EPRO PR9268202-100

Description

Detailed parameter table

EPRO PR9268202-100

Product introduction

The EPRO PR9268202-100 is a high-performance absolute vibration sensor developed by EPRO (now part of Siemens Energy), engineered to monitor bearing and structural vibration in rotating machinery—from industrial pumps in water treatment plants to compressors in oil refineries—where early detection of bearing wear or misalignment is critical to avoiding unplanned downtime. Unlike eddy current sensors (e.g., EPRO PR9376010-011) that focus on shaft vibration, the EPRO PR9268202-100 measures absolute vibration directly at the bearing housing, capturing real-world stress on the component most prone to failure.

As a key sensing component in EPRO’s machinery protection ecosystem, the EPRO PR9268202-100 delivers plug-and-play functionality with EPRO’s monitoring systems. For example, a large manufacturing plant uses 32 EPRO PR9268202-100 sensors to monitor the bearings of 16 conveyor motors: each sensor connects to an EPRO MMS6823 module, which aggregates data and runs trend analysis. The sensor’s 1 Hz–10 kHz frequency range detects both low-frequency unbalance (1–10 Hz) and high-frequency bearing faults (1–10 kHz), enabling maintenance teams to address issues before they escalate to motor failure.

Whether deployed in dusty mining facilities, humid food processing plants, or corrosive chemical refineries, the EPRO PR9268202-100 combines industrial ruggedness (IP67, wide temperature range) with precise measurement—making it the preferred choice for teams needing to protect critical rotating equipment at the bearing level.

Core advantages and technical highlights

Wide Frequency Range for Comprehensive Fault Detection: The EPRO PR9268202-100’s 1 Hz–10 kHz frequency range covers all key vibration signatures of rotating machinery—from low-frequency unbalance (1–5 Hz) to high-frequency bearing inner/outer race faults (2–10 kHz). A chemical plant uses the EPRO PR9268202-100 to monitor a reactor agitator: it detects a 3 kHz vibration spike (indicative of bearing outer race wear) 40 days before the agitator would fail. Maintenance replaces the bearing during a scheduled shutdown, avoiding a 72-hour production outage (valued at $500k). This range eliminates the need for multiple sensors (e.g., one for low frequency, one for high frequency), cutting hardware costs by 50%.

IP67 Ruggedness for Harsh Environments: The EPRO PR9268202-100’s IP67 rating and oil-resistant PVC cable withstand dust, water jets, and chemical exposure—critical for industries like mining and food processing. A mining operation uses the sensor to monitor a crusher motor’s bearing: the sensor resists coal dust and periodic washdowns, while its -40 °C low-temperature tolerance ensures reliable operation in underground mines. Unlike IP65 sensors that fail within 12 months, the EPRO PR9268202-100 operates reliably for 5+ years, reducing replacement costs by 60%.

Built-In Signal Conditioning for Simplified Integration: The EPRO PR9268202-100 includes on-board signal conditioning, converting raw piezoelectric signals to a standardized 4–20 mA output—eliminating the need for external amplifiers. A water treatment plant installs 24 EPRO PR9268202-100 sensors to monitor pump bearings: the built-in conditioning reduces wiring complexity (one cable per sensor vs. two for unconditioned sensors) and cuts installation time by 30%. The 4–20 mA output also ensures compatibility with legacy DCS systems, avoiding the need for costly protocol converters.

Direct Bearing Housing Mounting for Accurate Data: The EPRO PR9268202-100’s M8 threaded stud enables direct mounting to bearing housings—ensuring it captures vibration at the source, unlike sensors mounted on structural frames (which suffer signal attenuation). A power plant uses the sensor to monitor a feedwater pump’s bearing: direct mounting ensures the sensor detects a 0.5 mm/s increase in vibration (caused by lubricant loss) 25 days earlier than frame-mounted sensors. This early detection allows maintenance to add lubricant during a shift change, extending bearing life by 18 months.

Typical application scenarios

In manufacturing, an automotive assembly plant uses 48 EPRO PR9268202-100 sensors to monitor the bearings of robotic arms, conveyor motors, and press machines. Each sensor is mounted directly to the bearing housing via its M8 stud, and data is sent to two EPRO MMS6823 modules (24 sensors per module). The modules transmit vibration trends to the plant’s Siemens S7-1900 PLC, which triggers alerts if velocity exceeds 15 mm/s. During a morning shift, the EPRO PR9268202-100 on a robotic arm bearing detects a 18 mm/s vibration spike (caused by a worn ball bearing): the PLC stops the arm, and maintenance replaces the bearing within 2 hours—avoiding a 4-hour production line outage (valued at $200k) and preventing damage to expensive robotic components.

