© Siemens AG 2016 Process Protection Acoustic sensors for pump monitoring SITRANS DA400 acoustic diagnostic unit ■ Overview ■ Application In the version for pump monitoring, the SITRANS DA400 allows continuous, simultaneous and independent monitoring of up to four flow control valves in a pump for leaks. In addition, another four inputs are available for monitoring standard signals (e.g. diaphragm and temperature monitoring). This means that the condition of an oscillating displacement pump is monitored in every phase of its operation. The SITRANS DA400 is used in all industries where an oscillating displacement pump is used. The version for material flow monitoring monitors the material flow in liquids or gases that is usually as a result of impact or friction, e.g. against the pipe or channel wall. If the acoustic diagnostic unit is used in potentially explosive areas, the sensors as well as the acoustic diagnostic unit can be installed in the Ex-zone. The SITRANS DA400 acoustic diagnostic unit acoustically measures the structure-borne noise • In the version for pump monitoring; on oscillating displacement pumps • In the version for material flow monitoring; on pipes, conveying equipment or channels. It comprises an electric diagnostic unit and up to four acoustic sensors. ■ Benefits Benefits when pump monitoring • Increased availability of the system through: - Advanced maintenance planning thanks to early recognition of defective components - Reduced downtimes (no fault locating necessary) - Increased maintenance intervals - Greater pump reliability • Prevention of expensive consequential damage • Increased safety of critical applications • Early recognition of a reduction in power • Increased productivity Benefits when material flow monitoring • Detection of insufficient or excessive inflow of material in a liquid or gas flow • Detection of blockages or clogging • Reduction of down times • Increased product quality • Increased availability • Guaranteed operational safety • Increased productivity If using the unit in potentially explosive areas, you have two options: • Operation of the sensors over the safety barriers or • Operation of the sensors over the SITRANS DA400 with explosion protection ■ Function Product features Continuous and independent status monitoring: • Of the flow control valves, for leaks • Of the membranes, for material fatigue • Of the temperature loading of the hydraulic oil • Of flowing bulk solids in pipes, conveying equipment or channels Communication of the status to superordinate control systems: • Via digital outputs • Digitally, via PROFIBUS DP or PROFIBUS PA Simple to operate and parameterize: • Locally, via digital display and keys • PROFIBUS DP and PROFIBUS PA Mode of operation Principle of measurement Leaks in the flow control valves of oscillating displacement pumps are flows in which cavitation occurs. This results in sound waves that are transmitted to the valve housing, where they are recorded by the structure-borne sound sensor in the SITRANS DA400 on the outside. The SITRANS DA400 utilizes the fact that with both an open valve and a closed intact valve, no cavitation occurs and the measured sound level thus corresponds to the operating noise of the pump. By contrast, with a closed defective valve cavitation does occur, which can be identified by a period increase in the sound level (see figures). The measured value from the SITRANS DA400 corresponds exactly to this increase in the sound level. In the version for material flow monitoring, SITRANS DA400 continuously detects high-frequency acoustic oscillations by means