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.

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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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