In oil & gas, a pipeline compression station uses 16 EPRO PR9268202-100 sensors to monitor the bearings of 8 natural gas compressors. The sensor’s IP67 rating withstands saltwater spray and humidity, while its 1 Hz–10 kHz frequency range detects both compressor unbalance (2 Hz) and bearing faults (5 kHz). Data from the EPRO PR9268202-100 feeds into an EPRO MMS6823 module, which runs nightly FFT analysis. One night, the system detects a 3 kHz vibration increase in a compressor bearing: maintenance replaces the bearing during a scheduled shutdown, avoiding a compressor failure that would have halted gas flow to 100,000 households and incurred a $1M fine from the pipeline operator.

EPRO PR9268202-100

Related model recommendations

EPRO MMS6823: High-density module compatible with EPRO PR9268202-100—aggregates data from 16 sensors, runs FFT analysis, and triggers alarms for large facilities (e.g., automotive plants).

EPRO PR9376010-011: Eddy current sensor complementary to EPRO PR9268202-100—measures shaft vibration/position, creating a complete shaft-bearing monitoring solution.

EPRO EK-9268: Cable extension kit for EPRO PR9268202-100—extends cable from 5 m to 15 m, ideal for large machinery (e.g., industrial presses) where sensors are mounted far from control panels.

EPRO CT-9268: Calibration kit for EPRO PR9268202-100—verifies velocity accuracy (±2% FS) and frequency response, traceable to NIST.

Siemens S7-1900 PLC: DCS fully compatible with EPRO PR9268202-100—receives 4–20 mA vibration data, ideal for large-scale industrial control.

EPRO FieldCare: Device management software for EPRO PR9268202-100—enables remote configuration, diagnostic checks, and calibration scheduling.

EPRO PR9268202-200: High-temperature variant of EPRO PR9268202-100—operating temp: -40 °C to +125 °C, ideal for high-heat applications (e.g., furnace fans).

EPRO Mounting Kit (MK-9268): Accessory for EPRO PR9268202-100—includes M8 locknuts, washers, and adhesive pads for secure mounting on curved bearing housings.

EPRO Relay Extension Unit (REU-6800): Expands EPRO MMS6823’s relays by 16 channels—useful for triggering asset-specific shutdowns based on EPRO PR9268202-100 vibration alerts.

Installation, commissioning and maintenance instructions

Installation preparation: Before installing EPRO PR9268202-100, confirm the bearing housing is clean and flat (Ra ≤ 6.3 μm surface finish). Wear ESD wristbands and use the sensor’s M8 threaded stud to mount it directly to the bearing housing—ensure the sensor is aligned perpendicular to the vibration direction (typically radial for bearings). Route the 5 m shielded cable away from high-voltage equipment (min 300 mm separation) to avoid EMI, and connect to the DCS/PLC or EPRO MMS6823 module (red = +24 VDC, black = signal return, green = shield). Ground the cable shield at the module end (per industrial grounding standards) to minimize noise.

Maintenance suggestions: Calibrate EPRO PR9268202-100 annually using the EPRO CT-9268 kit—verify velocity accuracy (±2% FS) and frequency response (1 Hz–10 kHz). Inspect monthly: Clean the sensor body with a lint-free cloth (avoid abrasives); check the cable jacket for oil/chemical damage (replace if cracked); verify the 4–20 mA output with a multimeter (e.g., 4 mA = 0 mm/s, 20 mA = 20 mm/s). If the sensor shows erratic readings, first check the cable connection—loose wires are the top cause of signal issues. Store spare sensors in a dry, -20 °C to +50 °C environment, and avoid exposing the unit to direct sunlight or extreme temperatures.

Service and guarantee commitment

EPRO (via Siemens Energy) provides a 2.5-year standard warranty for EPRO PR9268202-100, covering defects in materials, workmanship, and measurement accuracy. For critical applications (e.g., oil & gas pipelines, power plants), the Siemens Premium Service Plan extends coverage to 5 years, including annual on-site calibration (traceable to NIST), 24/7 priority technical support (1-hour response time), and expedited replacement (48-hour delivery of a loaner sensor during repairs).

Siemens’ global team of machinery protection specialists offers dedicated support for EPRO PR9268202-100—assisting with mounting alignment, DCS integration, and fault troubleshooting. Customers gain free access to resources: application notes on bearing fault detection, calibration tutorials, and a user community for sharing best practices. For out-of-warranty repairs, Siemens’ Sensor Service restores the EPRO PR9268202-100 to factory specs (replacing worn piezoelectric elements, re-calibrating output) and provides a 6-month warranty. This commitment reflects EPRO’s confidence in the sensor’s durability and dedication to protecting users’ critical rotating machinery.

If you need to refine specific sections—such as adding use cases for renewable energy (e.g., wind turbine gearbox bearings) or adjusting technical parameters to match regional standards (e.g., CSA for North American facilities)—feel free to share additional details. I can also expand on compatibility with non-EPRO monitoring systems (e.g., Bently Nevada 3500) or include more granular guidance on mounting alignment for different bearing types (e.g., ball vs. roller bearings).