of structure-born noise sensors. Siemens FI 01 · 2016 6/5 6 © Siemens AG 2016 Process Protection Acoustic sensors for pump monitoring SITRANS DA400 acoustic diagnostic unit These oscillations are created by: • Friction and impact of bulk solids in: - pipes, raceways or channels - chutes - conveyors • Friction and impact of mechanical parts • Bursting of bubbles • Cavitation • Turbulence in gas and liquid flows The following shows an example of signal levels at an oscillating displacement pump ■ Technical specifications SITRANS DA400 Without Ex protection With Ex protection Input Acoustic channels 4 • Cycle time 10 ms Only for connection to intrinsically safe sensors with: • Max. voltage Uo - 5.5 V • Max. current Io - 70 mA • Max. power Po - 100 mW • Internal capacitance Ci - 1.2 F • Internal inductance Li - Universal inputs Negligible 4 • Cycle time 80 ms • Low pass filter time 1s Universal analog current input • Load < 105 • Resolution Signal from structure-borne sound sensor with intact valve • Accuracy • Fault signal 0.5 % > 21 mA or < 3.6 mA (at 4 ... 20 mA) • Alarm monitoring hysteresis • Static destruction limit 6 < 12 0.1 % 0.5 % 40 mA, 4 V - • Max. supply voltage Ui - 30 V • Max. short-circuit current Ii - 100 mA • Max. power Poi - 1W • Internal capacitance Ci - 11 nF • Internal inductance Li - 70 H For connection with approved intrinsically safe circuits with: Signal from structure-borne sound sensor with defective valve Universal input 24 V digital signal Sensor operation • Input resistance > 19 k The structure-borne sound sensor works on the piezoelectric principle. The structure-borne sound is injected into the sensor via the sensor base (mounting surface) and inside it is converted into an electrical voltage by a piezo-ceramic element. This is amplified in the sensor and transmitted via the cable. • Signal level Low < 4.5 V or open • Signal level High >7V The sensor frequency range lies in the ultrasonic range (> 20 kHz). The sensor is non-directional, i.e. the angle at which the sound wave impacts on the sensor base is not important. Mode of operation of the safety barrier The safety barrier comprises intrinsically-safe circuits. These circuits serve to operate intrinsically-safe components such as sensors and to isolate safety from the non-hazardous area with the SITRANS DA400 diagnostic unit. 6/6 Siemens FI 01 · 2016 • Hysteresis • Static destruction limit >1V ± 40 V - • Max. supply voltage Ui - 30 V • Max. short-circuit current Ii - 100 mA • Max. power Poi - 1W • Internal capacitance Ci - 11 nF • Internal inductance Li - 70 H For connection with approved intrinsically safe circuits with: © Siemens AG 2016 Process Protection Acoustic sensors for pump monitoring SITRANS DA400 acoustic diagnostic unit SITRANS DA400 Without Ex protection With Ex protection SITRANS DA400 Universal input closing contact Electromagnetic Compatibility For connection to closing contact with the maximum values: • Emitted interference and interference immunity • Max. voltage Uo - 10 V Usage limits for water • Max. current Io - 1 mA • Delivery side • Max. power Po - 5 mW • Number of strokes • Internal capacitance Ci - 11 nF Design • Internal inductance Li - 70 H Weight (without options) 8.2 V source for NAMUR signal (DIN EN 60947-5-6) Without Ex protection To EN 61326 and NAMUR NE 21 10 bar a Min. 4 min-1, max. 10 ... 500 min-1 Approx. 