close approximation or
sometimes even within the explosive hazardous gas require some measures which make it
impossible that any faults can cause sparks or any dangerous electrical discharge to the
surrounding. For this reason Vallen Systeme developed the ISAFE3 product family.

ISAFE3 stands for Intrinsically SAFE sensor system 3. It consists of AE-sensor(s) ISAS3 and

signal isolator(s) SISO3, interconnected over a 50 Ω coaxial cable. This cable transfers the DC

supply voltage from the signal isolator to the sensor and the amplified AE signal from the sensor
to the signal isolator.

The sensors and the cable are designed to be installed on a test object in an explosion
hazardous area of zone 0, zone1 or zone 2 (e.g. tank of a ship, above ground storage tank in a
refinery or pressure equipment on an oil rig). The signal isolator SISO3, the AE measuring
system (e.g. AMSY-6) and the control PC have to be located in a non-hazardous area. Figure
4-1 shows the block diagram of an ISAFE3 sample installation. The cable between the AE­sensor ISAS3 and the signal isolator SISO3 can be several hundred meters long.

According to the ATEX directives the three different zones are defined as:

Zone 0 — An atmosphere where a mixture of air and flammable substances in the form of

gas, vapor or mist is present frequently, continuously or for long periods.

Zone 1 — An atmosphere where a mixture of air and flammable substances in the form of

gas, vapor or mist is likely to occur in normal operation occasionally.

Zone 2 — An atmosphere where a mixture of air and flammable substances in the form of

gas, vapor or mist is not likely to occur in normal operation but, if it does occur, will persist
for only a short period.

SISO3 performs like a normal (not intrinsically safe) preamplifier with 28 VDC supply voltage,
50 Ω output impedance, driving up to 10 VPP into 50 Ω impedance of an AE signal processor.

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Hence, SISO3 can be used with any AE signal processor providing a preamplifier supply

Type

Description

Ex Protection

ISAS3-030

AE-Sensor for 25 to 80 kHz

<EX> II 1G Ex ia IIC T6 Ga

ISAS3-075

AE-Sensor for 50 to 300 kHz

<EX> II 1G Ex ia IIC T6 Ga

ISAS3-150

AE-Sensor for 150 to 450 kHz

<EX> II 1G Ex ia IIC T6 Ga

ISAS3-150-V01

AE-Sensor for 150 to 450 kHz

<EX> II 1G Ex ia IIC T6 Ga

ISAS3-375

AE-Sensor for 300 to 500 kHz

<EX> II 1G Ex ia IIC T6 Ga

ISAS3-900

AE-Sensor for 100 to 900 kHz

<EX> II 1G Ex ia IIC T6 Ga

SISO3

Signal Isolator (and barrier)

<EX> II (1) 3G Ex nA [ia Ga] IIC T4 Gc

Type

Description

Chapter

HISO3-08

Housing for up to 8 SISO3, IP54

6.1

HISO3-20

Housing for up to 20 SISO3, IP54

6.2

MAG4IS

Magnetic holder for all ISAS3 variants

8.1

SS-OIL-5MM

Sealing Set Hardware for ISAS3

8.3.1

voltage of 28 V

@ 90 mA over a coaxial cable of 50 Ω impedance.

DC

ISAFE3 supports automatic sensor coupling verification: An AE signal processor sends an AST­control-pulse (short-cuts of 28 V supply voltage for some microseconds duration) to the signal
isolator SISO3, which sends a similar pulse to the sensor ISAS3. The ISAS3 uses the pulse to
generate an AE wave that propagates through or along the test object to be picked up by
neighboring sensors. Changes of the received amplitudes of different pulsing tests are an
indication for coupling problems with the sensors. The AST control pulse is supported by
Vallen's AE signal processor ASIP-2/A.

For optimum performance and signal-to-noise ratio, the signal processing chain inside the AE
system should comprise application specific frequency filters optimized for the application, e.g.
as provided by Vallen ASIP-2/A.

4.1 Members of ISAFE3 family

ISAFE3 product family consists of the following variants of the intrinsically safe piezoelectric AE­sensor ISAS3-xxx, the signal isolator SISO3 and accessories.

Table 4-1 Members of ISAFE3 with ATEX type certification

ISAS3 variants differ only in the geometry of the piezoelectric element and piezo-cup, hence in
the frequency response. Every ISAS3 contains a preamplifier with 20 dB gain.

SISO3 gain can be set to 14 dB, 20 dB or 26 dB by jumpers and can be changed by the user.
Default gain is 14 dB for a total gain of 34 dB (including 20 dB of ISAS3).

Table 4-2 ISAFE3-Accessories, no certification required

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5 Signal Isolator SISO3

Figure 5-1 SISO3 Module.

BNC: to AE system
SMA: Ex I to ISAS3 (Terminal

screw 4: left most screw)

Figure 5-2 SISO3-Block Diagram

CAUTION:

 SISO3 must be installed within a dry and clean environment of pollution degree 2

or 1 (see EN 60079-11:2007 / F.2). For pollution degree see glossary. This needs
usually an enclosure of protection class IP54. See chapter 6 Accessories for
SISO3.

 SISO3 does not contain an overvoltage protection for atmospheric electricity. It is

assumed that protection against atmospheric electricity is provided by other
means.

SISO3 is a so-called associated apparatus. That means it is an electrical apparatus which
contains both, intrinsically safe circuits and non-intrinsically safe circuits. It is constructed so that
the non-intrinsically safe circuits cannot adversely affect the intrinsically safe circuits (EN 60079­0:2009 / 3.2). SISO3 is a module to be snapped on a DIN rail.

The purpose of signal isolator SISO3 is to

1.) electrically isolate the intrinsically safe sensor circuit from the AE system

2.) provide isolated DC-voltage for ISAS3 over the combined coaxial power/signal cable

3.) amplify the AE signal from the sensor and transfer it to the AE system

4.) transfer an AST control pulse from the AE system to the sensor

5.) limit the voltage, current, power and pulse energy on the intrinsically safe circuit in
accordance with EN 60079-11:2007 for use in zone 0, even in the case of two worst case
faults in SISO3 and two in ISAS3.

6.) ensure electro-static discharge of intrinsically safe cable over 220 kΩ to earth at DIN rail,
when cable is interrupted.

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5.1 SISO3 Labeling

II (1) 3 G Ex nA [ia Ga] IIC T4 Gc

Tamb: -20 to +60 °C IP30

5.1.1 Manufacturer and type:

Vallen Systeme GmbH, 82057 Icking, Germany
Signal Isolator SISO3 Type
SNo. yyyy-xxx Serial number (yyyy = year, xxx number produced)
CE

Notified body for EN 80079-34:2011 audit and surveillance: TÜV

0123

SÜD

TÜV-A 11ATEX0004X Notified body for type examination: TÜV Austria, X: Does not contain

overvoltage protection for atmospheric electricity.

5.1.2 ATEX / CENELEC label:

Meaning of the ATEX / CENELEC label elements:

Indicates the following symbols as terms defining the area of use

according to ATEX
II Group of device which can be used in explosive areas but not in mines
(1) This is an associated apparatus for a device of category 1 which is

useable in zone 0
3 This apparatus is of category 3 from the group of device (II) useable in

zone 2 (or in non-hazardous area). This operation manual does not deal

with the use of SISO3 in a hazardous area
G For use in explosion hazardous gas (not dust)
Ex Label indicating the following symbols are terms defining the protection of

devices according to CENELEC standards
nA This is a non-sparking apparatus for use in zone 2
[ia Ga] This is an associated apparatus of an intrinsically safe device "ia" in

accordance with Equipment Protection Level (EPL) “Ga”. Equipment for

explosive gas atmospheres, having a very high level of protection, which

is not a source of ignition in normal operation, expected malfunction, or

when subject to rare malfunction. Such equipment has a form of

protection which will remain effective even in the presence of two

potential faults or will have two independent means of protection (usable

in zone 0) (EN60079-0 3.18.3)
IIC Explosion group; for gases needing the lowest amount of energy to ignite

T4 Temperature class, defining that the maximum surface temperature a gas

Gc Equipment for explosive gas atmospheres, having a normal level of

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an explosion, e.g. hydrogen

can reach in this apparatus (SISO3) stays always below 135 °C

protection, which is not a source of ignition in normal operation.

