Model 603C01

Platinum Stock Products; General purpose, industrial, ceramic shear ICP® accel, 100 mV/g, 0.5
to 10k Hz, top exit, 2-pin conn., single point ISO 17025 accredited calibration

Installation and Operating Manual

For assistance with the operation of this product,

contact the PCB Piezotronics, Inc.

Toll-free: 800-959-4464
24-hour SensorLine: 716-684-0001
Fax: 716-684-3823
E-mail: imi@pcb.com
Web: www.imi-sensors.com
Repair and Maintenance Returning Equipment
If factory repair is required, our representatives will
PCB guarantees Total Customer Satisfaction through its provide you with a Return Material Authorization (RMA)
“Lifetime Warranty Plus” on all Platinum Stock Products number, which we use to reference any information you
sold by PCB and through its limited warranties on all other have already provided and expedite the repair process.
PCB Stock, Standard and Special products. Due to the This number should be clearly marked on the outside of
sophisticated nature of our sensors and associated all returned package(s) and on any packing list(s)
instrumentation, field servicing and repair is not accompanying the shipment.
recommended and, if attempted, will void the factory
warranty.
Contact Information
Beyond routine calibration and battery replacements PCB Piezotronics, Inc.
where applicable, our products require no user 3425 Walden Ave.
maintenance. Clean electrical connectors, housings, and Depew, NY14043 USA
mounting surfaces with solutions and techniques that will
Toll-free: (800) 828-8840
not harm the material of construction. Observe caution
24-hour SensorLine: (716) 684-0001
when using liquids near devices that are not hermetically
General inquiries: info@pcb.com
sealed. Such devices should only be wiped with a
Repair inquiries: rma@pcb.com
dampened cloth—never saturated or submerged.
For a complete list of distributors, global offices and sales
In the event that equipment becomes damaged or ceases
representatives, visit our website, www.pcb.com.
to operate, our Application Engineers are here to support
your troubleshooting efforts 24 hours a day, 7 days a
week. Call or email with model and serial number as well Safety Considerations
as a brief description of the problem.
This product is intended for use by qualified personnel
who recognize shock hazards and are familiar with the
Calibration precautions required to avoid injury. While our equipment
is designed with user safety in mind, the protection
Routine calibration of sensors and associated provided by the equipment may be impaired if equipment
instrumentation is necessary to maintain measurement is used in a manner not specified by this manual.
accuracy. We recommend calibrating on an annual basis,
after exposure to any extreme environmental influence, Discontinue use and contact our 24-Hour Sensorline if:
or prior to any critical test.
 Assistance is needed to safely operate equipment
PCB Piezotronics is an ISO-9001 certified company whose  Damage is visible or suspected
calibration services are accredited by A2LA to ISO/IEC  Equipment fails or malfunctions
17025, with full traceability to SI through N.I.S.T. In
addition to our standard calibration services, we also offer For complete equipment ratings, refer to the enclosed
specialized tests, including: sensitivity at elevated or specification sheet for your product.
cryogenic temperatures, phase response, extended high
or low frequency response, extended range, leak testing, Definition of Terms and Symbols
hydrostatic pressure testing, and others. For more
information, contact your local PCB Piezotronics The following symbols may be used in this manual:
distributor, sales representative, or factory customer
service representative. DANGER
Indicates an immediate hazardous
situation, which, if not avoided, may
result in death or serious injury.

Manual 21354 Rev E

ECN 50523
 CAUTION
Refers to hazards that could damage
the instrument.

NOTE
Indicates tips, recommendations and
important information. The notes
simplify processes and contain
additional information on particular
operating steps.

The following symbols may be found on the equipment

described in this manual:

This symbol on the unit indicates that

high voltage may be present. Use
standard safety precautions to avoid
personal contact with this voltage.

This symbol on the unit indicates that

the user should refer to the operating
instructions located in the manual.

This symbol indicates safety, earth

ground.

Manual 21354 Rev E

ECN 50523
 PCB工业监视和测量设备 - 中国RoHS2公布表
PCB Industrial Monitoring and Measuring Equipment - China RoHS 2 Disclosure Table
有害物质

汞 镉
部件名称 铅 (Pb) (Hg) (Cd) 六价铬 (Cr(VI)) 多溴联苯 (PBB) 多溴二苯醚 (PBDE)
住房 O O O O O O
PCB板 X O O O O O
电气连接器 O O O O O O

压电晶体 X O O O O O

环氧 O O O O O O

铁氟龙 O O O O O O

电子 O O O O O O
厚膜基板 O O X O O O
电线 O O O O O O

电缆 X O O O O O
塑料 O O O O O O
焊接 X O O O O O

铜合金/黄铜 X O O O O O

本表格依据 SJ/T 11364 的规定编制。

O： 表示该有害物质在该部件所有均质材料中的含量均在 GB/T 26572 规定的限量要求以下。
X： 表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T 26572 规定的限量要求。
铅是欧洲RoHS指令2011/65/ EU附件三和附件四目前由于允许的豁免。

