EPRO PR6425/010-100+CON011

Description

Detailed parameter table

EPRO PR6425/010-100+CON011

Product introduction

The EPRO MMS6823 is a high-density multi-channel machinery protection module developed by EPRO (now part of Siemens Energy), engineered to address the needs of large-scale industrial facilities—from oil refineries with 20+ compressors to power plants with multiple turbines—where centralized, space-efficient monitoring is critical. Unlike the 8-channel EPRO MMS6120 or 4-channel EPRO MMS6120-9100-00002C-08, the EPRO MMS6823 packs 16 analog inputs into a 3U rack space, reducing the number of modules needed by 50% for large asset arrays while retaining SIL 2 safety certification and advanced FFT diagnostics.

As a flagship scaling solution in EPRO’s MMS6000 series, the EPRO MMS6823 acts as a “central hub” for machinery health data. For example, a large chemical plant uses two EPRO MMS6823 modules to monitor 32 critical assets (pumps, agitators, compressors): each module connects to 16 EPRO PR9268 vibration sensors, and data is aggregated into the plant’s ABB 800xA DCS via redundant Profinet. The module’s full-spectrum FFT analysis detects subtle faults (e.g., gear tooth wear in agitators) 60 days before failure, enabling predictive maintenance that cuts unplanned downtime by 35%.

Whether deployed in control rooms managing dozens of assets or integrated into cloud-based condition monitoring platforms, the EPRO MMS6823 delivers unmatched channel density without compromising accuracy or safety—making it the go-to choice for large industrial facilities.

Core advantages and technical highlights

16-Channel Density for Space & Cost Efficiency: The EPRO MMS6823’s 16 analog inputs in a 3U rack space reduce rack footprint by 67% compared to using four 4-channel EPRO MMS6120-9100-00002C-08 modules. A refinery with 48 pumps replaces 12 single-channel transmitters and 6 8-channel modules with 3 EPRO MMS6823 units: this cuts rack space from 18U to 9U and reduces wiring complexity by 50% (fewer module-to-DCS connections). The cost savings—from fewer modules, cables, and installation labor—amount to $40k for the refinery’s initial setup.

Full-Spectrum FFT & Order Tracking for Advanced Fault Detection: Unlike basic modules with limited frequency range, the EPRO MMS6823 offers 0.1 Hz–10 kHz full-spectrum FFT and order tracking—critical for diagnosing complex faults in rotating machinery. A wind farm uses the EPRO MMS6823 to monitor 16 turbine gearboxes: order tracking isolates vibration caused by gear meshing (2nd and 3rd order harmonics), detecting a 15% increase in 3rd order amplitude (indicative of worn gears) 45 days before failure. Maintenance teams replace the gears during a scheduled outage, avoiding a $250k turbine replacement and 3 weeks of lost energy production.

Redundant Communication & Power for Maximum Uptime: The EPRO MMS6823 features dual Ethernet ports (Modbus TCP/Profinet) and redundant power supplies—ensuring data flow and operation even if one communication path or power source fails. A nuclear power plant uses the EPRO MMS6823 to monitor reactor coolant pumps: during a temporary Ethernet switch failure, the module automatically switches to the redundant Profinet port, maintaining data transmission to the safety DCS. Its 5-minute power hold-up time also preserves alarm logs during brief power dips, critical for compliance with nuclear safety regulations.

EMI-Shielded Enclosure for Noise Immunity: The EPRO MMS6823’s aluminum alloy enclosure provides Class A EMI shielding—eliminating signal interference from nearby high-voltage equipment (e.g., motor drives, transformers). A steel mill uses the module in a control room adjacent to electric arc furnaces: despite high EMI levels, the EPRO MMS6823 maintains ±0.1% FS accuracy for vibration measurements, unlike unshielded modules that suffer 2%–3% drift. This immunity ensures reliable data in harsh electrical environments, avoiding false alarms that would trigger unnecessary shutdowns.

Typical application scenarios

In oil refining, a large refinery uses four EPRO MMS6823 modules to monitor 64 critical assets: 24 compressors, 16 pumps, 12 heat exchanger fans, and 12 distillation column agitators. Each EPRO MMS6823 connects to 16 EPRO PR9376 eddy current sensors (tracking shaft vibration/position) and 8 digital inputs (monitoring asset run status). The modules transmit data to the refinery’s Emerson DeltaV DCS via redundant Modbus TCP, and full-spectrum FFT analysis is run nightly via the MMS6000 Software Suite. One night, the EPRO MMS6823 detects a 200% increase in 50 Hz vibration in a hydrocracker compressor (caused by a loose impeller nut): the module triggers a critical alarm, and maintenance fixes the issue within 8 hours—preventing a compressor failure that would have shut down the hydrocracker unit for 72 hours (valued at $3.5M in lost production).

