Vibro-Meter CA202 144-202-000-125 Piezoelectric Accelerometer

The CA202 144-202-000-125 is a medium-long cable length intrinsically safe version within the Vibro-Meter (now part of Meggitt Group) CA200 series of piezoelectric accelerometers. This model features Ex ia intrinsically safe explosion-proof design and is equipped with an 11-meter integrated stainless steel hose cable, specifically designed for industrial applications requiring medium-distance distributed vibration monitoring in explosive hazardous environments. As a safety instrumented device certified by multiple global authorities, it can operate safely and reliably in Zone 0/1/2 hazardous areas of industries such as petrochemicals, natural gas processing, and fine chemicals, providing an intrinsically safe solution for predictive maintenance of critical process equipment.

While inheriting the fully welded stainless steel sealed construction and wide temperature range operating capability of the CA200 series, this product is strictly designed and manufactured in accordance with intrinsic safety explosion-proof standards. Through precise internal circuit design and strict manufacturing process control, it ensures that under normal operating conditions and specified fault conditions, the electrical spark or thermal energy generated by the sensor and its associated circuit is below the minimum energy required to ignite a specific explosive gas mixture. The 11-meter cable length design fully considers the actual wiring requirements for distributed measurement points within hazardous areas, achieving an optimal balance between installation flexibility, wiring economics, and system reliability.

This model not only possesses high-performance characteristics for industrial vibration measurement but also serves as an important front-end component of a complete intrinsic safety monitoring system. The product complies with ATEX Directive 2014/34/EU, IECEx international standard system, cCSAus North American standards, and multiple regional explosion-proof certification requirements, providing users with a technically advanced, safe, reliable, and highly compliant professional solution for equipment condition monitoring in hazardous areas worldwide.

2. Core Design Features and Technical Advantages

2.1 Intrinsically Safe Explosion Protection System

• Highest Level Intrinsic Safety Certification: Achieves Ex ia level certification, suitable for gas explosive environments in Zones 0, 1, and 2, providing safety protection under dual fault conditions

• Comprehensive Gas Group Coverage: Certified for Group IIC, can be safely used in all explosive gas environments including hydrogen and acetylene

• Wide Temperature Adaptability Design: Temperature classes cover T6 to T2 range, adapting to harsh operating environment temperatures from -55°C to +260°C

• Global Compliance Assurance: Holds multiple international certifications including ATEX, IECEx, and cCSAus, ensuring compliance for access to major global industrial markets

2.2 Rugged Industrial Construction

• Full-Path Sealed Welding Technology: Sensor housing made of austenitic stainless steel (1.4441), cable hose made of heat-resistant stainless steel (1.4541), forming a complete leak-proof unit through hermetic welding

• Excellent Environmental Resistance: Protection level reaches IP68 equivalent standard, can withstand 100% relative humidity, high-pressure water washdown, steam, oil contamination, salt spray, chemical corrosion, and other harsh industrial environments

• High Mechanical Strength Design: Can withstand 1000g peak shock load and continuous vibration environments, ensuring long-term stable operation under severe mechanical conditions

• Optimized Thermal Management Design: Wide temperature operating range and low temperature coefficient characteristics ensure measurement consistency under different environmental temperatures

2.3 Superior Electrical and Measurement Performance

• High-Precision Vibration Measurement: Standard sensitivity of 100 pC/g with ±5% tolerance range, providing precise vibration signal acquisition capability

• Wide Dynamic Frequency Response: Flat frequency response range of 0.5 Hz to 6 kHz, covering full spectrum vibration characteristics from low-speed rotating equipment to high-speed gearboxes

• Complete Electrical Isolation Design: Complete electrical insulation between signal terminals and metal housing, insulation resistance ≥1×10⁹Ω, completely eliminating ground loop interference

• Low-Noise Signal Transmission: Twisted-pair shielded low-noise cable design combined with stainless steel hose protection ensures long-distance signal transmission quality

• Precise Temperature Compensation: Provides sensitivity temperature compensation characteristics across the full temperature range, ensuring measurement accuracy in wide temperature environments