CHINA RoHS COMPLIANCE

Manual 21354 Rev E

ECN 50523
Component Name Hazardous Substances
Lead (Pb) Mercury (Hg) Cadmium (Cd) Chromium VI Polybrominated Polybrominated
Compounds Biphenyls (PBB) Diphenyl Ethers
(Cr(VI)) (PBDE)
Housing O O O O O O
PCB Board X O O O O O
Electrical Connectors O O O O O O
Piezoelectric Crystals X O O O O O
Epoxy O O O O O O
Teflon O O O O O O
Electronics O O O O O O
Thick Film Substrate O O X O O O
Wires O O O O O O
Cables X O O O O O
Plastic O O O O O O
Solder X O O O O O
Copper Alloy/Brass X O O O O O
This table is prepared in accordance with the provisions of SJ/T 11364.
O: Indicates that said hazardous substance contained in all of the homogeneous materials for this part is below the limit
requirement of GB/T 26572.
X: Indicates that said hazardous substance contained in at least one of the homogeneous materials for this part is above the limit
requirement of GB/T 26572.
Lead is present due to allowed exemption in Annex III or Annex IV of the European RoHS Directive 2011/65/EU.

Manual 21354 Rev E

ECN 50523
 Piezoelectric ICP® Accelerometers Operating Guide

Operating Guide with Enclosed Warranty Information

3424 Walden Avenue, Depew, New York 14043-2495

Phone (716) 684-0003

Fax (716) 684-3823

Toll Free Line 1-800-959-4IMI

MANUAL NUMBER: 18405
MANUAL REVISION: A

ECN NUMBER: 49766

 General
OPERATING GUIDE
for use with
PIEZOELECTRIC ICP® ACCELEROMETERS
SPECIFICATION SHEET, INSTALLATION DRAWING AND CALIBRATION INFORMATION ENCLOSED
IMI ASSUMES NO RESPONSIBILITY FOR DAMAGE CAUSED TO THIS PRODUCT AS A RESULT OF
PROCEDURES THAT ARE INCONSISTENT WITH THIS OPERATING GUIDE

1.0 INTRODUCTION
Congratulations on the purchase of a quality ICP®
industrial sensor. In order to ensure the highest level of
performance for this product, it is imperative that you
properly familiarize yourself with the correct mounting
and installation techniques before attempting to
operate this device. If, after reading this manual, you
have any additional questions concerning this sensor or
its application, feel free to call an Application Engineer
at 716-684-0003 or 800-959-4464.

Proper sensor selection requires special attention to

three main areas: sensor design, dynamic
expectations, and application environment. Dynamic expectations are application-specific and
refer to the frequency range of measurement and the
Sensor design encompasses the actual sensing anticipated amplitudes of vibration. After careful
element, the physical material, and component review of the machinery to be monitored, minimum
selection for the sensor. Preferred industrial
and maximum measurement frequency ranges may
accelerometers employ a shear sensing element
with either a quartz or ceramic crystal.
be established. The minimum measurement
frequency is normally related to any sub-harmonics of
Quartz sensing elements are typically used when running speed or any lower frequencies where
long-term stability and minimum output shifts due vibration data is to be collected. The maximum
to temperature changes are desired. Ceramic measurement frequency of interest is determined by
sensing elements provide excellent resolution and the maximum number of harmonics of an event like
durability in noisy environments, and can be running speed, bearing frequencies, or gear mesh.
designed to supply low-frequency and high- This measurement frequency range should be well
frequency measurements. Shear-design sensors are within the specified frequency range of the sensor.
preferred because of their inherent insensitivity to
adverse environmental influences, such as case or
Amplitude range refers to the anticipated levels of
base strain and thermal transients. Internal case
vibration to be measured. These values are related
isolation and shielding is important in avoiding
to the alarm levels set for the machine. By carefully
erroneous signals resulting from ground loops
evaluating the idiosyncrasies of the machinery, the
and pick-up of electromagnetic and radio
predictive maintenance engineer can estimate the
frequency interference. Other critical material
minimum expected vibration levels and ensure that
selection criteria include non-magnetic stainless
the electrical noise floor of the accelerometer is less
steel housing, hermetic sealing, and industrial
than those levels.
military connectors. See Figure 1.
The environment of the application is a critical input voltage. Also, the diode can be changed to supply
consideration during program implementation. The higher currents for driving long cable lengths. Constant
sensor chosen must be capable of surviving the wide current diodes, as shown in Figure 3, should be used in
range of conditions to which it is subjected; ICP® signal conditioners. (The correct orientation of the
therefore, take time to evaluate potential diode within the circuit is critical for proper operation.)
conditions, such as high temperatures and chemical Except for special models, standard ICP® sensors require
contaminants. The specified temperature range of a minimum of 2 mA for proper operation.
the sensor must conform to the fluctuations of the
environmental temperature. If harsh industrial
chemicals are present, the sensor requires hermetic
sealing and construction that resists corrosion.
Finally, specific location of the sensor within the
environment must be sensible, as both cable and
sensor may be damaged by imprudent installation in
heavily traveled, physically punishing areas.