Vallen ISAFE3 Operation Manual - Operation Manual

Tamb: -20 to +60 °C This is the range of ambient temperature this apparatus can be operated

Protection class by module housing

IP30, means protected against particles larger than

2.5 mm diameter. No water protection.

Ambient temperature range,
operational

-20 … +60 °C

Maximum surface temperatures
(faulty)

T4: < 135°C
Module housing model

Phoenix ME, DIN rail clamp-on module

Case material

Polyamide

Case temperature range

-40 … +105 °C

Dimension

99 (H) x 114.5 (D) x 22.5 (W) mm

Weight

170 g

The front label of SISO3 is shown in Figure 5-3.
The string "to AE System" on top of the label belongs to the

BNC connector above (see Figure 5-1). This connector is to be
connected to an AE signal processor in the AE system.

The string "Ex i to ISAS3" at the bottom of the label belongs to
the SMA connector below (Figure 5-1). This is the connector for
the intrinsically safe circuit to the sensor ISAS3 in a hazardous
area.

The user can put a cross in one of three gain setting boxes and
write the channel number, the SISO3 belongs to, into the
foreseen field.

Figure 5-3 Front label

IP30 Degree of protection against ingress of dust and liquid according to

5.1.3 Front label

in

EN60529.

First digit "3" means protected against objects larger than 2.5 mm

diameter.

Second digit "0" means no protection against ingress of water.

5.2 Specifications of SISO3

5.2.1 Specifications with relevance to intrinsic safety (IS)

The most important IS relevant specifications are shown by label and described in chapter 5.1.

5.2.2 Mechanical specifications

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5.2.3 Safety relevant electrical parameters:

Connector type at SISO3 module

Coaxial, BNC, female, 50 Ω, right-angled cable
connector required due to limited height of HISO3.

Cable connector SISO3 side
(recommended)

BNC 50 Ω, crimp, angled
Telegärtner Art. No. J01000A1257
Assembly instruction: Figure 11-3

Cable connector ASIP-2 side
(recommended)

BNC 50 Ω straight,
Telegärtner J01000A1255
Assembly instruction: Figure 11-4

SISO3 input protection (fuse)

100 mA fuse

Maximum input DC voltage at which
fuse will not blow

32 V

Minimum resistance of power supply
(signal processor) to prevent blowing
the fuse by in-rush current

50 Ω

SISO3 supply voltage, functional

(28 ± 1) VDC 50 Ω AC impedance

Typical SISO3 supply current,
functional

33 mA (standby) / 66 mA (full scale) /
88 mA (fourfold saturated, continuous)

AC output range

±5 V (full scale) into 50 Ω (of AE-system)

AC output impedance

50 Ω

Gain

Ex works: 14 dB; 14/20/26 dB jumper selectable
(+20 dB of sensor)

AST-control pulse

Shortening 28 VDC for 0.5 to 5 µs by AE system
causing the sensor to generate an artificial AE-event
for test purposes

Noise

See ISAS3 specification

Typical Frequency Response (-1 dB /

-3 dB) without an ISAS3 connected

15 – 900 kHz / 10 – 1600 kHz

Maximum length of cable to AE
system

100 m (4.2 Ω)

Um = 250 V AC 50 - 60 Hz Maximum voltage to maintain intrinsic safety
UO = 13.8 VDC Maximum output voltage (open circuit)
IO = 60 mA Maximum output current (switches off at overload/short-cut)
PO = 0.3 W Maximum output power
CO = 397 nF Maximum external capacity
LO = 22 mH Maximum external inductivity

5.2.4 Electrical specifications of signal line at BNC connector (to/from AE­system):

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5.2.5 Electrical specifications of external intrinsically safe circuit

Connector type at SISO3 and ISAS3
side

Coaxial, SMA, female, 50 Ω

Connector type for cable end at
SISO3 side

(for use with HISO3 = right-angled,
gold plated)

SMA male, 50 Ω, Telegärtner
Art. No. J01150A0091
(Temp. and climate: IEC 60068 55/155/56)
Assembly instruction: Figure 11-2

Connector type for cable end at ISAS3
side (straight, stainless steel)

SMA male, 50 Ω, Huber+Suhner
Type 11_SMA-50-3-55/199_N
(specified to -65°C to +165°C, IP68)
Assembly instruction: Figure 11-1

Terminal block (test purposes only)

4 terminal screws,
4 = signal, 1 – 3 = shield (Ex i circuit),

Cable shield, ISAS3 side

Connected to metallic case of ISAS3

Cable shield, SISO3 side

Forms minus pole for voltage supply.

Output DC voltage, nominal

+12 V - 0.16 V/mA against cable shield

Output DC current, nominal,

13 mA (standby) / 20 mA (full scale) /
25 mA (fourfold saturated)

Output power (continuous, nominal)

300 mW (IS relevant)

AC input impedance of SISO3

50 Ω

AC output impedance of ISAS3

50 Ω

AC voltage range (full scale),
at 14/20/26 dB SISO3 gain

2 VPP @ 14 dB / 1 VPP @ 20 dB / 0.5 V

PP

@ 26 dB

AST-control pulse

Shortening intrinsically safe circuit for 0.5 – 5 µs by
SISO3 activates an ISAS3 internal pulse generating
an artificial AE event for test purposes.
(See ISAS3 specs for details)

Isolation voltage test SMA-shield
against BNC-shield

1500 V

RMS

for 60 s, each unit individually tested.

Module to be disconnected from DIN rail for this test

Resistance of shield to earth for
electrostatic discharge on SISO3 side

220 kΩ, 0.25 W to earth at DIN-rail
(0.125 W @ 60°C), (165 V

max

).

Parameters of cable type for SISO3­ISAS3-connection, not oil-proof

RG58C/U coaxial cable 50 Ω
CC < 100 pF/m,
LC < 0.34 µH/m
RC < 28 Ω/km (inner wire) + 14 Ω/km (shield)
Diameter: 5 mm

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Parameters for cable type for SISO3­ISAS3-connection, improved chemical
resistance

E&E 29392-1 coaxial cable 50 Ω
CC < 110 pF/m

LC < 0.34 μH/m
RC < 23 Ω/km (inner wire) + 12 Ω/km (shield)

Diameter: 5 mm

Maximum cable length between
SISO3 and ISAS3

Functional (85 Ω): 2.0 km
By capacity (397 nF) > 3 km
By inductivity (22 mH) > 3 km

5.3 Modifying SISO3-gain

Earth from DIN
rail

Figure 5-4 Position of the gain-jumpers on basic board, plug-on board lifted

SISO3 default gain setting is 14 dB and can be modified by jumpers to 20 or 26 dB. This
reduces the input range at the piezo element from 200 mVPP to 100 mVPP or 50 mVPP,
respectively. For gain modification one must separate the lower part of the clip-on case. The
upper part, where BNC and SMA connectors are mounted, can remain on the board.

For separation of the lower part of the green case use a small screwdriver and press slightly
through a rectangle hole at the side, where the upper part of the green case overlaps the lower
part and at same time pull the lower part few millimeters down. Do the same on the other side
and then you can completely detach the lower part.