2.4 Professional Safety System Integration Characteristics

• Clear Safety Parameter Definition: Provides complete intrinsic safety parameters including Ui, Ii, Pi, Ci, Li, facilitating system engineers in loop calculation and verification

• Optimized Cable Length Design: 11-meter cable length adapts to actual distance requirements for most sensor-to-safe-junction-box connections within hazardous areas

• Standardized Installation Interface: Uses industry-standard installation dimensions and interface specifications, facilitating system integration and equipment replacement

• Complete Technical Documentation Support: Provides complete technical documentation including explosion-proof certificates, installation guides, and safety parameter tables

3. Typical Application Scenarios and Industry Solutions

3.1 Deep Applications in Petrochemical Industry

• Large-Scale Refining-Chemical Integration Units: Critical equipment vibration monitoring for reactors and regenerators in catalytic cracking units, 11-meter cable adapts to multi-layer platform layout requirements

• Ethylene Cracking and Downstream Processing: Online monitoring systems for high-temperature, high-pressure equipment such as cracked gas compressors, propylene refrigeration units, ethylene pumps

• Aromatics Complex Units: Condition monitoring of critical rotating equipment such as reformer recycle hydrogen compressors, xylene fractionator bottom pumps

• Large-Scale Oil Storage and Transportation Facilities: Predictive maintenance of hazardous area equipment such as crude oil transfer pumps, refined product export pumps, liquefied hydrocarbon pumps

3.2 Natural Gas and Clean Energy Field

• Liquefied Natural Gas (LNG) Full Industry Chain: Vibration monitoring of refrigerant compressors in liquefaction production lines, LNG transfer pumps, high-pressure pumps in regasification units

• Natural Gas Processing and Purification: Critical equipment monitoring in desulfurization/decarbonization unit feed gas compressors, acid gas compressors, dehydration units

• Unconventional Natural Gas Development: Front-end sensing for distributed monitoring systems at shale gas compressor stations, coalbed methane booster stations

• Hydrogen Energy Industry Chain Critical Equipment: Intrinsically safe monitoring of hydrogen compressors, liquid hydrogen pumps, and critical equipment at hydrogen refueling stations

3.3 Fine Chemical and Pharmaceutical Industry

• High-Risk Process Reaction Systems: Monitoring of agitation drive systems for hazardous process reactors such as nitration, chlorination, fluorination, and hydrogenation

• Solvent Recovery and Refining Units: Online monitoring of various solvent recovery compressors, vacuum units, and distillation column feed pumps

• Active Pharmaceutical Ingredient Production Critical Equipment: Vibration condition monitoring of fermentation tank agitation systems, centrifugal separators, and spray drying towers

• High-Activity Drug Production: Monitoring of external drive equipment for sterile production line isolators and external transmission devices for high-containment systems

3.4 Other Special Hazardous Environments

• Military and Aerospace: Safety monitoring of rocket fuel loading systems, aircraft engine test stands, and fuel component test systems

• Specialty Material Production: Drive system monitoring for carbon fiber production line oxidation furnaces and carbonization furnaces, special gas delivery systems for semiconductor material production

• Laboratory and Research Facilities: Safety monitoring of analytical instruments, test devices, and special reaction systems involving flammable and explosive gases

4. Intrinsic Safety System Design and Installation Guide

4.1 Intrinsic Safety Loop Architecture Design

1. Energy Limitation Principle: Limit electrical energy entering hazardous areas through safety barriers, ensuring no incendive sparks are generated under any fault conditions

2. Parameter Matching Principle: Sensor safety parameters must completely match safety barrier output parameters, meeting conditions such as Ui≥Uo, Ii≥Io, Pi≥Po

3. System Certification Principle: The entire measurement loop must be certified or validated as a system to ensure overall safety

4. Documentation Integrity Principle: All design calculations, parameter selections, and installation records must form complete technical documentation

4.2 Intrinsic Safety Loop Parameter Calculation

4.2.1 Cable Parameter Calculation (11-Meter Cable)

• Total Distributed Capacitance Calculation: Cc_total = 11m × (105 pF/m) = ~1155 pF (inter-pole)

