Nexisense 800-202 High-Pressure Pressure Sensor: A Stable Guardian for High-Pressure Environments

In modern industrial systems, high-pressure operating conditions have become the norm for many critical processes. From heavy-duty hydraulic equipment to ultra-high-pressure water jet cutting, and from high-pressure oil and gas drilling to specialized cleaning systems, pressures often reach several thousand or even tens of thousands of bar. Under such conditions, conventional pressure sensors are prone to leakage, drift, or even structural failure. Once a failure occurs, it may reduce production efficiency at best, or lead to serious safety accidents at worst.

The Nexisense 800-202 high-pressure pressure sensor is specifically engineered for these extreme environments. Centered on integrated glass micro-fusion technology and combined with high-strength stainless steel materials and advanced temperature compensation techniques, it delivers long-term stable and high-precision measurement data even under ultra-high pressure, wide temperature variations, and strong mechanical shocks, making it a reliable “guardian” in high-pressure industrial process control.

Glass Micro-Fusion Technology: Fundamentally Solving Leakage and Strength Challenges

Traditional high-pressure sensors often rely on O-ring seals or welded structures. These joints tend to become weak points under high pressure and are susceptible to micro-leakage caused by fatigue, corrosion, or thermal stress. The Nexisense 800-202 completely eliminates these potential risks.

Its core employs glass micro-fusion technology: at a high temperature of approximately 500°C, the diffused silicon sensing element is permanently sintered and fused with a 17-4PH stainless steel elastic body and pressure interface, forming a truly integrated, seamless structure without welds. This process not only removes all traditional sealing components, but also significantly enhances overall mechanical strength and corrosion resistance. The product’s ultimate pressure resistance reaches 10,000 bar (approximately 1,000 MPa), with an overload capacity of 150%FS and a burst pressure as high as 300%FS, providing ample safety margins for ultra-high-pressure systems.

Wide Temperature Range, High Accuracy, and Fast Response: Stable Output Under Extreme Conditions

High-pressure systems are often accompanied by severe temperature fluctuations and instantaneous pressure shocks. The Nexisense 800-202 integrates a digital temperature compensation circuit, achieving excellent thermal stability across the full temperature range from -40°C to +85°C, with both zero drift and span drift effectively controlled.

Measurement accuracy options include ±0.3%FS or ±0.5%FS, with long-term stability better than ±0.1%FS per year. This means that even after years of continuous operation, the sensor can maintain its original factory reliability without frequent recalibration or inspection, significantly reducing operation and maintenance costs.

At the same time, the sensor features fast response and high sensitivity, capable of clearly capturing millisecond-level pressure transients. This makes it particularly suitable for dynamic high-pressure systems requiring rapid regulation, such as adaptive pressure control in high-pressure water jet equipment when cutting different materials.

Robust Protection and Broad Compatibility: Adapted to the Harshest Industrial Sites

The electronic housing of the Nexisense 800-202 is made of 304 stainless steel, while the sensing probe uses high-strength 17-4PH stainless steel. With an IP65 protection rating, it effectively resists dust, water jets, and corrosive media, making it suitable for long-term use in outdoor, humid, or chemical environments.

The sensor offers excellent shock and vibration resistance, with shock tolerance up to 100 g, fully meeting the requirements of heavy construction machinery, transport vehicles, and drilling platforms operating in high-vibration conditions.

Electrical output options are flexible, supporting mV/V signals (commonly 10 mV/V to 15 mV/V), as well as customized outputs such as 4–20 mA, 0–5 V, 0–10 V, or even digital outputs according to project requirements. A wide variety of pressure interface types are available (M20×1.5, G1/2, 9/16-18 UNF high-pressure cone, etc.), with support for non-standard customization, greatly facilitating integration with various high-pressure pipelines, pumps, and valve systems.

Typical Application Scenarios: A Versatile Performer in High-Pressure Fields

Ultra-High-Pressure Water Jet and Industrial Cleaning
In water jet cutting machines and high-pressure cleaning vehicles, the Nexisense 800-202 monitors jet pressure in real time, ensuring cutting precision and cleaning effectiveness while preventing overpressure damage to intensifier pumps and nozzles.

Heavy-Duty Hydraulics and Construction Machinery
High-pressure oil circuit monitoring in large excavators, road rollers, hydraulic breakers, and similar equipment helps precisely control operating force, improve efficiency, and protect hydraulic components.

Oilfield Drilling and High-Pressure Water Injection
In downhole high-pressure water injection systems and fracturing pump outlet pressure monitoring, the sensor provides reliable data under extreme conditions and supports remote automated control.

High-Pressure Sealed Vessels and Special Equipment
For high-pressure reactors, gas storage vessels, and military or special-purpose equipment, the sensor delivers overpressure warnings and process recording, significantly enhancing overall system safety.

Installation and Long-Term Use Recommendations

During installation, it is recommended to avoid strong vibration sources and to use high-pressure hoses or damping devices to reduce pulsation shocks. Electrical connections must be properly grounded. Zero calibration should be performed before commissioning, and accuracy verification is recommended every 1 to 2 years, depending on operating severity. Thanks to its seamless integrated structure and high-quality materials, the Nexisense 800-202 can achieve maintenance-free or minimal-maintenance long-term operation in most high-pressure applications.

Frequently Asked Questions (FAQ)

1. How should the 10,000 bar ultimate pressure rating be understood in practical use?
This value represents the sensor’s burst pressure limit. For optimal service life and accuracy, normal operation is recommended within 1.5 times the rated measurement range.

2. Does it support 4–20 mA current output?
The standard output is mV/V, but optional signal conditioning circuits can be added to provide 4–20 mA, voltage, or other standard industrial outputs.

3. Can high-pressure interfaces be customized?
Yes. Various high-pressure cone fittings, threads, and compression interfaces can be customized according to application requirements.

4. How does it perform in strong vibration environments?
With 100 g shock resistance and anti-vibration design, it has been widely validated in construction machinery and drilling platform applications.

5. What if the temperature exceeds 85°C?
Versions with heat dissipation structures or remote diaphragm assemblies can be selected to keep the electronics away from high-temperature media.

Conclusion: Under High Pressure, Stability Comes First

High-pressure environments are never a comfort zone for ordinary sensors. With its integrated glass micro-fusion structure, outstanding temperature stability, robust protective design, and reliable shock resistance, the Nexisense 800-202 high-pressure pressure sensor truly delivers “fearless of high pressure, stable at high temperature, and unshaken by impact.”

It is not merely a measurement device, but a guardian of safety and efficiency for high-pressure systems. Whether for ultra-high-pressure water jet applications demanding extreme reliability or oilfield equipment requiring long-term stable operation, choosing the Nexisense 800-202 represents a rational investment in system safety and long-term performance.

As industry continues to advance toward higher pressures and more extreme environments, a sensor that can truly withstand high-pressure challenges will bring irreplaceable peace of mind and value to your equipment and processes.