Figure 5-4 shows the position of the 3x2 pin jumper field for gain setting. One must shift up the

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plug-on-board (39LIMIT) a little to get access to the jumper. On default, the jumper shortens the

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inner pair of pins, this defines 14 dB gain. For 20 dB gain move the jumper to the middle pair,
for 26 dB move it to the outer pair of pins. Indicate the new gain on the front label by a cross.
Place back the 39LIMIT plug-on board and shift the lower part of the green case back over the
boards. Make sure the DIN-rail-connector inside the lower part of the green case will contact
earth to the board; see the indication on the left of Figure 5-4.

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5.4 Environmental conditions for SISO3

Environment
of SISO3

Pollution
Degree

Requirement on outer case for SISO3

Non­hazardous

2 (or 1)

Dry environment. EN 60079-11:2007 / F.2 applies. Case shall
be metallic and provide sufficient space and safe hold of
SISO3 modules and cabling. Internal DIN rail needed for
mounting and earth connection of SISO3 modules. Outer case
shall be connected to earth potential. Ex-label not required for
the case. Cable entry for intrinsically safe circuits to be labeled
"Ex-i"

Requirements are met by HISO3-xx products

Non
hazardous

> 2

As before. The outer case must be of protection class IP54
(IEC60529)

Requirements are met by HISO3-xx products.

Hazardous
area of zone 2

2 (or 1)

As before. The outer case must undergo mechanical tests (7
Joule impact test, IP54 test) to be performed according to
EN 60079-0:2009 / 6.2 and 26.4.2, 26.4.4, 26.4.5, if product is
not an approved Ex-component.

Ex-Label (same as SISO3) required.

This chapter describes relevant information applicable for selection or construction of the
housing of a number of SISO3 modules.

SISO3 modules must be installed into an outer case, where SISO3 modules can simply be
clamped-on to a DIN rail.

The DIN rail must be connected to earth. SISO3 connects earth from DIN rail over 220 kΩ to the
shield and minus of the intrinsically safe circuit to ensure electro static discharge when cable to
ISAS3 is interrupted.

Depending on the environment of SISO3, different requirements apply.

Additional requirements on the outer case of SISO3, if installed in a hazardous area of zone 2:
EN 60079-14:2008 / 6 Protection against dangerous sparks
EN 60079-14:2008 / 9.3 Cabling
EN 60079-14:2008 / 12 Additional requirements for intrinsically safe installations
Depending on the application, other standards may need consideration.

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6 Accessories for SISO3

Figure 6-1 Top view

into opened HISO3-08

Figure 6-2 Front view on

cable entry system

Figure 6-3 Side view on earth

connection point

6.1 HISO3-08

Box for up to 8 modules SISO3. It is for installation in a non-hazardous area.

The HISO3-08 (Figure 6-1 to Figure 6-3) (manufacturer Rose 25.232018) offers a screw­terminal on the outside for earth connection (see Figure 6-3). The box dimension is 232 x 202 x
180 mm³. It is made of aluminum with polymer-coated surface. The SISO3 modules are
clamped on a DIN rail. Cables enter over a so-called cable entry system, see Figure 6-2. A label
nearby the cable entries identifies the Ex i cable positions as well as the output cables positions,
see Figure 6-4. The label is not shown in Figure 6-2.

The cable entry system consists of a frame for up to 4 inserts, each insert (21 x 21 x 19 mm³,
icotek KT4/5 #39908) allows accommodating up to 4 cables of 5 mm diameter each. Cables can
be lead through the entry system with connectors already mounted. A top bar is screwed on the
frame and holds the inserts in place. The stress relief is in accordance with EN 50262. If there
are less cables to feed-in, the open holes must be closed with 5 mm diameter blind plugs. This,
in combination with a sealing part bonded to the box of HISO3, ensures protection code IP54.
The temperature range of the cable entry system is specified to -40°C to +140 °C.

As Figure 6-1 to Figure 6-3 show, all cables are connected to SISO3 over a right-angle plug.

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Figure 6-4 Label at cable entry of HISO3-08

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6.1.1 Mechanical specifications of HISO3-08

Protection class

IP54 means protected against dust and
splash water from all directions.

Temperature range

-20 … +60 °C (SISO3)

-40 … +140 °C (cable entry system)

-20 … +135 °C (outer case)

Dimensions and weight

232 x 202 x 181 mm³, 4.3 kg

Earth terminal

Two M6 threads on outer side of HISO3 (see
Figure 6-3) Material of screws and washer:
Stainless steel.

Ex-Label

HISO-08 is for installation in non-hazardous
area and does not carry an Ex label.
Ex i cable entries are clearly labeled.

Accessories:

HISO3-08 comes with 4 cable entries KT4/5,
each for 4 cables, 5 mm thick. Blind plugs for
unused cable holes.

Figure 6-5 Top view into

opened HISO3-20

Figure 6-6 Front view on

cable entry system (non Ex i

cables)

Figure 6-7 Front view on cable
entry system (Ex i cables) and

earth connection point

6.2 HISO3-20

Box for up to 20 SISO3 modules. It is for installation in a non-hazardous area.

The outer box of HISO3-20 (Figure 6-5 to Figure 6-7) (manufacturer: Rolec; series: Alu-Kom;
part number: AKH311) offers an outside screw-terminal for earth connection (see Figure 6-7).
The box dimension is 402.5 x 310 x 180 mm³. It is made of aluminum with polymer-coated
surface. The SISO3 modules are clamped on a DIN rail. Cables enter on two sides over two so­called cable entry systems (see Figure 6-6 and Figure 6-7). A label nearby the cable entries
identifies the Ex i cable entries (Figure 6-7) and the non Ex i cable entries (Figure 6-6).

The cable entry system consists of a frame for up to 5 inserts, each insert (21 x 21 x 19 mm³,
icotek KT4/5 #39908) allowing inserting up to 4 cables of 5 mm diameter each. Internal cable
channels are prepared to feed the AE system from one side, ending at the SISO3s’ BNC plug,
and the Ex i cables to the sensors from the other side, ending at the SISO3s’ SMA plug.

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Cables with connectors already mounted can be inserted. A top bar is screwed on the frame

Protection class

IP54 means protected against dust and splash water
from all directions.

Temperature range

-20 … +60 °C (SISO3)

-40 … +140 °C (cable entry system)

-20 … +135 °C (outer case)

Dimensions

402.5 x 310 x 180 mm³, 9.4 kg

Earth terminal

Two M6 threads on outer side of HISO3 (see Figure 6-7)

and holds the inserts in place. The stress relief is in accordance with EN 50262. If there are less
cables to feed-in, the open holes must be closed with 5 mm diameter plugs (icotek st5, #42906).
This, in combination with a sealing part bonded to the box of HISO3, ensures protection code
IP54. The temperature range of the cable entry system is specified to -40 °C to +140 °C.

Connectors mounted to the cable ends inside HISO3-20 must be right angled because of the
given enclosure dimension.

Figure 6-8 Label at cable entry of HISO3-20 (non Ex i cables).

Figure 6-9 Label at cable entry of HISO3-20 (Ex i cables).

6.2.1 Mechanical specifications of HISO3-20

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Material of screws and washer: Stainless steel

Ex-Label

HISO-20 is for installation in non-hazardous area and
does not carry an Ex label. Ex i cable entries are clearly
labeled.

Accessories:

HISO3-20 comes with 10 cable entries KT4/5, each for 4
cables, 5 mm thick. Blind plugs for unused cable hole.

Figure 6-10 Insert cable

Figure 6-11 Space for cables

on the right of right-most SISO3

Figure 6-12 Clamp 4 cables into

one insert

Figure 6-13 Lower part of frame

Figure 6-14 Top of frame

Figure 6-15 Fixing cable entry

unit

6.3 Cable entry instructions

Instructions given for HISO3-08 are similar for HISO3-20. Only difference is the recommended
positions for the ISxx cable and the Axx cables.

