Instruction
Manual
Non-hazardous
and hybrid/mixed
area system: AE-
Piezotron sensor
and coupler
Types
8852A...,
5125C2,
5125C3,
8152C...,
5252A1
ä
8852A_002-680e-09.20
Foreword
Foreword
8852A_002-680e-09.20
Thank you for choosing a Kistler quality product characterized
by technical innovation, precision and long life.
Information in this document is subject to change without notice.
Kistler reserves the right to change or improve its products and
make changes to the content without obligation to notify any
person or organization of such changes or improvements.
© 2014 ... 2020 Kistler Group. All rights reserved. Except as
expressly provided herein, no part of this manual may be repro-
duced for any purpose without the express prior written consent
of Kistler Group.
Kistler Group products are protected by various intellectual
property rights. For more details visit www.kistler.com. The
Kistler Group includes Kistler Holding AG and all its subsidiaries
in Europe, Asia, the Americas and Australia.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
info@kistler.com
www.kistler.com
Page 1
Page 38852A_002-680e-09.20
Content
Content
1. Introduction .......................................................................................................................................4
2. Important information ......................................................................................................................5
2.1 For your safety .......................................................................................................................5
2.2 Precautions ............................................................................................................................6
2.3 Disposal of electronic equipment ...........................................................................................6
2.4 Electromagnetic compatibility .................................................................................................6
2.5 Product types .........................................................................................................................7
3. Product description ..........................................................................................................................9
3.1 Acoustic emission (AE) as measurands .................................................................................9
3.2 Acoustic emission measuring system.....................................................................................9
3.3 AE-Piezotron sensor Type 8152C... .....................................................................................10
3.4 AE-Piezotron sensor Type 5125C... .....................................................................................11
3.5 Wideband zener barrier Type 5252A1 ..................................................................................13
4. Hazardous and non-hazardous area installation.........................................................................14
5. Mounting, installation & operation ...............................................................................................16
5.1 Mounting the AE-Piezotron Type 8152C... sensors .............................................................16
5.2 Installation ............................................................................................................................16
5.2.1 Wiring details ..........................................................................................................16
5.2.2 Connection of the AE sensor to the AE-Piezotron coupler .....................................19
5.2.3 Wiring Type 5252A to Type 8152C sensor and Type 5125C coupler .....................19
5.2.4 Operation ................................................................................................................20
5.2.5 Filters .......................................................................................................................20
5.2.6 RMS (Root Mean Square) converter ......................................................................21
5.2.7 Alarm switch and raw AE output .............................................................................22
5.2.8 Cable length recommendation for raw AE output ...................................................24
6. Application example .......................................................................................................................25
7. Calibration & maintenance ............................................................................................................26
7.1 General.................................................................................................................................26
7.2 Care & cleaning ....................................................................................................................26
7.3 Calibration ............................................................................................................................26
Page 38852A_002-680e-09.20
Content
Total pages: 41
8. Storage & transit considerations ..................................................................................................27
9. Warranty ..........................................................................................................................................28
10. CE declaration of conformity ......................................................................................................29
10.1 Type 8125C... sensor .........................................................................................................29
10.2 Type 5125C... coupler ........................................................................................................32
10.3 Type 5252A... barrier ..........................................................................................................33
10.4 Type 8852A... system .........................................................................................................34
11. CSA control drawings ..................................................................................................................37
11.1 Type 8152C... AE sensor ....................................................................................................37
11.2 Type 5252A1 barrier ...........................................................................................................38
12. Appendix .......................................................................................................................................39
12.1 Appendix A: Setting jumpers for gain, 4 to 20mA source/sink capability and
replacing lters ............................................................................................................................39
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 4
Thank you for choosing a quality product from Kistler. Please
read through this manual thoroughly to enable you to fully
utilize the various features of your product.
To the extent permitted by law Kistler accepts no liability if
this instruction manual is not followed, or if products other
than those listed under Accessories are used.
These instructions describe the AE-Piezotron sensor
Type 8152C… and the AE-Piezotron coupler Types 5125C2
and 5125C3, installed with or without intrinsically safe barri-
ers as part of a Type 8852A AE system.
Performance features at a glance:
Acoustic emission measuring chain
High sensitivity and wide frequency range from
50 ... 900 kHz (depending on sensor type chosen)
Insensitive to electric and magnetic noise elds
Robust, for industrial use (IP65)
Ingress Protection (IP57)
High operating temperature range: –55 ... 165 °C
[–67 ... 330 °F]
Ground isolated; prevents ground loops
Conforming to ä
Kistler offers a wide range of products for use in measuring
technology:
Piezoelectric sensors for measuring force, torque, strain,
pressure, acceleration, shock, vibration and acoustic
emission
Strain gage sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems, as well as
software for specic measurement applications
Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions
for the application elds engines, vehicles, manufacturing,
plastics and biomechanics sectors.