2.0 ICP® ACCELEROMETERS The typical limits for this type of diode are to a 4 mA
Enclosed in the back of this guide is a Specification maximum rating; however, several diodes can be placed in
Sheet, which lists the complete performance parallel for higher current levels. All line-powered signal
characteristics of the particular sensor. conditioners should use higher capacity (up to 20 mA)
constant current circuits in place of the diodes, particularly
All ICP® sensors require a constant current power when driving long signal cables (see Section 5).
source for proper operation. A typical sensing
system includes an ICP® sensor, ordinary two Decoupling of the data signal occurs at the output stage
conductor cable and a basic constant current power of the signal conditioner. A 10 to 30 µF capacitor coupled
supply (as shown in Figure 2). with a resistor shifts the signal level to essentially
eliminate the sensor bias voltage. The result is a drift-free
AC mode of operation.

3.0 OPTIONAL FEATURES

In addition to standard features, a variety of options
are also available. When listed before the model
number, the following prefix letters indicate that the
sensor is manufactured or supplied with optional
features:

CS - Canadian Standards Association Approved

Sensor
D - Dummy, non-working sensor for display purposes
EX - Cenelec Approved Sensor
FM - Factory Mutual Approval Sensor
HT - High temperature accelerometer (325 ˚F)
The signal conditioner consists of a well-regulated 18 LB - Low Bias electronics
to 30 VDC source (battery or line-powered), a LC - Limited Calibration (one point calibration)
current-regulating diode (or equivalent constant LP - Low Pass filter
current circuit), and a capacitor for decoupling M - Metric mounting hardware and cable length
(removing the bias voltage) the signal. U - Usable demonstration sensor (does not meet one
of more minor specifications)
The current-regulating device is used in place of a VO - Velocity Output Sensors
resistor for several reasons. The very high dynamic
resistance of the diode yields a source follower gain
which is extremely close to unity and independent of
MS – Mine Safety Approved Sensors 4.1 STANDARD STUD MOUNT
TO – Temperature Output Sensor This mounting technique requires smooth, flat
contact surfaces for proper operation and is
Note: Not all sensors are available with the optional recommended for permanent and/or secure
prefixes. Contact the factory to discuss special installations. Stud mounting is also recommended
features that may be needed. when testing at high frequencies.

4.0 INSTALLATION OVERVIEW Note: Do NOT attempt mounting on curved, rough,

When choosing a mounting method, consider closely both or uneven surfaces, as the potential for misalignment
the advantages and disadvantages of each technique. and limited contact surface may significantly reduce
Characteristics like location, ruggedness, amplitude range, the sensor’s upper operating frequency range.
accessibility, temperature, and portability are extremely
critical. However, the most important and often
overlooked consideration is the effect the mounting
technique has on the high-frequency operating range of
the accelerometer.

Shown in Figure 4 are six possible mounting techniques

and their effects on the performance of a typical
piezoelectric accelerometer. (Note: Not all of the
mounting methods may apply to your particular sensor.)
The mounting configurations and corresponding graph
demonstrate how the high-frequency response of the
accelerometer may be compromised as mass is added to
the system and/or the mounting stiffness is reduced.
STEP 1: First, prepare a smooth, flat mounting
surface and then drill and tap a mounting hole in the
Note: The low-frequency response is unaffected by the
center of this area as shown in Figure 5.
mounting technique. This roll-off behavior is typically fixed
by the sensor’s built-in electronics. However, when
A precision-machined mounting surface with a
operating AC-coupled signal conditioners with readout
minimum finish of 63 µin (0.0016 mm) is
devices having an input impedance of less than one
recommended. (If it is not possible to properly prepare
megaohm, the low frequency range may be affected.
the machine surface, consider using an adhesive
mounting pad as a possible alternative.) Inspect the
area, checking that there are no burrs or other foreign
particles interfering with the contact surface.

STEP 2: Wipe clean the mounting surface and spread

on a light film of grease, oil, or similar coupling fluid
prior to installation. See Figure 6.

