In industries such as oil & gas, hydrogen processing, chemical manufacturing, and pharmaceuticals, accurate pressure measurement is essential, but safety is paramount. Hazardous areas, where explosive gases or dust may be present, demand instrumentation that delivers both precision and strict compliance with intrinsic safety standards.
Until recently, accessing digital pressure data in these environments using ESI-USB software was not possible. Traditional approaches relied on standalone instruments or complex data acquisition systems, limiting flexibility. The introduction of the ESI-USB-PLUS has transformed this landscape, opening a new and accessible route to digital pressure measurement in hazardous applications.
When combined with an intrinsically safe pressure transmitter and a suitable Zener barrier, the ESI-USB-PLUS provides a reliable solution for capturing and analysing pressure data safely.
At its core, the ESI-USB-PLUS is a versatile analogue-to-digital interface that connects traditional analogue sensors directly to a computer via USB. Supporting both 4–20 mA and 0–10 V signals, it enables a wide range of transmitters and process instruments to be monitored, logged, and analysed without complex hardware. An additional input channel for a PT100 temperature sensor allows simultaneous pressure and temperature monitoring within one compact device. With plug-and-play connectivity and automatic device detection, users can quickly turn a laptop or PC into a complete measurement station.
Enabling Hazardous Area Measurement
Although the ESI-USB-PLUS is installed in the safe area, it integrates seamlessly into hazardous applications using an intrinsically safe pressure transmitter in the hazardous zone, connected via a Zener barrier.
The Zener barrier acts as a protective interface, limiting voltage and current entering the hazardous area to prevent ignition. This ensures that, even under fault conditions, energy levels remain below those required to ignite explosive atmospheres. This intrinsic safety method is widely used in low-power instrumentation because it prevents ignition rather than containing it.
A typical setup includes the GS4200EX intrinsically safe pressure transmitter. Installed in the hazardous area, it delivers accurate measurement and outputs a stable 4–20 mA signal suitable for safe transmission through a Zener barrier.
In operation, the GS4200EX measures pressure in the hazardous zone and transmits its signal safely into the safe area, where it connects to the ESI-USB-PLUS. The interface converts this analogue signal into digital data for PC-based analysis. This approach allows safe access to high-quality measurement data without placing non-certified electronics in hazardous zones, while also eliminating the need for bulky explosion-proof enclosures.
Powerful Data Acquisition with ESI-USB Software
Paired with ESI-USB software, the ESI-USB-PLUS transforms raw signals into meaningful insights, enabling analogue transmitters to be used digitally in hazardous applications.
The software automatically detects the device and streams live data for real-time monitoring. Users can view data graphically or in tables, select engineering units, and adjust scales. High-resolution sampling captures dynamic pressure events with precision.
Advanced features include data logging, export to Excel or PDF, and custom report generation. Alarm settings, automated test sequences, and multi-channel viewing for up to 16 sensors make it ideal for laboratory testing, field diagnostics, and process validation.
A Practical Solution for Modern Industry
The combination of an intrinsically safe transmitter, Zener barrier, and ESI-USB-PLUS creates a streamlined bridge between hazardous environments and digital analysis tools.
Compact, easy to deploy, and highly adaptable, the ESI-USB-PLUS simplifies complex measurement challenges into a straightforward, plug-and-play solution—bringing clarity, control, and accessibility to pressure measurement in demanding hazardous environments.