HISO3-20 uses two cable entry systems each with 5 inserts, each insert holds up to 4 coaxial
cables of 5 mm diameter. It is recommended to feed the cables to the AE system from left,
ending at the SISO3s right angle BNC plug and the cable to the sensors from right, ending at
the SISO3s right-angle SMA plug.

For connecting SISO3s the following sequence is recommended:
(Needs a 3 mm and a 4 mm hexagon socket screw driver)

1. Before or while plugging on the connectors to SISO3, it is recommended to label the cables

from AE-system with Axx (xx the channel number) and the intrinsically safe cables to the
sensor with ISxx, for easy identification.

2. Fasten SISO3 at its final location, connect the earth terminal (see Figure 6-3) to ground

using 4 mm2 copper wire with end piece. Remove cable entry frame. Leave the sealing at
the box. Remove the upper part of the frame.

3. Insert cables from AE system with right-angle BNC plug into the box (Figure 6-10)

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4. Place all cables from AE-system around the right of right-most SISO3 (Figure 6-11) and

connect them to SISO3

5. Lead all Ex i cables from ISAS3 sensors through the cable entry system and connect them to

SISO3. Ex i cables require a right-angled SMA connector to connect to SISO3. These
cables shall be marked light blue to identify their Ex i status, e.g. by using a piece of light
blue heat shrink or light blue adhesive tape.

6. Clamp 4 cables into one insert (Figure 6-12), the cable to the AE system in the right two

inserts, the Ex i cables from ISAS3 sensors into the left two inserts. See Figure 6-4.

7. Unused cable holes must be closed with 5 mm diameter closure plugs ST5 (See 6.1.1).

8. Shift the inserts into the lower frame (Figure 6-13) then mount the lower frame of the cable

entry system loosely to the box.

9. Screw the upper part of the frame firmly onto the lower part (Figure 6-14)

10. Screw the lower part of the frame firmly to the box (Figure 6-15). This presses the lower and

upper part of the frame against the sealing.

11. When all connections are made, mount the top cover of HISO3.

6.3.1 Dismounting a SISO3 from DIN rail

Figure 6-16 Opening the clip of SISO3 for removal from DIN rail

Figure 6-16 shows the position of the clip for the removal of a SISO3 from DIN rail. One must
put a screw driver into the rectangle opening of the clip and move the clip 2 mm outwards, this
will release the SISO3 from the DIN rail.

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7 ISAS3 Overview

Figure 7-1 View onto piezo-cup

Figure 7-2 SMA-connector & sealing adapter

A

A

A

Piezo­cup

C

C

SMA­connector

Ridge (11.5 mm)

Purpose of ISAS3 is to

1.) pick up the surface movement of a test object caused by an AE-source, e.g. corrosion, crack

growth or crack closure

2.) convert the surface movement into an electrical AE signal

3.) amplify the AE signal within a certain frequency range by 20 dB and send it over a coaxial

cable to the signal isolator SISO3

4.) convert the AST control pulse from SISO3 into an artificial AE event for an automated sensor

coupling verification.

Figure 7-1 shows ISAS3 with its sensitive face pointing upwards. Within the piezo-cup is the
piezoelectric element. The face of the cup must be pressed against the test object with a
coupling agent in between. The coupling agent is for functional reasons (i.e. acoustic
transmission), only. We recommend RTV162.

The two threads labeled "C" in Figure 7-1 are to screw-on earth connection wires for a safe
earth connection of the metallic sensor case (see chapter 9 for details). For perfect high­pressure-sealing, the piezo-cup is laser-welded to the base plate of the sensor.

Figure 7-2 shows the sensor ISAS3 from side. The cylindrical part is laser-welded to the base
plate and the SMA-protection adapter is laser welded to the cylindrical part. The SMA connector
is for the intrinsically safe cable to SISO3. The SMA connector is embedded in a sealing
adapter which allows for clamping on a flexible tube or a heat shrink. As Figure 7-2 shows, the
outer diameter of the sealing adapter is 11.0 mm over a width of 14 mm, the ridge is 11.5 mm
diameter over a width of 0.75 mm. This is for a durable sealing of the transition of either a cable
to ISAS3, or the transition of a flexible tube to ISAS3. Such sealing is recommended in case of
wet environment, e.g. on ship's deck or at tank cars. It is mandatory for installation inside a tank.
See chapter ISAS3-SpecIP68 for details how to seal the cable-to-sensor transition against oil
and 12 bar peak pressure.

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CAUTION:

 According to EN 60079-14:2008/12.2.2.3 a) and b) (earthing of cable screens) the metallic

case of ISAS3 must be safely connected to the metallic test structure by two wires of at
least 1.5 mm2 or one wire of at least 4 mm2.

 If ISAS3 is to be installed inside a tank of liquid, sloshing forces and peak pressures up to

12 bar must be expected. Provisions have to be made to seal ISAS3 for 12 bar peak
pressure as described in chapter 8.3 ISAS3-SpecIP68 and to protect the sensor case from
sloshing forces, see chapter 8.2 ISAS3-SpecMount.

7.1 ISAS3 Labeling

II 1G Ex ia IIC T6 Ga

IP68 Tamb: -20..+60°C

ISAS3 is ATEX certified for use in explosion hazardous atmospheres of zone 0, 1 or 2 of lowest
ignition energy (hydrogen).

7.1.1 Manufacturer and type:

Vallen Systeme GmbH, 82057 Icking, Germany (Manufacturer)
Type ISAS3-xxx ("xxx" can be 030, 075, 150, 150-V01, 375, 900, identifying the

frequency range)
Serial no: yyyy xxx (xxx = serial number, produced in year yyyy)
CE

Notified body for EN 80079-34:2011 audit and surveillance: TÜV

0123

SÜD
TÜV-A 2011 ATEX0005X Notified body for type examination: TÜV Austria, X: ISAS3 must be

safely connected to metallic test structure by two wires of at least

1.5 mm2 or one wire of at least 4 mm2. If installed in liquid, ISAS3 to

cable transition must be specially sealed. See Caution note on page

28.

7.1.2 ATEX / CENELEC label:

The meaning of this label is:

Indicates the following symbols as terms defining the area of use

according to ATEX
II Group of device which can be used in explosive areas but not in mines
1 This is a device of category 1 from the group of device (II) useable in

zone 0
G For use in explosion hazardous gas (not dust)
Ex Label indicating the following symbols are terms defining the protection of

devices according to CENELEC standards
ia This is an intrinsically safe device "ia" (useable in zone 0), safe at even

two worst case faults

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IIC Explosion group; for gases needing the lowest amount of energy

Protection class (EN60529)

IP68 (cable connected)
(for 12 bar peak pressure seal the cable-to-ISAS3-

transition according to specification in chapter 8.3)

Ambient temperature

-20 °C … +60 °C

Case material

Stainless steel 1.4571 (German: V4A)

Case isolation

None, case connected to shield and minus pole of
intrinsically safe circuit

Sealing

Three transitions (piezo-cup to base plate, base plate to
cylinder, connector-adapter to cylinder) laser-welded,
cover to cylinder sealed by threat and O-ring 1.78 mm
thickness, made of FKM

Sealing adapter
(for cable to ISAS3 sealing)

11.0 mm diameter, 14 mm width (for 11 mm wide clamp),
plus ridge with 11.5 mm diameter, 0.75 mm width. (See
Figure 7-2)

Earth connection

2 threads M4, see chapter 9.4 or 8.1

Maximum surface temperatures
(worst case fault)

T6: < 85 °C at 60 °C T

amb

(< 60 µJ, hydrogen) to ignite an explosion.