Adding a coupling fluid improves vibration

transmissibility by filling small voids in the mounting
surface and increasing the mounting stiffness. For
semi-permanent mounting, substitute epoxy or another METHOD 2 – Direct Adhesive Mount
type of adhesive.
For restrictions of space or for convenience, most sensors
STEP 3: Hand-tighten the sensor/mounting stud to the (with the exception of integral stud models) can be
machine, then secure the sensor with a torque wrench to adhesive-mounted directly to the machine surface.
the mounting surface by applying the recommended
mounting torque. (See enclosed specification data sheet STEP 1: Prepare a smooth, flat mounting surface. A
for proper mounting torque.) minimum surface finish of 63 µin (0.0016 mm) generally
works best.
It is important to use a torque wrench during this step.
Under-torqueing the sensor may not adequately couple STEP 2: Place a small portion of adhesive on the
the device; over-torqueing may result in stud failure and underside of the sensor. Firmly press down on the
possibly permanent damage. top of the assembly to displace any adhesive. Be
aware that excessive amounts of adhesive can make
4.2 ADHESIVE MOUNT sensor removal difficult. See Figure 8.
Adhesive mounting is often used for temporary
installation or when the machine surface cannot be
adequately prepared for stud mounting. Adhesives like
hot glue or wax work well for temporary mounts; two-part
epoxies and quick-bonding gels provide a more
permanent mount.

Note: Adhesively-mounted sensors often exhibit a

reduction in high-frequency range. Generally, smooth
surfaces and stiff adhesives provide the best frequency 4.3 MAGNETIC MOUNT
response. Contact the factory for recommended epoxies. Magnetic mounting provides a convenient means for
making portable measurements and is commonly used
METHOD 1 – Adhesive mounting base for machinery monitoring and other portable or trending
This method involves attaching a base to the machine applications.
surface, then securing the sensor to the base. This allows
for easy removal of the accelerometer. Note: The correct magnet choice and an adequately
prepared mounting surface are critical for obtaining
STEP 1: Prepare a smooth, flat mounting surface. A reliable measurements, especially at high frequencies.
minimum surface finish of 63 µin (0.0016 mm) generally Poor installations can cause as much as a 50% drop in the
works best. sensor frequency range.

STEP 2: Stud-mount the sensor to the appropriate Not every magnet is suitable for all applications. For
adhesive mounting base according to the guidelines set example, rare earth magnets are commonly used
forth in STEPS 2 and 3 of the Stud Mount Procedure. because of their high strength. Flat magnets work well
on smooth, flat surfaces, while dual-rail magnets are
STEP 3: Place a small portion of adhesive on the underside required for curved surfaces. In the case of non-magnetic
of the mounting base. Firmly press down on the assembly or rough surfaces, it is recommended that the user first
to displace any extra adhesive remaining under the base. weld, epoxy, or otherwise adhere a steel mounting pad
See Figure 7. to the test surface. This provides a smooth and
repeatable location for mounting.

STEP 1: After choosing the correct magnet type,

inspect the unit, verifying that the mounting surfaces
are flat and smooth. See Figure 9.
 ICP® accelerometers are internally amplified, two-wire
accelerometers. Connections to the sensor require two
leads: one for the power and signal, and the other for the
common and signal return. Often, coaxial cables are used
since only two conductors are needed. Coaxial cables are
less expensive. With coaxial cables, however, erroneous
signals can be introduced into sensor systems through
ground loops, electromagnetic interference, or radio
frequency interference (EMI or RFI). To avoid ground
STEP 2: Stud-mount the accelerometer to the loops, there should only be one ground in the system.
appropriate magnet according to the guidelines set
forth in STEPS 2 and 3 of the Stud Mount Procedure. It is recommended for permanent installations that the
sensor be case-isolated and internally shielded with a dual-
STEP 3: Prepare a smooth, flat mounting surface. A case design and use a two-conductor shielded cable to
minimum surface finish of 63 µin (0.0016 mm) insure clean vibration signal transmission. Two-conductor
generally works best. After cleaning the surface and shielded cables allow the signal and the signal return
checking for burrs, wipe on a light film of silicone (common) to be fully shielded from the sensor to the
grease, machine oil, or similar-type coupling fluid. readout equipment. To insure that ground loop signals are
not induced, the shield should only be terminated at one
STEP 4: Mount the magnet/sensor assembly to the end. Typically, the shield of a two-conductor shielded
prepared test surface by gently “rocking” or “sliding” cable is left open or not connected at the sensor end and
it into place. See Figure 10. is tied to earth ground at the instrumentation end.

Operation over long cables may affect the frequency

response of ICP® accelerometers, and introduce low
frequency noise and high frequency distortion when an
insufficient current is available to drive cable capacitance.

