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In the demanding world of industrial engineering, the EXNAL 8859 stands out as a pinnacle of sensor technology. Manufactured by Trafag AG, a Swiss-based leader in high-quality instrumentation, this device is specifically engineered to measure pressure in challenging environments. As an Ex-rated submersible pressure transmitter, it is designed to operate safely in hazardous locations, including those with explosive gas or dust atmospheres. By leveraging piezoresistive technology, it offers exceptional accuracy and reliability. Industries ranging from water treatment to oil and gas exploration rely on the EXNAL 8859 to provide real-time, precise data for critical monitoring, ensuring operational safety and efficiency across the globe.
| Feature | Details |
| Product | EXNAL 8859 |
| Manufacturer | Trafag AG |
| Type | Ex Submersible Pressure Transmitter |
| Technology | Piezoresistive |
| Key Applications | Oil & Gas, Water Treatment, Mining, Shipbuilding |
| Certification | ATEX, IECEx, DNV |
Engineering Excellence of the EXNAL 8859
The engineering behind the EXNAL 8859 represents years of innovation in sensor design. By utilizing a piezoresistive measuring principle, the transmitter captures fluid pressure with high sensitivity and minimal drift over time. The device is built without media-contacting O-rings, which significantly enhances its durability and long-term stability. Furthermore, the housing is constructed from high-corrosion-resistant materials, making it ideal for continuous submersion. Every aspect of the design, from the electrical connectivity options to the robust casing, reflects a commitment to quality that ensures the EXNAL 8859 performs reliably even under the most extreme industrial conditions found in modern manufacturing plants.
Intrinsic Safety in Hazardous Zones
A primary reason for the success of the EXNAL 8859 is its certification for use in hazardous areas. Rated for Ex Zone 0, 1, and 2, as well as dust zones 20, 21, and 22, it is fundamentally built for safety. The device is designed to be intrinsically safe, preventing the ignition of explosive atmospheres. By adhering to international standards such as ATEX and IECEx, the EXNAL 8859 provides peace of mind to operators working in high-risk environments. This level of safety compliance is essential for any modern industrial setup where preventing accidents is the highest priority for site engineers.
Versatile Industrial Applications
The flexibility of the EXNAL 8859 allows it to be used across a vast array of industrial sectors. In the water and wastewater industry, it is frequently used to monitor tank levels, ensuring proper fluid management. In the oil and gas sector, its ability to withstand corrosive environments makes it perfect for tracking fuel or chemical storage. Furthermore, the mining and shipbuilding industries utilize the EXNAL 8859 for its ruggedness and ability to handle vibration. Its wide measuring range, from 100 mbar up to 25 bar, ensures that it can adapt to almost any liquid-level monitoring requirement.
Piezoresistive Sensing Technology
At the heart of the EXNAL 8859 lies advanced piezoresistive technology. This method involves a semiconductor sensor that changes its electrical resistance when subjected to pressure, providing a very precise output signal. Compared to older mechanical sensors, the piezoresistive approach used in the EXNAL 8859 offers better accuracy, faster response times, and lower hysteresis. This technological superiority is what allows the device to achieve a high degree of precision, making it an excellent choice for critical processes that require consistent and stable data readings to maintain safe and efficient operational workflows throughout the entire production lifecycle.
Durability and Harsh Environment Performance
Industrial environments can be incredibly harsh, often exposing equipment to temperature swings, moisture, and chemical exposure. The EXNAL 8859 is built to IP68 protection standards, allowing for continuous submersion in water or other liquids. The optional use of titanium for the sensor and housing material provides exceptional resistance to corrosive substances, making the EXNAL 8859 a top choice for marine applications. With its ability to handle significant shock and vibration, this transmitter is not just a sensor but a durable component designed to last for years, reducing the need for frequent maintenance and equipment replacement costs.
Precision Measurement and Accuracy
Accuracy is a non-negotiable requirement in industrial monitoring, and the EXNAL 8859 delivers impressive performance. With an accuracy of up to 0.1% FS (Full Scale) in certain configurations, it minimizes measurement errors that could lead to operational inefficiencies. The device features excellent repeatability and long-term stability, meaning that calibration requirements are kept to a minimum. Whether monitoring the exact height of a column of water in a reservoir or the pressure of chemicals in a pressurized tank, the EXNAL 8859 provides consistent, reliable data, allowing plant managers to make informed decisions based on highly accurate, real-time measurements.