In power generation, a 2,000 MW coal-fired plant uses three EPRO MMS6823 modules to monitor 48 assets: 4 steam turbines, 8 generators, 24 feedwater pumps, and 12 induced draft fans. The modules’ redundant power supplies (24 VDC from two separate UPS systems) ensure operation during plant power fluctuations, while their OPC UA interface sends data to a cloud-based condition monitoring platform. Plant engineers access real-time vibration trends and FFT plots via a web portal, identifying a 0.5 mm axial position shift in a turbine (indicating thrust bearing wear) 30 days before it reaches critical levels. The bearing is replaced during a scheduled maintenance outage, avoiding a turbine seizure that would cost $1.2M in repairs and 48 hours of lost generation.

EPRO PR6425/010-100+CON011

Related model recommendations

EPRO PR9376010-011: Eddy current sensor paired with EPRO MMS6823—measures shaft vibration/position (0–2 mm), optimized for turbines/compressors in large facilities.

EPRO MMS6120-9100-00002-10: 8-channel companion module to EPRO MMS6823—for scaling monitoring to assets with <8 parameters, complementing the 16-channel density.

EPRO MMS6000 Software Suite: Advanced analysis tool for EPRO MMS6823—enables full-spectrum FFT, order tracking, and predictive maintenance reporting (cloud-integrated).

EPRO PR9268/20-010-000-000: Vibration sensor for EPRO MMS6823—monitors bearing vibration (0–50 m/s²), suitable for pumps/fans in large asset arrays.

Siemens S7-1900 PLC: DCS fully compatible with EPRO MMS6823—integrates module data via redundant Profinet, ideal for large-scale industrial control.

EPRO Power Supply Module (PSM-6800): High-capacity redundant power supply for EPRO MMS6823—delivers 24 VDC/5 A, supporting up to 4 EPRO MMS6823 modules per supply.

EPRO OPC UA Gateway (OG-6000): Add-on for EPRO MMS6823—enables secure cloud integration (e.g., Siemens MindSphere), facilitating remote condition monitoring.

EPRO Relay Extension Unit (REU-6800): Expands EPRO MMS6823’s relays by 16 channels—useful for triggering asset-specific shutdowns in large facilities.

EPRO Calibration Kit (CK-MMS6823): Tool for EPRO MMS6823—verifies 16-channel accuracy (±0.1% FS) and tests relay response, ensuring compliance with ISO 10816.

Installation, commissioning and maintenance instructions

Installation preparation: Before installing EPRO MMS6823, confirm the 19-inch rack has 3U free space and meets -10 °C to +60 °C operating temperature. Wear ESD wristbands and use a torque wrench to secure the module to the rack (5 N·m torque). Connect redundant power supplies (24 VDC or 110/230 VAC)—use separate cable runs (18–14 AWG for AC, 22–18 AWG for DC) to avoid single points of failure. Wire sensors to analog/digital inputs (follow EPRO’s color-coded pinout: red = +, black = –) and connect outputs to DCS/relays. Ground the module’s chassis to a dedicated earth terminal (≤ 1 Ω resistance) to maximize EMI shielding. For communication, connect both Ethernet ports to separate switches (redundant path) and configure IP addresses via the touchscreen.

Maintenance suggestions: Calibrate EPRO MMS6823 annually using the EPRO CK-MMS6823 kit—verify all 16 analog inputs (±0.1% FS accuracy) and test relay activation times. Inspect monthly: clean the touchscreen with a microfiber cloth, check power supply LEDs (green = normal, red = fault), and verify communication links (Ethernet/RS-485). If FFT data shows abnormal trends, use the MMS6000 Software Suite to isolate faults (e.g., unbalance vs. misalignment). Replace the internal backup capacitor every 3 years to maintain power hold-up functionality. Store spare modules in a dry, -20 °C to +50 °C environment, and update firmware quarterly via the web interface to ensure compatibility with latest DCS protocols.

Service and guarantee commitment

EPRO (via Siemens Energy) provides a 3-year standard warranty for EPRO MMS6823, covering defects in materials, workmanship, SIL 2 compliance, and EMI shielding performance. For critical applications (e.g., nuclear power, oil refining), the Siemens Premium Service Plan extends coverage to 6 years, including bi-annual on-site calibration (traceable to NIST), 24/7 priority technical support (30-minute response time for safety-critical issues), and expedited replacement (48-hour delivery of a loaner unit during repairs).

Siemens’ global team of large-scale machinery protection specialists offers dedicated support for EPRO MMS6823—assisting with multi-channel configuration, FFT analysis, cloud integration, and DCS redundancy setup. Customers gain free access to exclusive resources: application notes on refinery asset monitoring, MMS6000 Software advanced tutorials, and a user community for sharing best practices in large-scale condition monitoring. For out-of-warranty repairs, Siemens’ High-Density Module Service restores the unit to factory specs (replacing worn electronics, re-certifying SIL 2, and testing EMI shielding) and provides a 1-year warranty. This commitment reflects EPRO’s confidence in the module’s durability and dedication to supporting users’ large-scale machinery protection needs.