Group IIC specification covers also IIB and IIA, since these groups are for

gases of higher ignition energy (60 to 180 µJ with IIB, e.g. for ethylene,

and > 180 µJ with IIA, e.g. for propane)
T6 Temperature class, defining the maximum surface temperature a gas can

reach in this apparatus stays always at least 5 K below 85 °C. T6 is the

temperature class of lowest temperatures and covers the requirements of

T1 - T5.
Ga Equipment protection level (EPL) "Ga": Equipment for explosive gas

atmospheres, having a very high level of protection, which is not a source

of ignition in normal operation, expected malfunction, or when subject to

rare malfunction. Such equipment will have a form of protection which will

remain effective even in the presence of two potential faults or will have

two independent means of protection.
IP68 Degree of protection against ingress of dust and liquid.

First digit "6" means completely protected against ingress of dust.

Second digit "8" means suitable for continuous immersion in water under

conditions which shall be specified by the manufacturer.
Tamb: -20..+60°C This is the range of ambient temperature this apparatus can be operated

in. For maintaining intrinsic safety, the upper limit is essential. The lower

limit has no influence on intrinsic safety and is a pure functional

specification.

7.2 Specifications ISAS3-xxx

7.2.1 Mechanical specifications

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Internal molding

Completely molded

Dimension
(for ISAS3-030 add 7.5 mm

height)

53.5 (W) x 56 (L) x 47.5 (H) mm³,
Cover diameter: 46.5 mm

Weight

0.25 kg (sensor) + 0.17 kg (magnetic holder)

Mounting aid

Magnetic holder MAG4IS, see chapter 8.1

Outside height of piezo-cup

18 mm (ISAS3-030: 25.5 mm)

Outer diameter of piezo-cup

22 mm

Diameter of acoustic most
sensitive area (face)

14 mm

Diameter and height of bigger
cylinder incl. thickness of cover &
baseplate

Ø 45 x 29.5 (H) mm
Maximum safe impact energy

(Type examination)

7 J (EN 60079-0:2009 Annex C)

Connector type ISAS3 side

SMA female 50 Ω, IP68 (connected), stainless steel

Connector type, cable side

SMA male, 50 Ω, Huber+Suhner
Typ 11_SMA-50-3-55/199_N
(specified to -65 °C to +165 °C, IP68)

Voltage supply, operational

12 ± 1 V over 160 Ω

Current consumption, operational

13 mA (standby) / 20 mA (full scale) / 25 mA (fourfold
saturated)

Power Consumption, operational,
versus current

Ui = 12 V - 0.16 V/mA

129 mW (standby) / 176 mW (full scale) /
200 mW (fourfold saturated)

Input voltage range (from piezo)

±100 mVP

Integral gain

20 dB

Output impedance

50 Ω

7.2.2 Safety relevant electrical parameters:

Ui = 13.8 V Maximum supply voltage
Ii = 60 mA Maximum supply current
Pi = 0.3 W Maximum input power
Ci = 65 nF Maximum inner capacity
Li = 1 µH Maximum inner inductivity (due to threefold zener diodes)

7.2.3 Electrical specifications

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Output voltage range before
saturation

2 VPP into 50 Ω

Typical noise (referred to piezo)
Peak / RMS, measured using
ISAS3 -> SISO3 (26dB) -> post­amplifier (40dB) -> AMSY-6 at
shown filter settings,

12.8 µVP / 4.1 µV

RMS

25 - 45 kHz (ISAS3-030)

27.6 µVP / 9.1 µV

RMS

25 - 100 kHz (ISAS3-075)

25.6 µVP / 5.9 µV

RMS

95 - 300 kHz (ISAS3-150)

25.6 µVP / 5.9 µV

RMS

95 - 300 kHz (ISAS3-150-V01)

24.0 µVP / 4.4 µV

RMS

180 - 500 kHz (ISAS3-375)

33.1 µVP / 5.5 µV

RMS

95 - 960 kHz (ISAS3-900)

AST-pulse for sensor coupling
verification

ISAS3 controlled by ASIP-2/A via
SISO3,

Pulse ISAS3-internally generated,
in order to stimulate an AE event
for test purposes. Amplitude can
be controlled by AE system over
the length of AST control pulse,
to some extent.

Pulse width Amplitude (typical)

0.5 us 8.4 V
1 µs 15 V
2 µs 26 V
4 µs 31 V

Model

Typical Peak sensitivity

@ frequency

Typical Bandwidth (-10 dB)

ISAS3+SISO3

ISAS3-030

-63 dB re 1 V/µbar @ 55 kHz

23 – 75 kHz

ISAS3-075

-61 dB re 1 V/µbar @ 78 kHz

25 – 120 kHz

ISAS3-150

-64 dB re 1 V/µbar @ 150 kHz

120 – 180 kHz

ISAS3-150-V01

-64 dB re 1 V/µbar @ 150 kHz

120 – 180 kHz

ISAS3-375

-63 dB re 1 V/µbar @ 370 kHz

220 – 780 kHz

ISAS3-900

-64 dB re 1 V/µbar @ 340 kHz

220 – 910 kHz

7.2.4 Acoustic specifications

Sensitivities are given referred to the piezo element (independent on gain), typical values

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8 Accessories for ISAS3

Figure 8-1 Magnetic holder MAG4IS

Three threads M4 (labeled A in Figure 8-1) are to
fasten the base plate of sensor ISAS3. Two
threads M4 (labeled C in Figure 8-1) are to mount
e.g. a steel tape around a cylindrical tank for
stronger fastening against vibration and
acceleration when driving over bad roads.

Magnets are of material cobalt samarium. Each
magnet provides a holding force of 200 N.
Magnets are suitable for the full temperature
range of ISAS3.

Each spring provides a holding force of 25 N.
Springs are made of stainless steel.

MAG4IS is suited for all ISAS3 variants

C

A

A

3 spring­loaded
magnets

C

A

2 threads M4 for
earth wires

8.1 Magnetic Holder MAG4IS

Figure 8-1 shows a magnetic holder MAG4IS. It consists of a mounting plate of stainless steel,
which is pressed by three springs towards the test object. Three magnets have direct contact to
the surface of the test object.

Figure 8-2 shows the ISAS3 with the MAG4IS completely mounted. An earth connection must
be made using one wire of at least 4 mm2 copper (or two of at least 1.5 mm2) fastened at the
designated sensor thread M4 (see Figure 8-2, right) to an earth point nearby (EN 60079­14:2008, 12.2.4). Washers must be used and sufficient torque to ensure the earth connection is
not twistable.

Figure 8-2 ISAS3 on magnetic holder MAG4IS (right: earth connection)

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8.2 ISAS3-SpecMount

B

B

B

A

A

A

C

C

This describes an alternative mounting method of ISAS3 using welded screws instead of
magnets.

The mounting plate shall be fastened by three M5x16 screws (instead of magnets), with
hexagon screw-heads welded to the test object. The boreholes "B", 9 mm with MAG4IS, shall
be 5.1 mm for the welded holder. Each screw holds the mounting plate using screw-nuts and
washers on both sides. The mounting plate comes with the three screws already mounted and
the distance between screw-heads and mounting plate adjusted to 10 mm.

Figure 8-3 Mounting plate for magnetic holder, thickness 3 mm. (39MMP1_R0.2 of 29.04.2011)

A sensor position must be found, where the area between three welding points is perfectly flat
and where the sensor's sensitive face will meet a clean surface. The three screw-heads holding
the mounting plate shall be welded to the test object. Then the sensor ISAS3, with some
coupling agent on the sensitive face, shall be mounted to the mounting plate using three screws
M4, exactly as with MAG4IS (Figure 8-3), to threads "A" in Figure 8-1. If the test object's surface
is not perfectly flat, the three pairs of screw-nuts must be loosened, the best position found and
the screw-nuts re-fastened. The best position is found, when the sensor's sensitive area is
exactly parallel and pressed onto the test object surface.

