Description

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　　Other names for CA202 144-202-000-205:

Vibration Sensor CA202 144-202-000-205

CA202 144-202-000-205 Measuring Instrument

Digital Vibration Meter/Tester CA202 144-202-000-205

　　I. Operating Principle

The CA202 utilizes a symmetrical shear-mode polycrystalline piezoelectric sensing element. It converts acceleration into an electrical signal based on the direct piezoelectric effect. The core operating mechanism is as follows:

Mechanical Sensing: The internal seismic mass and the piezoelectric crystal form an inertial system. When the sensor experiences vibration acceleration along with the equipment being monitored, the mass exerts a shear force on the piezoelectric element that is proportional to the acceleration, in accordance with Newton’s Second Law.

Piezoelectric Conversion: Subjected to shear force, the polycrystalline piezoelectric material generates a charge signal on the electrode surface that is proportional to the applied force; the magnitude of the charge maintains a precise linear relationship with the measured acceleration value.

Structural Optimization: The symmetrical shear design effectively cancels out interference errors caused by temperature gradients and transverse vibrations; the internal housing insulation structure suppresses parasitic capacitance and common-mode interference, ensuring signal stability.Signal Conditioning: The sensor outputs a charge signal in the picocoulomb (pC) range. It requires an IPC704 or IPC707 series charge amplifier to convert this charge signal into a standard voltage or current signal for transmission to downstream monitoring systems for analysis.

　　II. Key Technical Advantages

1. Extreme Temperature Adaptability

The sensor operates within a temperature range of -55°C to +260°C and withstands short-term exposure to 280°C. It ensures stable, long-term operation on high-temperature components—such as gas turbine and steam turbine casings—surpassing the temperature limits of standard piezoelectric sensors.

2. Wide Frequency Band and High Measurement Performance

With a frequency response range of 0.5 Hz to 6000 Hz, the sensor captures low-frequency structural vibrations while also detecting high-frequency signals indicative of issues like bearing wear and gear faults. A high sensitivity of 100 pC/g combined with a wide dynamic range (0.01 g to 400 g peak) meets the measurement requirements for both subtle fault vibrations and high-impact operating conditions.

3. Highly Reliable Sealed Structure

Featuring an austenitic stainless steel housing and fully welded sealing, along with an integrated cable protected by flexible stainless steel conduit, the sensor offers dust-proof, waterproof, and corrosion-resistant capabilities. It is suitable for long-term service in harsh industrial environments characterized by dust, humidity, and oil contamination.

4. Robust, Interference-Resistant Signal Output

The built-in differential output structure and case-isolated design effectively suppress electromagnetic interference and common-mode noise found in industrial settings. This ensures longer transmission distances and higher data fidelity, making it ideal for industrial monitoring scenarios requiring long cable runs.5. Compliance and Certification Systems

This series holds hazardous area certification (Ex version), meeting requirements for use in explosive gas environments. Additionally, it is certified by major global OEMs, allowing for direct integration with various industrial vibration monitoring systems and reducing integration and adaptation costs.

　　III. Impact and Value for Application Industries

The CA202 accelerometer serves as a core sensing unit in industrial predictive maintenance systems, playing an irreplaceable role across various industries:

1. Power Generation Industry

Installed at critical locations—such as bearing housings and casings—on core equipment like gas turbines, steam turbines, and hydroelectric generator sets, it monitors vibration characteristics associated with faults such as rotor imbalance, misalignment, bearing fatigue, and blade fracture in real time. Early warnings help prevent unplanned downtime, enhance operational reliability, reduce major overhaul costs, and ensure grid stability.

2. Oil and Gas Industry

Suitable for monitoring rotating equipment—including compressors, pumps, and fans—at offshore drilling platforms, refineries, and along oil pipelines. The explosion-proof version can be deployed directly in hazardous areas, meeting safety compliance standards for the petrochemical industry, enabling equipment condition visualization, and mitigating operational safety risks.