Unlike charge mode systems, where the system

noise is a function of cable length, ICP® sensors
provide a high voltage, low impedance output well-
suited for driving long cables through harsh
environments. While there is virtually no increase in
Note: Magnetically mounting accelerometers
noise with ICP® sensors, the capacitive loading of the
carelessly has the potential to generate very high
longer cable may be distort or filter higher frequency
(and very damaging) g levels. To prevent damage,
signals depending on the supply current and the
install the assembly gently. If unsure, please contact
output impedance of the sensor.
the factory for assistance.
Generally, this signal distortion is not a problem with
4.4 HANDHELD OR PROVE TIP MOUNT
lower frequency testing within a range up to 1,000
This method is NOT recommended for most
Hz. However, when monitoring higher frequency
applications. It is generally used where access to
vibrations traveling over cables longer than 500ft,
machinery may be a safety concern. Both the
the possibility of signal distortion exists.
accuracy and repeatability at low (<5 Hz) and high
frequency (>1 kHz) ranges are questionable.
The maximum frequency that can be transmitted
over a given cable length is a function of both the
5.0 CABLING
cable capacitance and the ratio of the peak signal
The selection of connectors and cables has a direct
voltage to the current available from the signal
impact on the ruggedness and reliability of the sensor
conditioner according to:
installation. A consideration when dealing with cables is
the way in which the cable conductors are terminated.
𝑓 109 (Equation 1) exceed its maximum temperature specification. For this
max= 2𝜋𝐶𝑉
[𝐿𝑐 −1]
reason, do not supply excessive current over short cable runs
or when testing at elevated temperatures.
Where, fmax = maximum frequency (hertz)
C = cable capacitance (picofarads) 5.1 CABLE CONNECTOR PROCEDURE
V = maximum peak output from sensor Care and attention to installation is essential, as the
(volts) reliability and accuracy of your system is no better than that
Lc = constant current from signal of the output cable.
conditioner (mA)
109 = scaling factor to equate units STEP 1: Ascertain that you have ordered the correct cable
type.
Note that in this equation, 1 mA is subtracted from the total
current supplied to sensor (Lc). This is done to compensate As with sensors, no cable can satisfy all applications. Special
for powering the internal electronics. Also, note that these low-noise cabling should be used with high impedance,
are typical values only. charge-output devices. ICP® sensors usually operate with
any ordinary tow-wire cable. Industrial applications often
When driving long cables, Equation 1 shows that, as the require twisted/shielded cables to reduce the effects of EMI
length of the cable, peak voltage output or maximum and RFI. PTFE-jacketed cabling may be necessary to
frequency of interest increases, a greater constant current withstand corrosive environments.
will be required to drive the signal.
STEP 2: Connect the cable to the accelerometer. A small
The nomograph on page 12 of this manual provides a amount of thread-locking compound placed on the
simple, graphical method for obtaining the expected connector prior to attachment helps secure the cable during
maximum frequency capability of an ICP® measurement testing. In harsh environments, the connection can be
system. The maximum peak signal voltage amplitude, cable sealed with silicone rubber, O-rings, and flexible heat-shrink
capacitance and supplied constant current must be known tubing.
or presumed.
STEP 3: Plug the connector of the cable into the mating
For example, when running at 100 ft (30.5 m) cable with a sensor connector. Then, holding the sensor stationary,
capacitance of 30 pF/ft, the total capacitance is 3,000pF. secure the connector in place by tightening down the
This value can be found along the diagonal cable attached threaded cable sleeve.
capacitance lines. Assuming the sensor operates at a
maximum output range of 5 volts and the constant current STEP 4: Route the cable to the signal conditioner, making
available from the power supply is 2 mA, the ratio on the certain to stress-relieve the sensor/cable connection and
vertical axis can be calculated to equal 5. The intersection of minimize motion by clamping the cable at regular intervals.
the total cable capacitance and this ratio result in a
maximum frequency of approximately 10.2 kHz. Common sense should be used to avoid physical damage
and minimize electrical noise. For instance, avoid routing
The nomograph does not indicate whether the frequency cables near high-voltage wires. Do not route cables along
amplitude response at a point is flat, rising or falling. For floors or walkways where they be stepped on or become
precautionary reasons, it is good general practice to contaminated. Shielded cables should have the shield
increase the constant current (if possible) to the sensor grounded at one end only, normally at the instrumentation
(within its maximum limit) so that the frequency end.
determined from the nomograph is approximately 1.5 to 2
times greater than the maximum frequency of interest. STEP 5: Finally, connect the remaining cable end to the
signal conditioner or readout device. To dissipate charge
Note: Higher current levels will deplete battery-powered that may have accumulated in the cable short the signal to
signal conditioners at a faster rate. Also, any current not ground prior to attachment.
used by the cable goes directly to power the internal
electronics and will create heat. This may cause the sensor to
6.0 POWERING the system still does not operate properly, consult
All ICP® sensors require constant current excitation an IMI Application Engineer.
for proper operation. For this reason only use
approved constant-current sources. A typical system Note: Always operate the accelerometer within the
schematic is shown in Figure 11. limitations listed on the Specification Sheet of your
sensor. Operating the device outside of its
parameters can cause temporary or permanent
damage to the sensor.

8.0 ACCELEROMETER CALIBRATION

Note: It is good measurement practice to verify the
performance of each accelerometer before and after
each measurement.