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No spring is used with the welded holder, so motion or sloshing forces cannot influence the seat

Figure 8-4

Figure 8-4 shows a 50 mm long
section of a heat shrink of type
RW200-E with 9.5 mm inner diameter
before shrinking)

This type of heat shrink model can be
shrinked at 150 °C to half of the
diameter before shrinking. Thickness
will be 0.9 mm after shrinking.

This part is used to make the cable
thick enough for sealing by a thicker
heat shrink.

of the sensor. The cable leaving the sensor shall be fastened by an additional welded screw to
avoid forces from cable to sensor from movements or sloshing.

Since all metallic parts are in direct contact to the test object, no extra earth wire is needed.
The distance of the mounting plate to the test object is nominal 10.0 mm with all ISAS3 variants,

due to different distance pieces for the sensor. These are 12.5 mm long with ISAS3-030 and
5 mm with all other variants.

Two threads "C" in Figure 8-3 are symmetric to ISAS3 and foreseen to fasten the mounting
plate by a steel tape around the circumference of a cylindrical tank (e.g. tank car monitoring).

8.3 ISAS3-SpecIP68 – oil resistant sealing of a cable-to-sensor
transition against 12 bar peak pressure

8.3.1 Sealing Set Hardware: SS-OIL-5MM

This sealing set is needed to seal the transition of a 5 mm thick cable to ISAS3. It consists of:

1. 1 piece of heat shrink hose, oil resistant, Raychem RW-200-E-3/8-0, 9.5 mm inner
diameter before shrinking, 50 mm length, -55 °C to +200 °C

2. 1 piece of heat shrink hose, oil resistant, Raychem RW-200-E-1/2-0, 12.7 mm inner
diameter before shrinking, 60 mm length, -55 °C to +200 °C

3. 1 cable clamp for 7.4 to 10 mm diameter, oil resistant, 11 mm width

4. 1 cable clamp for 9.6 to 14 mm diameter, oil resistant, 11 mm width

The cable clamps are made of steels 1.4310, 1.4567 and 1.4305.

8.3.2 Usage of Sealing Set SS-OIL-5MM

For a temporary installation, cables don’t have to be installed in protective tubes, so for use for
instance in a crude oil tank, oil proof coaxial cable must be used and inserted into the tank
usually through a partly open man hole. Safety consideration must be provided by a safety
expert on site. This chapter specifies only the recommended sealing of the cable-to-sensor
transition against oil and 12 bar peak pressure. If sealing is needed for water, a less expensive
heat shrink material than specified below may be used.

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Figure 8-5

Figure 8-5 shows the heat shrink of
Figure 8-4 shrunk onto the cable and
partly onto the SMA connector.

Figure 8-6

Figure 8-6 shows a 60 mm long
section of heat shrink type RW200-E,

12.7 mm inner diameter before
shrinking.

The shown stainless steel screwed­clamps are for sealing both heat
shrinks on the coaxial cable.

The smaller one is to clamp both
layers of heat shrink onto the cable,
the bigger one is to clamp one heat
shrink layer onto the connector
adapter of ISAS3.

Figure 8-7

As seen in Figure 8-7, first the smaller
clamp and then the larger clamp and
then the heat shrink must be shifted
over the cable end before the SMA
connector is screwed on.

Figure 8-8

Figure 8-8 shows the heat shrink
already shrunk over the connector­adapter on ISAS3 side.

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Figure 8-9

Figure 8-9 shows the smaller stainless
steel clamp being screwed onto the
other end of the heat shrinks for safe
tightening of heat shrink and cable.

The clamp is needed for durable
sealing.

Figure 8-10

Figure 8-10 shows the completed
cable to sensor transition. The
sensitive face of the sensor is pointing
downwards; no magnetic holder and
earth connection wire is shown.

8.4 Sealing the transition of a cable-in-a-tube to sensor against
12 bar peak pressure

Within for instance a ship's tank it is assumed that for protection of permanently installed cables
from mechanical damage and from oil, the coaxial cable run through a sealed tube to ISAS3. At
ISAS3 side the tube must end in a flexible part which is sealed to ISAS3 with a heat shrink of
appropriate diameter. RW200-E heat shrinks are available with inner diameters (before
shrinking) of 15.9 mm, 19.1 mm, 22.2 mm and 25.4 mm.

If the inner diameter of the flexible tube is bigger than 11.0 to 11.5 mm (the outer diameter of
the connector adapter), a heat shrink hose might be needed which is directly fitted onto the
connector adapter.

For a long term sealing, clamps must be used as shown in the chapter before. These are
available for the following diameter ranges: 12.2 to 17 mm, 14 to 19 mm, 15.5 to 21 mm, and

17.3 to 22 mm. Up to Ø 22 mm tubes and clamps (before clamping) are possible.

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9 Installation

9.1 General hints

The applicable standards for intrinsic safety installations, especially EN 60079-14:2008 and
EN 60079-25:2010 must be considered for intrinsically safe installations. Since SISO3 is an
isolating barrier, severe requirements for non-isolating barriers do not apply. For example, it is
not required to connect the intrinsically safe circuit at the signal isolator side to earth and it is
also not required to use an isolating transformer before each mains powered device on the safe
side of the installation (EN 60079-14:2008 / 12.3).

Beside of safety considerations, AE-experts have to provide AE-specific test procedures, e.g. to
define sensor locations and maximum sensor distances. These considerations are not topic of
this document.

Additional standards and rules may have to be considered for other aspects.

9.2 Sensor mounting – functional requirements

Sensor ISAS3 shall pick up very small surface movements in a pm range (1 pm = 10
location for installing an AE sensor must be flat and clean. For best acoustic coupling a
diameter of at least 25 mm shall be free from painting/coating for direct contact of the face of
ISAS3 (14 mm diameter) to the test object. A coupling agent shall be used between face of
ISAS3 and test object. For a permanent installation, a cold hardening silicon rubber, e.g.
RTV162, is recommended as coupling agent. It also protects the area of removed coating
against corrosion. RTV162 needs about 24 hours for curing. For temporary installations, silicon
grease or other proven coupling materials can be used.

-12

m). The

The sensitive face of ISAS3 must be pressed onto the surface of the test object with a constant
force of at least 60 N. The magnetic holder MAG4IS is one example how this can be achieved
for a temporary installation. Chapter 8.2 “ISAS3-SpecMount” shows details for a replacement of
the 3 magnets by 3 bolts that can be welded to the test object for a permanent sensor
installation.

9.3 Cabling between sensor ISAS3 and SISO3 (Ex i)

We recommend two types of 50 Ω coaxial cable:

 RG58C/U, if the cable will not come in contact with oil.

 E&E 29392-1, an ETFE cable that can come into contact with crude oil.

Cable parameters and maximal cable length (2 km) are listed under 5.2.5.
For mounting SMA connectors see the assembly instructions in Figure 11-1 (ISAS3 side) and

Figure 11-2 (SISO3 side).
For sealing the cable-to-sensor transition against 12 bar peak pressure, see chapter 8.3 and

8.4.
For use on deck of a ship or at a tank car we recommend to protect the connector by using a

normal heat shrink material that is less costly than RW200-E.

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9.4 Sensor installation - safety relevant requirements for EPL “Gb”
and “Gc” (Earth connection)

EN 60079-14:2008 / 12.2 defines the safety relevant requirements for the erection of intrinsically

safe electrical installations of Equipment Protection Level (EPL) “Gb” (for hazardous areas of
zone 1) and “Gc” (for hazardous areas of zone 2.)