2.5 kg Dimensions (W x H x D) in mm (inch) Enclosure material • Open circuit voltage 8.2 V ± 0.3 V, short-circuit proof • Input resistance < 950 - • Static destruction limit for incorrect wiring +20 V/-10 V - Digital outputs 6 6 (applicable for NAMUR switch hardener) • Semiconductor relay Individually isolated, short circuit-proof - Output With Ex protection 172 x 320 x 80 (6.8 x 12.6 x 3.2) Macrolon (polyMakrolon carbonate + 20 % (polycarbonate glass fiber) + 20 % glass fibers), surface attenuated with CrNi layer and painted Electrical connection via screw termi- • Rigid 2.5 mm (0.984 inch) • Flexible 1.5 mm (0.59 inch) nals • Flexible with connector sleeves 1.5 mm (0.59 inch) Cable inlet via plastic cable joints • 2 x Pg 13.5 • 5 x Pg 11 Power supply 24 V AC/36 V DC, any polarity Rated voltage 24 V DC 16 V DC Operating range 19 ... 36 V DC 15 ... 17 V DC • Destruction limit 35 V AC, 50 V DC - Current consumption < 100 mA < 40 mA • Max. switching current 100 mA - • Signal status Low (no response) - 1.2 mA (source to DIN 19234) For connection with approved intrinsically safe circuits with: - 17.4 V - 2.1 mA (source to DIN 19234) • Max. supply voltage Ui • Signal status High (response) • Max. short-circuit current Ii - 191 mA • Max. power Poi - 1.35 W • Internal capacitance Ci - 33 nF • Internal inductance Li - 28 H • Switching voltage For connection with an intrinsically safe switching amplifier to DIN 19234 with: 6 • Max. supply voltage Ui - 15.5 V • Max. short-circuit current Ii - 25 mA • Max. power Poi - 64 mW Explosion protection to EN 50014, EN 50020 and EN 50021 • Internal capacitance Ci - 5.2 nF Intrinsic safety "i" - • Internal inductance Li - Negligible TÜV (German Technical Inspectorate) 06 ATEX 2952 Marking - II 2(1) G EEx is [ia] IIC T6 - Certificates and approvals Conditions of use Installation conditions Vertical wall mounting, cables fed in from below Climatic class Class 4K4 according to EN 60721-3-4 Communication Mounting location - Zone 1 or zone 2 PROFIBUS DP Permissible ambient temperature -20 ... +60 °C (-4 ... +140 °F) - RS 485, switchable terminating resistor Protocol Cyclic with Master C1 and acyclic with Master C2 • Temperature class T5 – T1 -20 ... +60 °C (-4 ... +140 °F) • Temperature class T6 -20 ... +50 °C (-4 ... +122 °F) Mechanical load Degree of protection to EN 60529 Class 4M3 according to EN 60721-3-4 Power supply - Bus-supplied Bus voltage - 9 ... 24 V Current consumption - 10.5 mA ± 10 % IP65 Siemens FI 01 · 2016 6/7 © Siemens AG 2016 Process Protection Acoustic sensors for pump monitoring SITRANS DA400 acoustic diagnostic unit SITRANS DA400 Without Ex protection With Ex protection Bus connection with FISCO supply unit, ia/ib group IIC or IIB - Yes Layer 1 and 2 from PROFIBUS PA, transfer technology from IEC 1158-2 - • C2 connections - 4 connections are supported in master class 2 Ex barriers for sensors Application area For the intrinsically safe supply of the acoustic sensors in zone 1; the safety barriers must be installed between the SITRANS DA400 acoustic diagnostic unit and the sensor if only the sensors are being operated in the Ex zone. Input A maximum of two sensors can be connected. • Device profile - PROFIBUS PA Profil V3.0 Rev. 1, Class B Conditions of use Degree of protection to EN 60529 IP20 • Device address - 1 ... 126 (126 factory-set) Permissible Ambient Temperature -20 ... +60 °C (-4 ... +140 °F) PC parameterization software SIMATIC PDM (not included in the scope of delivery) Sensor for SITRANS DA400 Design Weight 115 g (0.254 lb) Housing material Plastic, polyamide Type of installation Installation on mounting rail NS 32 or NS 35/7.5. • Piezoceramic sensor with pre-amplifier Setup The acoustic diagnostic unit SITRANS DA400 and the safety barrier must be operated outside the Ex zone. • Encapsulated electronics • 4-wire cable with anti-kink sleeve