• Total Distributed Inductance Calculation: Lc_total = 11m × (dependent on cable type) = needs to be determined based on actual cable specifications

• System Total Capacitance Verification: Cc_total + Ci ≤ Co (maximum external capacitance allowed by safety barrier)

4.2.2 Safety Barrier Selection Verification

1. Voltage Verification: Uo (safety barrier maximum output voltage) ≤ Ui (sensor maximum input voltage)

2. Current Verification: Io (safety barrier maximum output current) ≤ Ii (sensor maximum input current)

3. Power Verification: Po (safety barrier maximum output power) ≤ Pi (sensor maximum input power)

4. Energy Storage Verification: Total energy storage of cable and sensor must be within safe limits

4.3 Hazardous Area Installation Specifications

4.3.1 Sensor Installation Technical Requirements

1. Mounting Surface Preparation:

• Surface Flatness Requirement: ≤0.01 mm

• Surface Roughness Requirement: Ra ≤ 1.6 μm

• Cleanliness Requirement: Free of oil, rust, and particulate matter

2. Mounting Hole Machining:

• Drill Hole Diameter: 4.8 mm (M6 thread bottom hole)

• Drill Hole Depth: 20 mm

• Tap Depth: 14 mm (M6×1.0 thread)

3. Fastener Installation:

• Screw Specification: M6×35 Socket Head Cap Screws

• Washer Specification: M6 Single-Coil Spring Lock Washers

• Thread Locking: Use LOCTITE 241 or equivalent medium-strength thread locking compound

• Tightening Torque: 15 N·m, use torque wrench to tighten in cross-pattern sequence in steps

4.3.2 11-Meter Cable Professional Routing Specifications

1. Route Planning Principles:

• Shortest Path Principle: Select shortest routing path while meeting safety requirements

• Safety Isolation Principle: Minimum 50mm spacing between intrinsically safe cables and non-intrinsically safe cables

• Mechanical Protection Principle: Avoid areas where mechanical damage may occur

• Thermal Impact Avoidance: Stay away from equipment and piping with surface temperatures exceeding cable allowable limits

2. Bend Radius Control:

• Minimum Static Bend Radius: 50 mm (cable in unstressed state)

• Minimum Dynamic Bend Radius: 75 mm (cable may move during equipment operation)

• Bend Angle Limitation: Avoid 90° sharp bends, use gentle arc transitions

3. Fixation and Support Requirements:

• Fixation Point Spacing: Horizontal routing 1.0-1.5 meters, vertical routing 0.8-1.2 meters

• Clamp Selection: Stainless steel material, suitable for Φ8mm tube diameter

• Stress Relief Design: Provide 200mm service loops at sensor exit and junction box entry points

• Vibration Protection Measures: Increase fixation points in high vibration areas, use vibration-resistant clamps

4. Environmental Protection Measures:

• High-Temperature Protection: Use thermal sleeving when near high-temperature surfaces (temperature >150°C)

• Mechanical Protection: Use protective conduits or protective channels when passing through areas prone to mechanical damage

• Chemical Protection: Use corrosion-resistant cable clamps and fasteners in corrosive environments

4.3.3 Electrical Connection and Wiring Specifications

1. Junction Box Requirements:

• Explosion-Proof Rating: At least Ex e (increased safety) or higher rating

• Protection Rating: IP65 or higher

• Material Requirements: Corrosion-resistant material, typically stainless steel or corrosion-resistant coating

• Internal Space: Sufficient to accommodate terminals and cable entry devices

2. Terminal Requirements:

• Material: Copper alloy or silver-plated copper with good conductivity and corrosion resistance

• Structure: Crimp terminals with insulation sleeves to prevent accidental short circuits

• Fixation: Use anti-loosening washers or spring washers to ensure reliable connection

• Identification: Clear polarity marking and circuit numbering

3. Shielding Treatment Specifications:

• Shield Connection Point: Single-point grounding only on safe area side through safety barrier or dedicated terminal