Simplified Installation and Maintenance
Trafag AG designed the EXNAL 8859 with the end-user in mind, ensuring that installation and maintenance are as straightforward as possible. The device arrives pre-configured for its intended environment, and the cable options—available in PUR or FEP—allow for easy integration into existing wiring systems. Because there are no internal O-rings to wear out or replace, the maintenance cycle is significantly extended. Should the need arise, the design of the EXNAL 8859 allows for quick inspection or adjustment. This ease of use saves companies valuable time and resources, allowing personnel to focus on other critical maintenance tasks.
Global Compliance and Certification Standards
In a global market, products must meet various regional and international standards. The EXNAL 8859 complies with major global benchmarks, including ATEX for Europe and IECEx for international markets. It also holds DNV approval, which is critical for maritime and offshore applications. These certifications are not just labels; they are proof that the EXNAL 8859 has undergone rigorous testing to ensure it meets strict safety and performance requirements. By adhering to these global norms, the device is recognized and trusted by industries around the world, from European water treatment facilities to offshore oil rigs in Asia.
Optimized Output Signals for Data Integration
The EXNAL 8859 utilizes a standard 4-20 mA output signal, which is the industry standard for analog instrumentation. This choice ensures full compatibility with a wide range of Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), and monitoring displays. The 4-20 mA signal is known for its robustness against electrical noise, which is common in large industrial facilities. By integrating the EXNAL 8859 into existing control loops, companies can easily upgrade their monitoring capabilities without the need for complex, costly overhauls of their current electrical and data management infrastructure, ensuring a smooth and efficient transition.
Customizable Options for Specialized Needs
While the standard EXNAL 8859 is highly capable, Trafag AG offers customizable features to meet specific operational demands. For instance, customers can choose between different pressure connection styles, such as open or closed designs, to better fit their specific vessels. The option for chemical-resistant materials like titanium allows the EXNAL 8859 to be used in processes where standard stainless steel might fail. Furthermore, temperature classes like T4 or T6 can be selected to match the specific thermal requirements of the hazardous zone. This high degree of customizability ensures that the device is always perfectly suited for the application.
Role in Modern Fluid Management
Modern fluid management relies heavily on reliable sensors, and the EXNAL 8859 is central to this effort. By providing constant monitoring, the device helps prevent spills, overflows, and inventory shortages. In an era where resource conservation and waste prevention are critical, the precision of the EXNAL 8859 is invaluable. It enables automated responses to tank levels, allowing for more efficient pump operation and reduced energy consumption. As industries move toward smarter, more automated systems, the EXNAL 8859 provides the essential data foundation needed to support these advanced management processes and improve overall industrial sustainability across various sectors.
Supporting Safety in Underground Mining
Underground mining represents one of the most hazardous work environments, and the EXNAL 8859 is specifically rated for these conditions. Its rugged construction allows it to withstand the high humidity and confined spaces typical of mines. Furthermore, its explosion-proof rating is vital in areas where combustible dust or methane gas might be present. The EXNAL 8859 helps in monitoring water drainage systems in mines, preventing flooding and ensuring that personnel can work in a safe, controlled environment. Its reliability in such high-stakes conditions is a testament to the robust engineering and high-quality standards maintained by its manufacturers.
Maritime and Shipbuilding Advantages
In the maritime industry, equipment must withstand the constant exposure to saltwater and the mechanical stresses of a moving vessel. The EXNAL 8859, with its high corrosion resistance and DNV approval, is a preferred choice for shipbuilders. Whether used for ballast tank monitoring or monitoring levels in freshwater tanks, the EXNAL 8859 performs consistently despite the challenging environment. Its compact design also makes it easy to install in the limited spaces found on modern ships. By providing durable and accurate measurements, it helps maintain the stability and efficiency of maritime vessels throughout their global operations.
The Importance of Lightning Protection
In certain industrial setups, electrical surges caused by lightning can pose a threat to electronic instruments. The EXNAL 8859 offers optional integrated lightning protection (IEC 61000-4-5), which can withstand surges of up to 10kA. This feature is crucial for outdoor installations, such as large reservoir tanks or remote pipelines where lightning strikes are a potential hazard. By protecting the sensor’s electronics from electrical spikes, this feature extends the lifespan of the EXNAL 8859 and ensures that it remains operational even during severe weather conditions, which is essential for remote or unmanned industrial sites.