Conditions of use -40 ... +110 °C (-40 ... +230 °F) Degree of protection to EN 60529 P66/IP68 Mechanical load Class 4M7 according to EN 60721-3-4 Class 4K4 according to EN 60721-3-4 Climatic class 6 Dimensions (W x H x D) in mm (inch) Permissible ambient temperature Design Housing material Stainless steel 1.4571 (316Ti SST) Cable Ends with wire protectors and cable shoe for connection to the SITRANS DA400 Weight 125 g (0.276 lb) Mounting location Zone 0/1 or zone 20/21/22 Dimensions (W x H x D) in mm (inch) 26 x 29 x 40 (1.02 x 1.14 x 1.57) Power Supply Power fed from device Certificates and approvals Explosion protection Intrinsic safety "i" TÜV 2005 ATEX 2876 X Marking II 1 G EEx ia IIC T6/T5/T4 or II 1 D EEx ia D 20/21/22 T160 Permissible ambient temperature • Category 1G - Temperature class T4, T5 - Temperature class T6 -20 ... +60 °C (-4 ... +140 °F) -20 ... +50 °C (-4 ... +122 °F) • Category 2G - Temperature class T4 - Temperature class T5 - Temperature class T6 -40 ... +110 °C (-40 ... +230 °F) -40 ... +80 °C (-40 ... +176 °F) -20 ... +65 °C (-4 ... +149 °F) • Category 1D or 2D - Temperature class T160 -40 ... +110 °C (-40 ... +230 °F) 68 x 77 x 42 (2.68 x 3.03 x 1.65) Certificates and Approvals Explosion protection Intrinsic safety "i" TÜV 05 ATEX 2917 X Marking II (2) G [EEx ib] IIC Selection and Ordering data Article No. Acoustic diagnostics unit SITRANS DA400 with local programming and display 7MJ2400- 7 7 A0 7 Click on the Article No. for the online configuration in the PIA Life Cycle Portal. Communication • PROFIBUS DP 1A • PROFIBUS PA 2B Explosion protection • Without A • With EEx ia/ib to ATEX1) B Application software For continuous condition monitoring of positive displacement pumps For material flow monitoring in pipes, raceways and conveyors Acoustic sensors for diagnostics unit SITRANS DA400 7MJ2000-1 7 7 0 0 Explosion protection • Without A • With EEx ia to ATEX B Cable (incl. pin and allen screw M6) 20 m B 40 m C 100 m F For rail mounting NS 32 and NS35/7.5 in non-hazardous areas Explosion-protected output circuit EEx ib 1) Siemens FI 01 · 2016 2 Click on the Article No. for the online configuration in the PIA Life Cycle Portal. Safety barriers for sensors 6/8 1 Not in combination with trigger sensor. 7MJ2010-1AA © Siemens AG 2016 Process Protection Acoustic sensors for pump monitoring SITRANS DA400 acoustic diagnostic unit 9 (0.35) 12 (0.5) 26 (1.02) 70 (2.7) 6 (0.24) Ø3 (0.12) In1, In2 SITRANS DA400 49 (1.9) 47 (1.8) 42 (1.6) Ø40 (1.57) Out1, Out2 SENSOR 10 (0.39) 15 (0.59) 6.5 (0.26) 11 (0.43) 7 (0.28) ■ Dimensional drawings 28.5 (1.12) Foot element 68 (2.7) Sensor for SITRANS DA400, dimensions in mm (inch) 10 (0.394) 172 (6.77) D 5 (0.2) ■ Schematics 6 In1 Approx. 30 (1.18) Out2 41 42 51 52 80 (3.15) A 22 21 32 31 Ground terminal A 17 (0.67) Safety barrier for SITRANS DA400, dimensions in mm (inch) 41 42 51 52 Out1 152 ± 0.2 1) (5.98 ± 0.008) Pg 13.5 SW 24 77 (3.0) 269 (10.59) Ø13 (0.511) 286 ± 0.2 (11.26 ± 0.008)1) 94 (3.70) 306 (12.05) 94 (3.70) Ø6.5 (0.26) D-D D Pg 11 SW 22 1) Intrinsically safe towards sensor 3 mounting holes (M6) In2 22 21 32 31 Not intrinsically safe towards SITRANS DA400 Safety barrier for SITRANS DA400, terminal assignment SITRANS DA400, dimensions in mm (inch) Supply L+/L- Power supply (Any polarity with PROFIBUS PA) DO Digital output Sens Sensor In yl gr br bl I+ Input Yellow Green Brown Black Analog current input + DI A B Ground Digital input Signal A (green) with PROFIBUS DP, any with PROFIBUS PA Signal B (red) with PROFIBUS DP, any with PROFIBUS PA SITRANS DA400, terminal assignment Siemens FI 01 · 2016 6/9