Our product and application brochures, in addition to our
detailed data sheets, will provide you with an overview of our
product range. All unit measurements provided are listed in
order of metric units, followed by imperial units [in brackets].
If you require additional assistance beyond what can be loca-
1. Introduction
8852A_002-680e-09.20
Important information
Page 5
2. Important information
The instruments are CE-compliant within the meaning of EU
Directive 2004/108/EC and conform to the EMC standard
EN 61326-1:2013; compliance is required with the correspon-
ding installation notes. All equipment is tested and has left
the factory in a perfect, safe condition. In order to maintain
this condition and ensure safe operation, compliance is requi-
red with the instructions and warning notes contained within
this manual or imprinted on the product itself.
Compliance with local safety regulations, which may apply
to the use of power line operated electrical and electronic
equipment, is strongly recommended.
It is essential for you to review the following information,
which is intended to ensure your personal safety when
working with the acoustic emission sensors and contribute
toward a longer service life.
2.1 For your safety
ted online or in this manual, please contact Kistler‘s extensive
support organization or visit us online at www.kistler.com.
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 6
2.3 Disposal of electronic equipment
2.2 Precautions
Compliance with the following precautionary measures is
vital to ensure safe and reliable operation:
Check all equipment packaging for transporation damage.
Report any damage to the transporter and to Kistler.
The equipment should be used only under the specied ope-
rating conditions and must be protected against excessive
dust and mechanical stress (shock, vibration, etc.).
Avoid high atmospheric humidity, which can lead to conden-
sation during changes in temperature.
If there is evidence that safe operation is no longer possib-
le, the instrument must be powered off and rendered safe
against accidental start-up. Safe operation is no longer pos-
sible when the product
▪ shows visible signs of damage
▪ is no longer operating
▪ has been subjected to prolonged storage under unsuitable
conditions
Do not discard old electronic equipment in municipal trash.
For disposal at end of life, please return this product to the
nearest authorized electronic waste disposal service or
contact your Kistler sales ofce for disposal instructions.
2.4 Electromagnetic compatibility
The Type 8852A… AE System meets the EMC regulations:
EN 61326-1:2013
Connections in explosive environments and differences in
ground potential when connecting the cable can produce
sparking.
8852A_002-680e-09.20
Important information
Page 7
With normal coaxial connections, as used with most
piezoelectric sensors, the shield utilizes a signal return lead
with connections over long distances. Therefore, different
ground potentials can produce equalizing currents in the
cable shield. In this case, it may be necessary to forgo
grounding at both ends to prevent ground loops. Using an
additional equipotential bonded lead, with a sufciently
large cross-sectional area and the lowest possible internal
resistance, may also provide a solution.
The Type 5125C2 and 5125C3 couplers contain oating
circuitry, which makes shields of little use since they cannot
be grounded. Effective suppression of electromagnetic
interference is gained by installing the supplied ferrite chokes
on power, RMS and 4 ... 20 mA connections, as shown in Fig.
6, Fig. 7 & Fig. 8. A fourth choke is supplied for use on the
sensor connection.
Use an unshielded, twisted pair with a round jacket of 6 mm
[0.24 in] max. external diameter to t the cable glands (see
Section 4).
2.5 Product types
This instruction manual summarizes non-hazardous, hybrid
and mixed area acoustic emission system Type 8852A…,
which includes the AE sensor Type 8152C… and coupler
Type 5125C…
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 8
Type 8152Cxxx0001/2 ATEX AE-sensor with polyurethane cable
Type 8152Cxxxxxx1/2 ATEX AE-sensor with steel braid conduit
Type 5125C2 and Type 5125C3 non-hazardous AE-coupler
Fig. 1: Type 8852A... AE system for non-hazardous,
hybrid and mixed areas
Fig. 2: Type 5252A1 wideband zener barrier for hybrid and
mixed areas
8852A_002-680e-09.20
Product description
Page 9
3. Product description
3.1 Acoustic emission (AE) as measurands
Acoustic emissions (AE), also called "sound emissions",
involve phenomena in which short, acoustic pulses are
emitted as a result of deformation processes or crack
propagation in a material. A common example of this is what
is known as "tin cry", which occurs during the deformation
of tin by hammering or bending. The acoustic pulses emitted
are so strong that they can be heard by the human ear.
Normally, the effects which lead to acoustic emissions
have a much lower intensity. This means that very sensitive
measuring instruments must be used in order to "hear" these
acoustic emissions. Highly sensitive piezoelectric sensors,
such as Type 8152C…, can demonstrate that almost all
materials (i.e. metals, ceramics, glass, and compound
materials) emit acoustic emissions under stress.