Accelerometers are precision measuring

The power supply consists of a regulated 18 to 30 instruments. They are highly engineered to provide
VDC source. In general, battery-powered devices accurate electrical signals representative of the
offer versatility for portable, low-noise vibration being monitored. Each sensor is calibrated
measurements, whereas line-powered units provide by comparison to a known acceleration level. Some
the capability for continuous monitoring. This power calibrations include frequency response curves,
is regulated by a current-limiting circuit, which resonant frequency measurements, transvers
provides the constant-current excitation required for sensitivity, and many other valuable tests.
proper operation of sensors with integral Applications requiring a high degree of accuracy or
electronics. those in plants requiring certification and traceability
require full calibration test results.
Note: Under no circumstances should a voltage be
supplied to an ICP® accelerometer without a current-
regulating diode or equivalent electrical circuit.
A capacitor at the output stage of the device
removes the sensor output bias voltage from the
measurement signal. This provides a zero-based, AC-
coupled output compatible with most standard
readout devices.

Today, many FFT analyzers, data acquisition

modules, and data collectors have constant-current
excitation for direct use with ICP® sensors. However,
before using this feature, check that the supply
voltage and constant current are adequate for use
with your sensor. Please contact the respective
signal conditioner manufacturer or check the Some applications have much less stringent
product manual for more information. requirements for calibration certification. Simple
sensitivity measurements at a single frequency may
7.0 OPERATING be sufficient; operational verification and certificates
After completing the system setup, switch on the of conformance to published specifications may
conditioner, the meter (or LED) and allow the sensor satisfy many plants’ calibration needs. Reducing the
to power up. If a faulty condition is monitored, first final calibration requirements reduces the cost of
check all system connections, then check the manufacturing the sensor and should lower the price
functionality of the cable and signal conditioner. If for predictive maintenance users.
Periodic recalibration may be required by plants with piezoelectric accelerometers. This method relies on
strict certification and traceability requirements. It is a simple comparison to a previously calibrated
always recommended that the user has the sensor accelerometer, typically referred to as a reference
recalibrated periodically, particularly if the sensor standard, as shown in Figure 12.
has experienced a very high shock level or extreme
temperatures for extended periods of time. Some
plants develop in-house calibration capabilities for
periodically verifying the performance of
accelerometers. Products are available that provide
a set 1 g-acceleration level at a fixed frequency for
quick sensor checking.

For these reasons, it is recommended that a Figure 12. Reference Standard Accelerometer
recalibration cycle be established for each
accelerometer. This schedule is unique and is based These high-accuracy devices, which are directly
on a variety of factors, such as extent of use, traceable to a recognized standards laboratory, are
environmental conditions, accuracy requirements, designed for stability, as well as configured to accept
trend information obtained from previous a test accelerometer. By mounting a test
calibration records, contractual regulations, accelerometer to the reference standard and then
frequency of “cross-checking” against other connecting this combination to a suitable vibration
equipment, manufacturer recommendation, and any source, it is possible to vibrate both devices and
risk associated with incorrect readings. International compare the data as shown in Figure 13. (Test set-
standards, such as ISO 10012-1, provide insight and ups may be automated and vary, depending on the
suggested methods for determining recalibration type and number for accelerometers being
intervals for most measuring equipment. With the calibrated.)
above information in mind and under “normal”
circumstances, a conservative suggestion of 12 to 24
month recalibration cycle for most piezoelectric
accelerometers is advised.

8.1 SENSOR CALIBRATION

Accelerometer recalibration services are typically
performed by IMI’s internal metrology laboratory.
(Other international and private laboratories are also
available.) The IMI laboratory is certified to ISO
9001, complies with ISO 10012-1 (and former MIL-
STD-45662A), and uses equipment directly traceable Figure 13. Typical Back-to-Back Calibration System
to NIST. This assures an accurate calibration of
relevant specifications. Because the acceleration is the same on both
sensors, the ratio of their outputs (VT/VR) must also
The following includes a broad overview of the Back- be the ratio of their sensitivities. With the sensitivity
to-Back Calibration technique normally used when of the reference standard (SR) known, the exact
calibrating accelerometers. This technique provides sensitivity of the test sensor (ST) is easily calculated
a quick and easy method for determining the by using the following equation:
𝑉𝑇
sensitivity of a test accelerometer over a wide 𝑆𝑇 = 𝑆𝑅 ( )
frequency range. 𝑉𝑅