The metallic case of sensor ISAS3 is in electric contact to the intrinsically safe circuit (shield &
minus pole). It must be safely and reliably connected to potential equalization of the test object
(EN 60079-14:2008 / 12.2.4). Most metallic test objects provide potential equalization at the
point of sensor location due to their full metallic construction.

Pressing the contact face of an AE sensor to a test object, even if painting is removed, is not a
safe electrical contact. Welded bolts used for holding the ISAS3 mounting plate are well suited
contact points for potential equalization. Where ISAS3 cannot be directly screwed onto a
metallic surface carrying potential equalization, ISAS3 provides two threads M4, one with a pre­mounted screw, earth symbol, nut, and a ring cable lug, chopper disk and another nut (see
Figure 8-2). A wire of at least 4 mm2 copper (or two wires of at least 1.5 mm2 copper each) is to
be used to connect the ISAS3 to the potential equalization. Sufficient torque to ensure the
connection is not twistable at ISAS3 as well as at the welded bolts must be used.

For temporary installations, where magnet holders are used instead of welded bolts, safe
access points for connecting ISAS3 case with the potential equalization must be found and
used nearby.

Block diagram in Figure 9-1 applies.

9.5 Sensor installation - safety relevant requirements for EPL “Ga”
(Earth connection)

EPL “Ga” is required for zone 0, the most hazardous environment.
The requirements for EPL “Ga” installations are summarized in EN 60079-14:2008 / 12.3. There

it is urgently recommended to use isolating barriers, as given with SISO3. This eliminates
additional requirements for safety transformers and allows that earth connection of the
intrinsically safe sensor is only required at the sensor side and not at the side of the isolating
barrier.

In addition, EN 60079-14:2008 / 12.3 requires a risk analysis that the installation is protected
against atmospheric electricity (in worst case a lightning strike). If a risk of atmospheric
electricity cannot be excluded, an appropriate overvoltage protection (10 kA 8/20µs) is required.
ISAFE3 does not provide overvoltage protection against atmospheric electricity.

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Non Hazardous Area

Cable A-1

Cable A-1: RG58 C/U 50R coaxial

Cable B-1

Uncertified apparatus,

powered e.g. by 230 V AC

Cable B-2

Cable B-2: one wire 4 mm2 copper or
two wires 1,5 mm2 copper

Cable B-1: RG58 C/U 50 R coaxial or

E&E 29392-1

SMA

ISAS3-xxx
Intrinsically
safe sensor
element

Hazardous Area /

Zone 0 (or 1)

SISO3-xx
Intrinsically
safe signal
isolator

SMA

BNC

BNC

Control

Unit

HISO3-xx

DIN
Rail

PE

L1

N

220k

L1
N

Figure 9-1 Block Diagram for use of ISAS3 in zone 0 (or 1, or 2) and SISO3 and Control Unit in

non-hazardous area

9.6 Functional verification

Usage and functional verification of a set of ISAS3 & SISO3 shall be made as with any other AE
sensor model, e.g. by verifying the response on a pencil lead break or the response on the
artificial AE as generated by a pulsing sensor nearby. When used with a Vallen AE system,
defining SISO3-xx dB (xx means the gain setting 14, 20 or 26 dB) as input device will
automatically select the correct settings for pulsing method (AST), power supply (28 V) and gain
(xx). Pulse amplitude can be modified by varying the pulse-width in the pulser setting dialogue
in acquisition software.

With the first installation and during each periodical maintenance of the test object it is
recommended to perform a functional verification of sensors, signal isolator and AE system as
described in EN 13477-2:2010 (English).

9.7 Maintenance

There are no maintenance requirements other than described in EN 13477-2 which applies to
all kind of AE equipment.

9.8 Adjustment

There are no adjustments needed or possible for the user with the exception of SISO3 gain
setting to either 14, 20 or 26 dB.

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10 Product code overview

Code

Product description

# ISAFE3, Intrinsically Safe sensor system

ISAS3-030

AE sensor for EX Zone 0, 1 or 2; peak sensitivity at 30 kHz

ISAS3-075

AE sensor for EX Zone 0, 1 or 2; peak sensitivity at 75 kHz

ISAS3-150

AE sensor for EX Zone 0, 1 or 2; peak sensitivity at 150 kHz

ISAS3-150-V01

AE sensor for EX Zone 0, 1 or 2; peak sensitivity at 150 kHz; reinforced sensitive face plate

ISAS3-375

AE sensor for EX Zone 0, 1 or 2; peak sensitivity at 375 kHz

ISAS3-900

AE sensor for EX Zone 0, 1 or 2; with high sensitivity up to 900 kHz

MAG4-IS

Magnetic holder for ISAS3-xxx

SISO3

Signal isolator in clip-on box, must be mounted into an IP54 protected case

HISO3-08

Box for mounting up to 8 SISO3 in non-hazardous area, protection class IP54

HISO3-20

Box for mounting up to 20 SISO3 in non-hazardous area, protection class IP54

# BNC cables for connecting ASIP with SISO3

CBL-1-2M-V26

Coaxial cable RG-58, one BNC-connector straight, one BNC-connector right-angled, 2m length

CBL-1-5M-V26

Coaxial cable RG-58, one BNC-connector straight, one BNC-connector right-angled, 5m length

# Coaxial cable (not oil resistant) with SMA-connector for connecting ISAS3 with SISO3

CBL-1-5M-V4

Coaxial cable RG-58, one SMA-connector straight, one SMA-connector right-angled, 5m length

CBL-1-10M-V4

Coaxial cable RG-58, one SMA-connector straight, one SMA-connector right-angled, 10m length

CBL-1-25M-V4

Coaxial cable RG-58, one SMA-connector straight, one SMA-connector right-angled, 25m length

CBL-1-50M-V4

Coaxial cable RG-58, one SMA-connector straight, one SMA-connector right-angled, 50m length

CBL-1-100M-V4

Coaxial cable RG-58, one SMA-connector straight, one SMA-connector right-angled, 100m length

CBL-1-1M-V27

Coaxial cable RG-58 without connectors as bulk stock

# Coaxial cable (ETFE) with SMA-connector for connecting ISAS3 to SISO3

CBL-1-5M-V32

Coaxial cable, ETFE, one SMA-connector straight, one SMA-connector right-angled, 5m length

CBL-1-10M-V32

Coaxial cable, ETFE, one SMA-connector straight, one SMA-connector right-angled, 10m length

CBL-1-25M-V32

Coaxial cable, ETFE, one SMA-connector straight, one SMA-connector right-angled, 25m length

CBL-1-50M-V32

Coaxial cable, ETFE, one SMA-connector straight, one SMA-connector right-angled, 50m length

CBL-1-100M-V32

Coaxial cable, ETFE, one SMA-connector straight, one SMA-connector right-angled, 100m length

CBL-1-1M-V33

Coaxial cable, ETFE, price per meter, without connectors

SMA-M-S

SMA-connector male, straight, not mounted to cable (add SMA-MNT)

SMA-M-R

SMA-connector male, right-angled, not mounted to cable (add SMA-MNT)

SMA-MNT

Mounting of SMA-connector (SMA-M-S or SMA-M-R) to cable ( CBL-1-1M-V27 or CBL-1-1M-V33)
on one side

# Sealing set for cable transition to ISAS3, oil resistant

SS-OIL-5MM

Sealing Set for oil resistant sealing of 5mm cable to sensor transition ISAS3, without mounting

SS-MNT

Mounting of SS-OIL-5MM onto ISAS3

# Grounding cable for ISAS3 and HISO3, oil resistant

CBL-1-1M-V29

Grounding Cable, 4 mm², oil resistant, price per meter, without mounting. For mounting to cable
shoe included in ISAS3 sensor add GNDC-SHOE-MNT