• Shield Insulation: Shield must remain insulated and not grounded within hazardous areas

• Shield Continuity: Ensure electrical continuity of shield throughout the entire loop

• Shield Termination: Use dedicated shield connectors or crimp terminals, avoid "pigtail" connections

4. Cable Entry Sealing:

• Sealing Device: Use certified explosion-proof cable glands

• Sealing Rating: At least IP65 protection requirement

• Installation Requirements: Install correctly according to manufacturer instructions to ensure sealing effectiveness

• Regular Inspection: Regularly check sealing integrity, especially in environments with large temperature variations

4.4 Safe Area Equipment Installation

1. Safety Barrier Installation Requirements:

• Installation Location: Safe area or in Zone 2 explosion-proof cabinets

• Mounting Method: DIN rail mounting, ensure secure fixation

• Heat Dissipation Considerations: Ensure sufficient space for heat dissipation to avoid excessive temperatures

• Clear Identification: Clearly mark input and output terminals, mark relevant safety parameters

2. System Grounding Requirements:

• Ground Resistance: Safety barrier ground terminal to earth resistance ≤1Ω

• Ground Wire Specification: Select appropriate cross-sectional ground wire according to system requirements

• Ground Continuity: Regularly check continuity of grounding system

• Ground Identification: Clearly mark grounding points and grounding paths

5. Operation, Maintenance, and Safety Management

5.1 Pre-Operation Safety Checks

5.1.1 System Integrity Check

• Confirm all explosion-proof housings are intact without cracks or deformation

• Check cable hose integrity for scratches, wear, or deformation

• Verify tightening status of all fasteners, no loosening phenomena

• Confirm all sealing devices are correctly installed and effectively sealed

5.1.2 Electrical Parameter Verification

• Use certified intrinsically safe loop tester to verify loop parameters

• Measure loop insulation resistance to ensure compliance with requirements

• Verify safety barrier parameter settings match design

• Check connection quality at all connection points

5.1.3 Environmental Condition Confirmation

• Measure installation environment temperature, confirm within equipment allowable range

• Confirm hazardous area classification matches equipment certification

• Check if special chemical substances exist in environment that may affect equipment performance

• Confirm mechanical vibration levels are within equipment tolerance range

5.2 Regular Maintenance Plan

5.2.1 Daily Inspection Content

• Visual Inspection: Sensor, cable, junction box appearance integrity

• Tightening Check: Tightening status of all mechanical fasteners

• Environmental Check: Whether any abnormal changes in installation environment

• Operational Check: Whether monitoring system signals are normal

5.2.2 Monthly Inspection Items

• Sealing Performance Check: Sealing condition of all explosion-proof joint surfaces

• Cable Status Check: Cable hose wear condition, fixation status

• Grounding System Check: Ground connection reliability and ground resistance

• Operational Data Analysis: Vibration trend analysis, anomaly warning

5.2.3 Annual Comprehensive Inspection

• Explosion-Proof Performance Check: Comprehensive inspection of all explosion-proof structure integrity

• Electrical Performance Testing: Comprehensive testing of insulation resistance, loop parameters

• Mechanical Performance Check: Installation tightness, cable fixation status

• System Calibration Verification: Compare with standard signal source to verify measurement accuracy

• Document Update: Update maintenance records, check document integrity

5.3 Fault Diagnosis and Handling

5.3.1 Common Fault Phenomena and Causes

1. No Signal Output:

• Possible Causes: Power failure, safety barrier failure, cable break, sensor failure

• Diagnostic Steps: Troubleshoot section by section from safe area to hazardous area using intrinsically safe test instruments

2. Excessive Signal Noise:

• Possible Causes: Poor grounding, shield failure, improper cable routing, external interference

• Diagnostic Steps: Check grounding system, verify shield continuity, check cable routing

3. Signal Drift or Instability:

• Possible Causes: Temperature change effects, mounting stress changes, sensor failure

• Diagnostic Steps: Check environmental temperature, recheck installation condition, comparative testing

5.3.2 Safety Fault Handling Principles

• Power-Off Operation Principle: Must cut power before performing any maintenance operations within hazardous areas