3. Metallurgy and Heavy Manufacturing Industries

Designed for harsh operating environments characterized by high temperatures, intense vibration, and heavy dust—such as those involving rolling mills, large motors, and gear reducers—the sensor provides stable, long-term vibration data acquisition. This supports equipment fault diagnosis and remaining useful life (RUL) prediction, reduces unplanned maintenance, and enhances the continuous production capability of manufacturing lines. 4. Nuclear Power and High-End Energy Sectors

Meets long-term monitoring requirements for high-safety-class equipment; provides precise vibration data for nuclear-grade rotating machinery to ensure operational safety; and complies with the nuclear power industry’s stringent reliability and quality assurance standards.

　　IV. Standard Operating and Installation Procedures

1. Pre-installation Preparation

Visual Inspection: Verify that the sensor housing and cable conduit are free from damage or deformation, and confirm that the label information matches model 144-202-000-205;

Measurement Point Preparation: Clean the mounting surface to remove rust, oil, and burrs; ensure the surface is flat and rigid to prevent resonance and signal attenuation;

Tools and Accessories: Prepare the specified mounting screws and a torque wrench; confirm that the associated charge amplifier and monitoring system wiring are ready.

2. Sensor Installation

The CA202 utilizes a four-screw mounting method:

Position the sensor against the measurement point, ensuring the sensor’s sensitive axis aligns with the primary direction of the vibration being measured;

Pre-tighten the four mounting screws in a diagonal sequence, then fully tighten them evenly to the manufacturer’s specified torque; avoid overtightening individual screws, as this can deform the housing and introduce measurement errors.3. Cable Routing and Signal Connection

Secure cables along the equipment housing or cable trays, placing a fixing point every 30–50 cm to prevent noise caused by dangling or swaying cables;

Ensure the cable bending radius is not less than the specified minimum; strictly avoid sharp kinks or deformation due to crushing;

Use a single-point grounding method for the cable shield—typically at the signal conditioner end—to prevent ground loop interference;

Connect the sensor output to the charge amplifier input, ensuring correct wiring polarity.

4. System Commissioning and Calibration

Power on the signal conditioner and observe the static output baseline to confirm the noise level is within the normal range;

Where conditions permit, perform on-site calibration using a standard vibration calibrator to verify that sensitivity and linearity meet technical specifications;

Connect to the downstream monitoring system and verify the proper functioning of data acquisition, waveform display, and alarm functions.

　　V. Precautions for Use and Maintenance

1. Installation and Usage Restrictions

Do not install the sensor on surfaces with insufficient rigidity, such as thin shells or cover plates, to avoid signal distortion;

Strictly control installation torque; do not overtighten screws, as this may damage the piezoelectric element;

Ensure the deviation of the sensitive axis does not exceed the specified angle; otherwise, transverse sensitivity errors may be introduced.2. Cable and Signal Protection

Charge-output sensors must use the manufacturer-supplied low-noise cables; replacing them with standard cables is prohibited;

Route cables away from sources of strong electromagnetic interference, such as high-power motors and variable frequency drives (VFDs), and avoid laying them in the same conduit or tray as power cables;

Regularly inspect the integrity of cable conduits to prevent damage caused by high temperatures or friction.

3. Operating Conditions and Environmental Limits

The sensor’s long-term operating temperature must not exceed 260°C; avoid direct contact with open flames and exposure to instantaneous thermal shock;

Do not subject the sensor to shock loads exceeding a peak of 400g to prevent damage to the internal seismic mass and piezoelectric elements;

Avoid prolonged contact with corrosive media, such as strong acids or alkalis, to maintain the integrity of the housing seal.

4. Routine Maintenance and Calibration

Inspect the installation status and cable securing arrangements quarterly; promptly address any issues regarding looseness or damage;

Perform traceable vibration calibration at least once a year to ensure measurement accuracy meets requirements;

Conduct insulation resistance tests and sensitivity verification before returning the sensor to service after a prolonged period of inactivity.

5. Safety and Compliance

Explosion-proof models must be used in areas corresponding to their specific hazard rating; power must be disconnected before opening the housing or performing wiring operations, and all explosion-proof safety protocols must be followed;

System grounding must comply with industrial electrical safety standards to prevent damage to the sensor and associated equipment caused by static electricity or voltage surges. With its ability to withstand extreme operating conditions, high reliability, and precision measurement capabilities, the Vibro-Meter CA202 (144-202-000-205) piezoelectric accelerometer stands as a benchmark product for vibration monitoring in industrial rotating machinery, providing essential data support for predictive maintenance and safe equipment operation across various industries.

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