Acoustic emissions always occur in a solid when elastic
energy is suddenly released. Such energy releases can have
a wide variety of causes:
a) Plastic deformation, i.e. sliding processes (displacement
motion) or twinning, such as in the case of “tin cry”
b) Phase conversions, particularly those which occur rapidly,
i.e. martensitic conversions
c) Crack formations and crack propagation or fracture
processes
d) Friction processes in a crack or between two other
materials.
The causes can therefore be microscopic or submicroscopic
dimensions (a … b), as well as macroscopic dimensions
(c … d).
3.2 Acoustic emission measuring system
A number of variants are included under the Kistler
Type 8852A… acoustic emission system, based on a
selection of sensitivities, lter characteristics and cable
lengths accommodating the needs of various applications.
Below is the detail code of the type number:
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 10
The Kistler Type 8852A… Acoustic emission measuring
system for hazardous locations contains three parts. Please
refer to Fig. 6, Fig. 7, and Fig. 8, which are system block
diagrams to assist in visualizing the following explanation.
3.3 AE-Piezotron sensor Type 8152C...
The AE-sensor consists of the sensor case, the piezoelectric
measuring element and the integral impedance converter.
The measuring element of piezoelectric ceramic is mounted
on a thin steel diaphragm. Its structure determines the
sensitivity and frequency response of the sensor.
The diaphragm, which is welded into the case, has a slightly
protruding coupling surface allowing the surface to be
pressed with an accurately dened force during mounting.
This ensures constant and reproducible coupling of the
AE transmission into the sensing element. The measuring
element is acoustically insulated by the specic design
of the sensor case and is well-protected against external
interference. The Kistler AE-sensors have a very high
sensitivity to surface (rayleigh) and longitudinal waves over
a wide frequency range. Type 8152C… covers the frequency
range of 100 … 900 kHz.
A miniature impedance converter is incorporated in the
AE-sensor, allowing a low impedance voltage signal to
become available at the output. The power supply and signal
processing are provided by the AE-coupler Type 5125C….
Connecting cables do not need to be highly insulating or low
noise.
The Type 8152C… AE-sensor is available in a simple cable
with pigtails or a cable with exible conduit protection. The
maximum cable length for use in hazardous areas is 20 m
[65 ft].
8852A_002-680e-09.20
Product description
Page 11
The Type 8152C AE sensor is available in either a non-
hazardous sensor type for completely non-hazardous
installations (designated by the “N” in the system numbering)
or a ATEX/CSA sensor type for hybrid/mixed installations
(designated by a “H” or “M” in the system numbering).
“H” designates a Zone 2, sensor while “M” designates a
Zone 0 sensor. In hybrid/mixed systems, the sensor must
have a ATEX/CSA-approved barrier to couple the ATEX/CSA
sensor with the non-hazardous Type 5125Cx coupler.
23.5 mm [0.9 in]
SENSOR CASE
CUSTOMER SUPPLIED LENGTH OF CABLE TO 20 m [65 ft]
PIGTAIL END
TRIAXIAL PFA CABLE
DIAPHRAGM & COUPLING SURFACE INTERNAL HOUSING CONTAINING
PIEZOELECTRIC MEASURING ELEMENT
AND INTEGRAL IMPEDANCE CONVERTER
Ø8.9 mm [0.35 in]
16 mm [0.6 in]
25 mm [0.98 in]
CUSTOMER SUPPLIED LENGTH OF CABLE TO 20 m [65 ft]
CUSTOMER SUPPLIED LENGTH OF ARMOR TO 20 m [65 ft]
FLEXIBLE CONDUIT PROTECTION
7/16-20 UNF FEMALE FLARED JIC END TO MATE WITH TYPE 5125C
OR TO BE USED WITH ADAPTOR CONVERTING TO
M13 x 1.0 MALE THREAD OR ¼” MALE NPT
AND INTEGRAL IMPEDANCE CONVERTER
PIGTAIL END
TRIAXIAL PFA CABLE
25 mm [0.98 in]
23.5 mm [0.9 in]
Ø14.2 mm [0.56 in]
16 mm [0.6 in]
Fig. 3: AE sensor Type 8152C... with pigtail (above) and
exible conduit (below)
3.4 AE-Piezotron sensor Type 5125C...
The Type 5125C… AE coupler serves multiple functions in
the system. The coupler supplies constant-current power for
the IEPE amplier contained in the sensor. While the constant
current ows though the cable to the sensor, the sensor
bias voltage varies in response to the acoustic wave signal
produced by the ceramic transducer element. The coupler
chooses the signal from the bias voltage and amplies it by
unity, x10, x100 or x1 000 as appropriate to the application.