Environmental and Temperature Adaptability
The EXNAL 8859 is designed to function across a broad range of temperatures, typically from -5°C to +80°C. This wide operational window ensures that the device remains accurate and functional regardless of whether it is installed in a cold water storage tank or a process line with higher ambient heat. The temperature compensation built into the device ensures that fluctuations in the environment do not lead to significant errors in pressure measurement. This level of adaptability makes the EXNAL 8859 a versatile tool that can be deployed across various climates and industrial processes with consistent results.
Reliability in Long-Term Deployment
For many industrial operators, the cost of replacing a sensor in a difficult-to-access location is high. Therefore, the long-term reliability of the EXNAL 8859 is a significant financial benefit. With a low long-term drift of less than 0.2% per year, the device requires less frequent calibration and maintenance than many competing products. Its robust, sealed construction prevents moisture ingress, which is the leading cause of sensor failure in submersible applications. By choosing the EXNAL 8859, businesses are making a long-term investment in a sensor that is designed to provide years of dependable service in the most demanding conditions.
Strategic Benefits of Data-Driven Monitoring
The data collected by the EXNAL 8859 is more than just a pressure reading; it is a vital business intelligence tool. With real-time level information, companies can optimize their supply chain, predict maintenance needs, and reduce idle time. Automated monitoring enabled by the EXNAL 8859 allows for predictive analytics, where software can detect patterns in usage and alert operators to potential issues before they become critical failures. This transition from reactive to proactive monitoring is a key benefit of incorporating high-precision sensors like the EXNAL 8859 into the modern digital factory and global supply chain ecosystem.
Professional Support and Technical Documentation
Trafag AG supports the EXNAL 8859 with comprehensive technical documentation and professional customer service. Operators have access to detailed datasheets, declaration of conformity documents, and mounting instructions in multiple languages. This wealth of information ensures that installation teams have everything they need to correctly set up and calibrate the device for optimal performance. Furthermore, professional support teams are available to provide guidance on specific application challenges or configuration needs. This level of service ensures that users are never left on their own when integrating the EXNAL 8859 into their complex and often sensitive industrial processes.
Future Outlook for Sensor Technology
As we look toward the future, sensors like the EXNAL 8859 will play an even greater role in the “Industrial Internet of Things” (IIoT). While the current model excels in traditional analog control, the continued evolution of sensor technology suggests that future versions may incorporate even more advanced diagnostic capabilities. The core strengths of the EXNAL 8859—its reliability, safety, and precision—will remain essential as industries continue to digitize their operations. By maintaining high standards for these fundamental characteristics, the EXNAL 8859 remains a vital component that supports the ongoing advancement of safe and efficient industrial practices worldwide.
Summary of Impact on Industrial Safety
To conclude, the EXNAL 8859 is an essential piece of technology for any industry that prioritizes safety, accuracy, and long-term durability. By effectively managing pressure measurement in hazardous and challenging environments, it plays a critical role in preventing accidents and optimizing operations. Whether in mining, oil and gas, or water treatment, the reliability of the EXNAL 8859 ensures that critical systems run smoothly.
FAQs
- What is the primary purpose of the EXNAL 8859?
- It is an Ex-rated submersible pressure transmitter designed to measure fluid levels and pressure accurately in hazardous or explosive environments.
- Is the EXNAL 8859 safe to use in explosive gas atmospheres?
- Yes, it is intrinsically safe and certified for use in Ex Zones 0, 1, and 2, as well as dust zones.
- What makes the EXNAL 8859 durable for long-term submersion?
- It features an IP68-rated, corrosion-resistant housing and lacks media-contacting O-rings, which prevents common causes of sensor failure.
- Can the EXNAL 8859 be used in marine environments?
- Yes, with its DNV approval and options for titanium construction, it is well-suited for shipbuilding and offshore maritime applications.
- What type of output signal does the EXNAL 8859 provide?
- It uses the industry-standard 4-20 mA output signal, ensuring easy integration with PLCs and other industrial monitoring systems.