GNDC-SHOE-MNT

Mounting grounding cable CBL-1-1M-V29 to cable shoe included in ISAS3 sensor

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11 Assembly instructions for SMA and BNC connectors

Figure 11-1 Assembly Instruction SMA, straight, ISAS3 side

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Figure 11-2 Assembly instruction SMA, angled, SISO3 side

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Figure 11-3 Assembly Instruction BNC, angled, SISO3 side

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Figure 11-4 Assembly Instruction BNC, straight, ASIP-2 side

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12 Abbreviations

AE acoustic emission
AMSY-6 AE acquisition system from Vallen used for AT
ASIP-2 Signal processor from Vallen, part of AMSY-6, which processes the

analogue signal from SISO3
AST  Auto Sensor Test
AT Acoustic emission testing
ATEX "Appareils destinés à être utilisés en Atmosphères Explosibles"

The ATEX directive, consisting of two directives, 2014/34/EU and

1999/92/EC, defines requirements for equipment and workplaces used in

explosive atmosphere
BNC Type of connector for coaxial cables
dB decibel (dB), a logarithmic dimensionless unit of measurement expressing

the magnitude of a physical quantity relative to a reference value
EN European Norm
EPL Equipment protection level
HISO3 Housing for AE-signal isolator and barrier for installation in non-hazardous

area
IPxy Housing protection according to IEC 60529

x:

3 = protected against solid objects (Ø 2.5 mm)

5 = dust protected

6 = dust-tight

y:

0 = non protected

4 = protected against splashing water

8 = protected against the effects of continuous immersion in water
IS intrinsically safe or intrinsic safety
ISAFE3 Family of intrinsically safe AE-products
ISAS3 Intrinsically Safe AE-Sensor, part of ISAFE3 family
MAG4IS Magnetic holder for all ISAS3 variants
RG58C/U standard coaxial cable type, 50 Ω impedance
RTV162 coupling agent type
RW200-E oil resistant heat shrink type
SISO3 AE-signal isolator and barrier, part of ISAFE3 family
SMA type of connector for coaxial cables
SS-OIL-5MM oil resistant sealing set for the transition of cable (5mm diameter) to ISAS3.
T4, T6 Temperature class according, to EN 60079-0:2009, Table 2, defining a

maximum surface temperature of 85 or 135 °C, respectively
Tamb Ambient temperature range

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USB Universal serial bus
USYC System interface of AMSY-6 to USB

13 Glossary

Automated sensor coupling verification:

A series of artificial burst AE, sequently sent by AE sensors, received by neighbored
AE sensors, and a data presentation that lets an operator easily verify proper
coupling quality of each sensor. Artificial burst AE is generated by  Pulse-Through
or  AST

Auto Sensor Test (AST):

The capability of an AE sensor-preamplifier-combination to send an internally
generated artificial AE burst for an  automated sensor coupling verification

AST control pulse:

A short-cut of the power supply voltage of an AE preamplifier, variable in duration,
for the  Auto sensor test (AST)

DIN rail:

A metallic rail of a standard type widely used for mounting industrial control
equipment inside an encapsulation. In this document the special form "Top hat rail
according to EN 50022", 35 x 7.5 mm, is addressed

Equipment protection level:

Level of protection assigned to equipment, based on its likelihood of becoming a
source of ignition and distinguishing the differences between explosive Gas
atmospheres (Ga, Gb, Gc), explosive dust atmospheres (Da, Db, Dc) and explosive
atmospheres in mines (Ma, Mb) (EN 60079-0:2009, 3.18)

Fourfold saturated:

Input voltage of an amplifier is 4 times above the linear range

Intrinsic safety:

Type of protection based on the restriction of electrical energy, within apparatus and
interconnections exposed to a potentially explosive atmosphere, to a level below that
which can cause ignition by either sparking or heating effects (EN 60079-11:2007)

Pulse Through:

The capability of a preamplifier to pass a pulse from the AE system to the sensor for
an  automated sensor coupling verification

Pollution Degree

Pollution degree is a classification according to the amount of dry pollution and
condensation present in the environment. This classification is important since it
affects creepage and clearance distances required to insure the safety of a product.

IEC-60664-1 has established four degrees of pollution severity:
Pollution Degree 1; No pollution or only dry, nonconductive pollution occurs. The

pollution has no effect (on the electrical conductivity)

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Pollution Degree 2: Normally only nonconductive pollution occurs. Temporary
conductivity caused by condensation is to be expected.
Office and laboratory areas are considered pollution degree 2 environments
according to safety standards and certification bodies.

Pollution Degree 3: Conductive pollution or dry nonconductive pollution that
becomes conductive due to condensation occurs. To be found in industrial
environment or construction sites (harsh environments).

Pollution Degree 4: The pollution generates persistent conductivity caused by
conductive dust, rain, or snow.

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14 Standard compliance

Directive

Applicable Standards

EMV

2014/30/EU

DIN EN 61326-1; Elektrische Mess-, Steuer-, Regel- und
Laborgeräte - EMV-Anforderungen - Teil 1: Allgemeine
Anforderungen

DIN EN 61326-2-2; Elektrische Mess-, Steuer-, Regel und
Laborgeräte - EMV-Anforderungen - Teil 2-2: Besondere
Anforderungen - Prüfanordnung, Betriebsbedingungen und
Leistungsmerkmale für ortsveränderliche Prüf-, Mess- und
Überwachungsgeräte für den Gebrauch in Niederspannungs­Stromversorgungsnetzen

ATEX

2014/34/EU

EN 60079-0; Explosive atmospheres - Part 0: Equipment ­General requirements

EN 60079-11; Explosive atmospheres - Part 11: Equipment
protection by intrinsic safety “i”

EN 60079-15; Explosive atmospheres - Part 15: Equipment
protection by type of protection "n"

EN 60079-26; Explosive atmospheres - Part 26: Equipment with
equipment protection level (EPL) Ga

AE-sensor system complies with following standards and directives

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15 Declaration of Conformity

SISO3:

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ISAS3-xxx:

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16 EC Type Examination Certification

SISO3 Page 1:

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SISO3 Page 2:

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SISO3 Page 3:

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ISAS3 Page 1:

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ISAS3 Page 2:

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ISAS3 Page 3:

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17 2014/34/EU ATEX Certificate for Quality Assurance of

Production

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Revision History:

Rev. Nr.

Date

Signed

Short description of changes

0

18.01.2013

DA, HV,
TD

first external version

1

27.09.2013

TD

small editorial changes, modified dimensions of HISO3­20, implementation of chapter 10 “Product code
overview”

2

25.07.2016

HT, MF

Added ISAS3-150-V01
New Directive 2014/34/EU
New ATEX Certificate for Quality Assurance of

Production (TÜV SÜD)
English EC Type Examination Certificate
SISO3 marking corrected typo errors
Added related year to each EN reference
Editorial changes
Changed cable names
Changed “oil proof” cable

3

21.04.2017

HT

Updated TÜV SÜD Certif. No. TPS 17 ATEX Q 55515
006 valid until 2020-03-17

Update, Declaration of Conformity – SISO3 and ISAS3

4

26.09.2018

HT

New Quality Assurance Certification: ISO 9001:2015

Freigabe:

Mit der Freigabe wird die Übereinstimmung aller Angaben in diesem Dokument mit den
Angaben in den Zertifizierungsunterlagen der EG-BMP Nr.

„TÜV-A 11ATEX0004X“ und
„TÜV-A 11ATEX0005X“ bestätigt.

Unterschrift

Horst Trattnig
Entwicklungsleiter und ExSchB
Datum: 26.09.2018

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