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 12
Next, the coupler applies high-pass and low-pass ltering in
order to remove that frequency content which is of no interest
and measures the RMS level of the resultant signal. Finally,
the RMS level is converted to a representative DC level.
The coupler outputs available to the user system are the
DC representation of RMS level, a 4-20 mA representation
of RMS level, an adjustable switch closure of the RMS level
for alarm purposes and a raw acoustic output signal for
monitoring on a data acquisition system, digital multimeter,
oscilloscope or spectrum analyzer.
The raw acoustic output signal is a buffered output that can
drive a signal >10 meters. System power for the AE coupler
is supplied as 24 VDC, nominal, at 30 mA, maximum. The
Type 5125C2 and 5125C3 couplers can only be installed in
non-hazardous or "safe" areas. A barrier must be used to
couple the Type 5125C2 and 5125C3 coupler to a hazardous
area sensor location.
Fig. 4: AE coupler
8852A_002-680e-09.20
Product description
Page 13
3.5 Wideband zener barrier Type 5252A1
The Type 5252A1 wideband zener barrier is made to operate
with a cut-off frequency of >6 MHz. The wide bandwidth
allows for the barrier to be used with the Type 8152C AE-
sensor, which has usable frequencies up to 900 kHz. A block
diagram of the barrier is shown below.
WARNING: Only ATEX sensors Type 8152C... with
serial number SN 4944583 and higher are compatible with
the Type 5252A1 wideband zener barrier.
The Type 5252A zener barrier must be ordered separately.
It is not part of the included deliveries of the Type 8852A
system.
Fig. 5: Block diagram of Type 5252A... barrier
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 14
4. Hazardous and non-hazardous area installation
If the Type 8152C sensor must be installed in a Zone 0
hazardous area and the Type 5125C2 and 5125C3 coupler
is on the other end in the safe area, the sensor should be
ATEX/CSA and a barrier must be used to couple the sensor to
the coupler. Refer to Fig. 6 for details. Kistler Type 5252A1 is
recommended to ensure full usage of the real-time AE output
of 900 kHz. In case of a sensor mounted in a Zone 2 hazardous
area or a completely non-hazardous area installation, the
barrier is not needed anymore (as shown in Fig. 7 & 8).
Intrinsic safety barriers limit the voltage and current available
to the Type 8152C sensor, which in this case is located within
the hazardous area from the control system (located in the
safe area).
For EMC considerations, three 2-turn ferrite chokes need
to be installed on the power, RMS, and 4 to 20 mA wires. A
single 1-turn ferrite choke needs to be installed on the sensor
line within the Type 5125C coupler (as shown in Fig. 6, Fig. 7,
and Fig. 8). Notice the two turns on each of the three chokes:
each choke is secured near the connector by tightening the
cable glands while the chokes are in that position.
Fig. 6: Type 8852AxxxxxxM2 system used together with
Type 5252A1 zener barrier. Type 8152C sensor
lies inside zone 0 hazard area. Type 5125C lies
into the safe area.
8852A_002-680e-09.20
Hazardous and non-hazardous area installation
Page 15
Fig. 8: System 8852AxxxxxxN2 conguration. Type 8152C
and 5125C couplers are both in safe areas.
Only ATEX sensors Type 8152C... with serial number
SN 4944583 and higher are compatible with the Type 5252A1
wideband zener barrier.
Fig. 7: Type 8852AxxxxxxH2 system conguration.
Type 8152C sensor lies into zone 2 hazard area.
Type 5125C non-hazardous coupler lies in the safe
area.
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 16
5. Mounting, installation & operation
5.1 Mounting the AE-Piezotron Type 8152C... sensors
The AE sensor is secured to the surface of the structure sim-
ply with one M6 screw, one ¼–28 screw, or with the magnetic
clamp Type 8443B. A low tightening torque is sufcient for
a reproducible and constant coupling: the ner the mounting
surface, the better the coupling. The use of a highly viscous
coupling medium (i.e. silicone grease) between the coupling
surfaces is recommended. High frequency AE signals can be
greatly attenuated by the length and number of joints within
the transmission path between the AE source and the moun-
ting location of the sensor. The AE sensor should therefore
be mounted as close as possible to the AE source.
5.2 Installation
5.2.1 Wiring details
Fig. 9: Type 5125C... with cover removed
8852A_002-680e-09.20
Mounting, installation & operation
Page 17
Fig. 10a: Layout of terminals on Type 8152C PCB assembly
Fig. 10b: Specic wiring conguration for usage of the
4 ... 20 mA output in SOURCE conguration
8852A_002-680e-09.20
Non-hazardous and hybrid/mixed area AE system
Page 18
Fig. 10c: Specic wiring conguration for usage of the
4 ...20 Ma output in SINK conguration
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