Nexisense Digital Explosion-Proof Pressure Transmitter: A Reliable Choice for Compressed Air Systems

As the “fourth utility” of industrial production, compressed air systems play an indispensable role in petrochemical, metallurgical, machinery manufacturing, automotive painting, food and pharmaceutical processing, and environmental water treatment industries. Pressure stability in compressed air systems directly affects equipment efficiency, production safety, and energy consumption.

Once pressure fluctuations get out of control, they may not only lead to process interruptions and reduced product quality, but also accelerate equipment wear and increase unnecessary energy consumption. The Nexisense digital explosion-proof pressure transmitter is designed precisely for such demanding operating conditions.

By integrating high-precision measurement, intuitive digital display, robust explosion-proof construction, and intelligent communication, it provides reliable technical support for the stable operation of compressed air systems. This article comprehensively analyzes how this transmitter helps enterprises improve system reliability and operational efficiency from the perspectives of core technical advantages, typical application scenarios, and installation and maintenance practices.

Core Technical Highlights: A Perfect Balance of Accuracy, Explosion Protection, and Usability

The Nexisense digital explosion-proof pressure transmitter adopts advanced digital temperature compensation and nonlinear correction algorithms. Even across a wide temperature range of -40°C to 85°C, it maintains measurement accuracy of ±0.25%FS (or better). This ensures stable and reliable output signals during low-temperature winter startups or high-temperature continuous summer operation, effectively avoiding the temperature drift commonly seen in traditional analog transmitters.

One of the most intuitive highlights of this product is its built-in high-definition LCD digital display. On-site operators can directly read real-time pressure values without additional handheld instruments, with selectable units such as bar, psi, and MPa.

Through the panel buttons, users can complete zero adjustment, range configuration, or damping settings within seconds, greatly simplifying inspection and calibration processes. This design is particularly suitable for factories operating 24/7 with continuous production.

Explosion-proof performance is a mandatory requirement for compressed air systems used in hazardous areas. This transmitter uses a high-strength aluminum alloy housing that complies with the Exd II CT6 Gb flameproof standard and achieves an IP67 protection rating.

Even in environments with heavy dust, moisture, corrosion, or flammable gases such as hydrogen and hydrocarbons, the transmitter can operate safely for long periods, significantly reducing explosion risks.

In terms of signal output, the standard configuration is a two-wire 4–20mA current loop, compatible with most PLC and DCS systems. Additionally, the optional HART communication protocol enables remote parameter reading, configuration, and diagnostics.

Using a handheld communicator or host software, users can easily adjust ranges, check device status, and even predict potential faults from the control room, greatly enhancing automation levels and maintenance efficiency.

Key Application Points in Compressed Air Systems

Compressed air systems typically consist of air compressors, air receiver tanks, drying and filtration units, and pipeline distribution networks. The Nexisense digital explosion-proof pressure transmitter provides accurate monitoring at multiple critical points.

1. Compressor Discharge Pressure Monitoring

Installed at the discharge port or after first-stage or second-stage compression, the transmitter captures pressure changes in real time. Excessively high pressure may cause frequent safety valve activation and increased energy consumption, while insufficient pressure affects downstream supply stability.

With accurate data, enterprises can optimize load/unload pressure setpoints and achieve more economical operating modes.

2. Air Receiver Tank Pressure Monitoring

The air receiver tank acts as the system’s “buffer,” and its pressure fluctuations directly affect supply continuity. The transmitter provides stable output and supports high and low alarm thresholds.

In case of abnormal pressure, it can immediately trigger shutdowns or alarms, preventing overpressure or vacuum risks.

3. Pipeline End Pressure Management

In long-distance pipeline networks, end pressure is often lower than the source pressure. Deploying transmitters at multiple points forms a pressure gradient map, helping engineers diagnose leaks, blockages, or pipe diameter design issues.

This data-driven approach guides pipeline optimization and retrofitting.

Practical Value: Triple Optimization of Safety, Efficiency, and Cost

In explosive environments such as petrochemical plants or metallurgical workshops, using certified explosion-proof equipment is mandatory. Nexisense transmitters have passed rigorous flameproof testing, helping enterprises smoothly pass safety inspections and avoid shutdown costs caused by improper equipment selection.

From an efficiency perspective, precise pressure control can reduce unloaded compressor operation time by 10%–30%, directly lowering electricity costs. Compressed air systems typically account for 10%–30% of a factory’s total power consumption.

At the same time, reduced pressure shocks minimize damage to valves, fittings, and seals, extending overall equipment lifespan.

The integration of the HART protocol further reduces maintenance difficulty. Traditional inspections require frequent on-site visits, whereas remote diagnostics now allow technicians to check sensor drift or wiring conditions in advance.

This significantly reduces personnel exposure to hazardous environments and improves intrinsic safety.

Installation and Maintenance Best Practices

During installation, it is recommended to select locations away from strong vibration sources and direct sunlight. Use stainless steel tubing or explosion-proof flexible conduits for process connections, and ensure reliable electrical grounding.

Before commissioning, perform zero calibration and record baseline values after system stabilization for future comparison.

Routine maintenance mainly includes checking display clarity, cleaning dust from the housing, and performing annual accuracy verification, which can be completed using a HART communicator.

Thanks to its solid-state design and high-quality components, the product’s mean time between failures (MTBF) is significantly higher than the industry average, truly delivering “install and use with confidence.”

Frequently Asked Questions (FAQ)

1. What pressure ranges are supported?
Standard ranges cover 0–1 MPa up to 0–100 MPa. Gauge pressure, absolute pressure, and vacuum customization are available to meet most compressed air system requirements.

2. Is the LCD display readable in bright or dark environments?
The high-contrast backlit LCD ensures clear visibility even outdoors or in low-light workshop conditions.

3. Which communication and control systems are supported?
Standard 4–20mA output with optional HART protocol, compatible with mainstream PLCs, DCS systems, and handheld communicators.

4. How long is the explosion-proof certification valid?
The explosion-proof certificate is valid long-term, but periodic re-inspection is recommended according to local safety regulations.

5. How can zero drift after long-term use be handled?
Zero adjustment can be easily performed via panel buttons or HART remote operation, without disassembly.

Conclusion: Choose Reliability, Safeguard Every Moment of Production

As compressed air systems continue to scale up, automate, and become more intelligent, a pressure transmitter that balances accuracy, explosion-proof performance, and on-site usability has become a critical component for ensuring safe and efficient operation.

With its solid technical foundation and practical design, the Nexisense digital explosion-proof pressure transmitter offers a trustworthy solution for users in petrochemical, metallurgical, and manufacturing industries.

It not only enables precise pressure control, effective energy reduction, and minimized safety risks, but also brings tangible convenience and peace of mind to daily operation and maintenance.

If your facility is planning a compressed air system upgrade, expanding monitoring points, or addressing safety compliance requirements, this visible and reliable solution is well worth considering to safeguard your production processes.