8.2 BACK-TO-BACK CALIBRATION THEORY By varying the frequency of the vibration, the sensor
Back-to-back calibration is perhaps the most may be calibrated over its entire operating
common method for determining the sensitivity of frequency range. The typical response of an
unfiltered accelerometer is shown in Figure 14.
 ICP® sensors are two-wire sensors. They are
powered with a constant current DC source. The
power supply is typically 18 to 30 volts DC current
limited via a constant current between 2 and 20 mA.
Typical battery operated supplies offer 2mA of
constant current to extend battery life while
Figure 14. Typical Test Accelerometer Response continuous monitoring systems offer more current in
order to drive longer cables. Figure 16 shows a
9.0 TROUBLESHOOTING typical system for a sensor with integral electronics.
Piezoelectric sensors are dynamic measuring equipment.
They use piezoelectric sensing elements to convert or The signal output of a sensor with integral
transduce the mechanical phenomena to an electrical electronics is a low impedance voltage signal
signal. The mechanical parameter may be force, pressure proportional to the dynamic measurement such as
or vibration. The raw electrical signal from a piezoelectric force, pressure, or vibration. This voltage signal is
charge element is a high impedance signal. This charge carried on a DC bias voltage. The AC dynamic signal
signal is normally converted to a low impedance voltage is superimposed on the DC bias voltage and is
signal by either an external charge amplifier or an external allowed to swing between the supply voltage and
voltage amplifier. The cables between the charge sensor ground as shown in Figure 17. Unlike an operational
and the amplifier must be high quality, low noise cable amplifier that requires a plus and minus supply and
and must be kept as short as possible. Figure 15 shows a allows the signal to “ride” on ground and “swing”
typical high impedance system. between the plus and minus “rails,” the sensor with
integral electronics requires the output signal to be
DC biased.

Figure 15. High Impedance System Connection

Internally amplified sensors employ miniature Figure 17. Sensor DC Bias Voltage
amplifiers to convert the high impedance charge
signal into a low impedance voltage signal. These This DC bias voltage is an excellent diagnostic tool.
amplifiers are internal to the sensor, and therefore, The voltage provides a means of verifying that the
do not require low noise cables or external amplifier is “turned on.” Typical input/output power
amplifiers. These amplifiers have set gain so that supplies will block this DC bias voltage at the output
output sensitivities are standardized. via a blocking capacitor in order to AC couple the
signal to readout devices. By “teeing” off the input
into a DC volt meter, as shown in Figure 18, the bias
voltage can be measured.

While measuring the supply voltage, the bias voltage

can be measured agter the sensor is plugged in. If
the meter stays at supply, something in the system is
open or not connected. If the meter reads “0,”
something in the system is shorted. If the meter
reads within the bias voltage range of the sensor,
Figure 16. Sensor with Integral Electronics System then the sensor and cabling are functioning properly.
Connector
 RMA. For assistance, please call (716) 684-
0003, or fax us at (716) 684-3823. You may also
receive assistance via e-mail at imi@pcb.com or
visit our website at www.pcb.com.

11.0 CUSTOMER SERVICE/WARRANTY

IMI, a division of PCB Piezotronics, guarantees Total

Customer Satisfaction. If, at any time, for any
Figure 18. DC Bias Voltage Measurement reason, you are not completely satisfied with any IMI
product, IMI will repair, replace or exchange it at no
10.0 REPAIR/RETURN PROCEDURE charge. You may also choose to have your purchase
Because of the nature of most IMI price refunded.
instrumentation, field repair is typically NOT
IMI instrumentation is warranted against defective
recommended and may void any warranty. If
material workmanship for 1 year unless otherwise
factory service is required, contact IMI for a
expressly specified. Damage to instruments caused
RETURN MATERIAL AUTHORIZATION (RMA) by incorrect power or misapplication, is not covered
number prior to sending equipment to the by warranty. If there are any questions regarding
factory. Please have information available, such power, intended application, or general usage,
as model and serial number. Also, to insure please consult with your local sales contact or
efficient service, be sure to include a written distributor. Batteries or expendable hardware items
description of the symptoms and problems with are not covered by warranty.
the equipment to a local sales representative or
distributor, or contact IMI if none are located in IMI offers to all customers, at no charge, 24-hour
phone support. This service makes product or
your area.
application support available to our customers, day
or night, seven days a week. When unforeseen
Customers outside the U.S. should consult their problems or emergency situations arise, call the IMI
local IMI distributor for information on Hot Line at (716) 684-0003, and an application
returning equipment. For exceptions, please specialist will assist you.
contact the International Sales department at
IMI to request shipping instructions and an
PB P IEZOTR
MIS SYSTEMS CORPORATION.