• Professional Personnel Operation: All maintenance operations must be performed by personnel trained in explosion protection

• Explosion-Proof Integrity Protection: Must maintain equipment explosion-proof integrity during maintenance

• Complete Records: Complete records must be kept for all fault phenomena, diagnostic processes, and handling measures

5.4 Special Safety Requirement Management

5.4.1 "X" Special Conditions for Use Management
This model's explosion-proof certificate carries "X" marking, indicating special conditions for use that must be strictly followed:

1. Ambient Temperature Monitoring Requirements:

• Must continuously or regularly monitor installation environment temperature

• Establish temperature record files, record maximum and minimum temperatures

• Must take corresponding measures when temperature exceeds limits

2. Installation Personnel Qualification Requirements:

• Installation and maintenance personnel must hold valid explosion-proof equipment installation qualification certificates

• Regular explosion protection knowledge update training

• Establish personnel qualification management files

3. Technical Document Management Requirements:

• Must establish complete technical document filing system

• Documents include: explosion-proof certificates, installation drawings, loop calculation sheets, maintenance records, etc.

• Documents must be regularly updated and reviewed

5.4.2 Change Management Requirements

• Any design changes must undergo re-evaluation of intrinsic safety

• Any equipment replacement must ensure new equipment parameter matching

• Any installation changes must re-verify explosion-proof safety

• All changes must have complete records and approval processes

6. Technical Advantages and Value Proposition

6.1 Safety Performance Advantages

• Intrinsic Safety Design: Uses Ex ia highest safety level design, ensuring no explosion even under dual fault conditions

• Global Certification System: Passes ATEX, IECEx, cCSAus, and other major global certification systems, meeting international project requirements

• Long-Term Reliability: Fully welded stainless steel construction ensures long-term environmental resistance, reducing maintenance needs

• Complete Documentation Support: Provides complete technical documentation and safety parameters, facilitating system design and verification

6.2 Technical Performance Advantages

• Wide Temperature Operating Capability: -55°C to +260°C operating temperature range adapts to extreme environments

• Precise Vibration Measurement: 100 pC/g high sensitivity combined with wide frequency response range provides accurate equipment condition information

• Excellent Anti-Interference Capability: Differential output design and complete shielding system ensure signal quality

• Optimized Cable Length: 11-meter cable length balances installation flexibility and wiring economics

6.3 Economic Advantages

• Reduced Installation Costs: Reasonable cable length reduces cable material and installation labor hours

• Reduced Maintenance Costs: High reliability design reduces maintenance frequency and costs

• Avoid Production Losses: Early fault warnings avoid losses caused by unplanned shutdowns

• Extended Equipment Life: Effective condition monitoring extends critical equipment service life

6.4 System Integration Advantages

• Standardized Interface: Uses industry-standard interfaces, facilitating system integration

• Parameter Completeness: Provides complete intrinsic safety parameters, facilitating loop design

• Strong Compatibility: Compatible with Meggitt's full range of safety barriers and monitoring systems

• Complete Technical Support: Provides full-process technical support from design to installation

7. Technical Support and Service Commitment

7.1 Technical Support System

• Application Engineering Support: Provides intrinsic safety loop design consultation and calculation support

• Installation Guidance Service: Provides on-site installation guidance and technical training

• Fault Diagnosis Support: Provides remote and on-site fault diagnosis services

• Technical Documentation Support: Provides complete technical documentation and certification documents

7.2 Training Service System

• Basic Training Courses: Intrinsic safety basic knowledge training

• Product Application Training: CA202 series product application and installation training

• System Integration Training: Complete monitoring system integration training

• Safety Regulation Training: Hazardous area work safety regulation training

7.3 After-Sales Service Commitment

• Rapid Response Mechanism: Establish 24-hour technical response mechanism

• Spare Parts Supply Assurance: Maintain stock of common spare parts to ensure quick supply

• Regular Follow-Up System: Establish user regular follow-up and technical support system

• Technical Update Notification: Promptly notify technical updates and product improvement information