SIL Declaration of Conformity

Functional safety according to IEC 61508

Manufacturer: PCB Piezotronics

3425 Walden Avenue
Depew, NY 14043 USA

PCB Piezotronics declares as manufacturer, that the vibration transmitters:

• 602 Series (XX)602yzzz/aaa (XX) Options include one or more of the following:
• 603 Series (XX)603yzzz1aaa EX Approved for Hazardous Locations
-

• 606 Series (XX)606yzzz/aaa M Metric Mounting Hardware

-

o 607 Series (XX)607yzzz/aaa TO Dual Output (Vibration/Temperature)

-

608 Series (XX)608yzzz/aaa Note: "yzzz" completes the model, "aaa" indicates cable length (if applicable)

Is hardware suitable for use in safety-instrumented systems according to IEC 61508, if the safety instructions and the
following parameters are observed:
Parameter 60x Series* EX60x Series*
SIL 2 2
Proof Test Interval (Annual) 8,760 h 8,760 h
Device Type B B
HFT 0 0
SFF 79.59% 79.59%
PFDAV' 7.45 x iO 7.45 x iO
XciuX 10.6 0.3348 0.3348
SIL Capability (Low Demand Mode) 2 2
SIL Capability (Continuous Demand Mode) 2 2
MTTF2 9.5y 9.5y
1. The values comply with SIL2 according to ISA S84.01
2. According to Siemens SN29500 and Proven In Use data
* With or without the M (metric) option

The PCB sensor hardware is suitable for inclusion in Safety Instrumented Systems (SIS) that are designed using IEC
61511 (for the process industry sector), IEC 62061 (safety of machinery), EN 50129 (railway applications), and ISO 26262
(automotive industry).

Note: The use of SIL Hardware in specific safety standard appli apply different number of sequences or
definitions to those in IEC 61508. v'
LO t r
....
July 2, 2019
zC -
PCB Piezotron s Authorized R )resenttie: -
EQ SEAL
199
Carrie Termin /
Regulatory Affairs and Product C .rtification Specialist
S
*
"PII'lEZOTRONlCS, INC. CORPORATE HEADQUARTERS
-

3425 Walden Avenue, Depew, New York 14043-2495 USA

Phone: 716-684-0001 Fax: 716-684-0987
E-mail: info@pcb.com
Web site: www.pcb.com
AS9100 and 1S09001 Certified
ISO 17025 Accredited
 intertek
Total Quality. Assured.

INTERTEK ASSURANCE
SAFETY INTEGRITY LEVEL
SUMMARY REPORT

CLIENT NAME
PCB Piezotronics, Inc.
3425 Walden Ave
Depew, NY 14043-2417

REPORT NO
103685042CSL1-003

COMPILED BY
Ashton D. Hainge, CFSP, PMP

PROJECT NAME
G103685042

DATE
02 April 2019

utertek
On
PCB FUNCTIONAL SAFETY SIL SUMMARY AND RESULTS

Summary
This report details the results of the reliability analysis performed on the PCB Piezotronics ICP Sensor model
60X series. Design changes from this documentation package would need to be evaluated for the impact on
the reliability characteristics. These results are based on the following PCB Piezotronics documentation:

1. Electrical schematic 23402-NR

2. 603C01 MTTF Calculation
3. 602C1 I 602D1 1 MTTF Calculation
-

4. 607-608 MTTF Calculation

5. Manual of603C0I

Results
The results from the FMEA are given below for the ICP Sensor model 60X Series:

Name Result

Architecture loot

Proof test interval (Annual) 8,760 h

PFDavg 7.45x10 5

SFF 79.59%

HFT 0

SIL Capability (Low Demand Mode) 2

SIL Capability (Continuous Demand Mode) 2

Architecture 1001

60X PCB SL Sensor Rating

Report No: 103685042CSL1-003 2o13
 O n
Name Result

Safe Detected failure rate 2usD x i0' 0.019

Safe Undetected failure rate ksu x 10 6 0.013

Dangerous Detected failure rate 2DD x 10 0.033

Dangerous Undetected failure rate 6

XDU xI 0.017

Average frequency of a dangerous

PFH > 0.796
failure on demand

Type B components: 60X Series

The safety relevant parameter PFDavg is in compliance with the corresponding requirements for SIL 2
according to IEC 615081. The safety relevant parameters HFT and SFF are in compliance with the
corresponding requirements for SIL 1 according to IEC 61508. The user should consider, that the
hardware fault tolerance of all inspected devices is zero and that a single fault can lead to a
dangerous failure. Even though PFDavg has the range of SIL 4, the hardware fault tolerance limits
the capability to SIL 2.

Senior Consultant,

Ashton Hainge, lntertek

CFSP, PMP

The assessment results described in this report only refer to the safety-related parameters PFD avg, HFT, and SFF
according to IEC 61508.

This report does not make any statements, that the manufacturer meets all other requirements of the above cited
standards for hardware, software, documentation, management of functional safety, verification, and validation.
This report does not imply that the examined pressure sensors have been certified for functional safety by the assessor
according to IEC 61508 or any other standards.

The sensors are only one part of a complete safety function. It is at the responsibility of the end-user to prepare and to
apply an extensive reliability model, that brings out the complete safety function and that meets all requirements of
the claimed SIL level according to IEC 61508.

60X PCB SIL Sensor Rating

Report No: 103685042CSLT-003 3 of 3