Temperature Sensor Installation Methods Part-2

Temperature Sensor Installation Methods (Part 2) | Room, Outdoor, Strap-On, Wind, Solar & Frost Protection Sensors

Welcome to Insight Control System Blog Page

Introduction

Temperature sensors are essential components in HVAC, ventilation, and building automation systems. Proper installation ensures accurate temperature readings, reliable system control, and long-term equipment protection.

Temperature Sensor Installation Methods (Part 2)

In this 2nd part of the series, we explore additional sensor types including frost protection sensors, room sensors, outdoor sensors, strap-on sensors, wind sensors, and solar sensors. Each section explains sensor functionality, installation guidelines, and real-world applications to support technicians, engineers, and automation professionals.

✅ Frost protection (Air)

Frost protection (Air)

Frost protection for air systems is a safety measure used in HVAC and ventilation equipment to prevent coils, heat exchangers, and air-handling components from freezing during low-temperature conditions.
When outdoor air is extremely cold, moisture inside coils can freeze, causing blockages, reduced airflow, equipment damage, and system shutdowns. Frost protection sensors monitor the temperature of incoming air or coil surfaces and trigger alarms or system adjustments such as opening heating valves, reducing airflow, or shutting down dampers before freezing occurs.
This ensures reliable operation, prevents costly repairs, and maintains safe temperature levels in AHUs, ventilation units, and cold-weather installations.

Method of Installation:

1. Leave a spare capillary loop of 20 cm so that functioning can be tested outside the unit.

2. If the supply ductwork is outdoors or in an unheated space, then both the measuring head and the test loop of the thermostat must be located inside the duct and downstream of the heat exchanger.

3. Install the capillary in the direction of air flow, downstream of the first water-filled heating coil exposed to frost. The capillary must be installed diagonal to the heat-exchanger pipes.

4. When installing on "drawer"-type units, ensure that the electrical connections are long enough to enable the units to be pulled out.

5. If a water-filled cooling coil is installed upstream of the first heat exchanger, then the frost protection thermostat must be installed upstream of the cooling coil, in the direction of the air flow.

6. With large heat exchangers, or with heat exchangers comprising several units, more than one frost thermostat must be installed (minimum 1 per unit).

7. Do not bend the capillary too tightly (radius of bend must not be less than 50 mm).

8. When routing the capillary through internal or external walls, for example, always use a lined and insulated conduit.

9. Where the capillary passes through sheet metal, protect it with a rubber grommet (to prevent shearing).

10. Any unused length of capillary should be neatly rolled.

11. Use spacing clips to maintain a 50 mm clearance.

12. Install the sensor element using capillary supports.

✅ Room sensors

Room sensors

Room temperature sensors are devices used to measure the indoor ambient temperature for accurate monitoring and control of HVAC and building automation systems.
They help maintain comfortable indoor environments by sending real-time temperature data to controllers, thermostats, or automation devices. These sensors are typically wall-mounted and designed to blend with interior spaces.
Room temperature sensors improve energy efficiency, enhance comfort, and support precise climate control by ensuring heating, cooling, and ventilation systems operate based on actual room conditions.

Method of Installation:

1. Install sensors at a height of 1.5 m in occupied spaces, and at least 50 cm from the adjacent wall.

2. Do not install where sensor will be exposed to direct solar radiation.

3. Always use a thermally-insulated backing when fitting to solid walls (steel, concrete etc.)

4. Do not install on external walls.

5. Avoid recesses (e.g. shelving) and alcoves.

6. Do not install near lamps or above radiators.

7. Avoid chimney walls.

8. Do not install directly adjacent to doors.

9. Do not install behind curtains.

10. Do not fit to walls concealing hot-water pipes.

11. Seal gaps between cable/plastic tubing and conduit. Otherwise measurements will be falsified by incorrect circulation of the air.

Applications

homes, offices, hospitals, data centers, schools, and commercial buildings.

✅ Outdoor sensors

Outdoor sensors

Outdoor temperature sensors are devices designed to accurately measure the ambient temperature in external environments.
Built with weather-resistant materials, these sensors can withstand sunlight, rain, humidity, dust, and extreme temperatures.
Outdoor temperature sensors provide real-time temperature data that helps control heating, cooling, ventilation, and environmental systems more efficiently.
Their durable construction, stable performance, and ability to deliver precise readings in harsh conditions make them essential for reliable temperature monitoring outdoors.

Method of Installation:

1. The system design determines the façades (N,S,E,W) on which the sensor should be located.

2. Do not expose to direct solar radiation.

3. Do not install on façades affected by significant rising heat.

Do not install on façades warmed by solar radiation.

4. Avoid chimney walls.

5. Do not install under eaves.

6. Do not install above windows.

7. Do not install above ventilation shafts.

8. Seal gaps between cable/plastic tubing and conduit.

Otherwise measurements will be falsified by incorrect circulation of the air.

9. Do not paint the sensor.

10. Ensure accessibility (for inspection/testing).

Outside Cable sensors

The same rules apply to outdoor cable sensors as to any other outdoor sensors.
The cable should be connected from below (to protect it from dripping water).

Applications

HVAC systems, building automation, weather stations, smart homes, agriculture, and industrial monitoring.

✅ Surface-mounted strap-on sensors

Surface-mounted strap-on sensors

Surface-mounted strap-on sensors are temperature sensors designed to measure the temperature of pipes or surfaces without direct insertion into the fluid.
They are attached externally using a strap, clamp, or band, making installation quick, safe, and non-invasive.
They provide reliable temperature readings for control systems, even when cutting pipes or inserting probes is not possible. Surface-mounted strap-on sensors are highly versatile, easy to maintain, and ideal for retrofit projects or situations where system shutdown is not allowed.

Method of Installation:

1. The surface must be clean and smooth (remove paint). The sensor must be fixed firmly to the surface. Use heat-conductive compound.

Important: Avoid exposure to external heat gains.

2. Consider cable length when fitting to windows which can be opened! The sensor must be fixed directly to the window surface.

3. The sensor must be fixed directly to the surface. Use heat-conductive compound.

4. When mixing water at different temperatures, always maintain an adequate distance between the mixing point and the sensor (to take account of stratification).

Applications

HVAC systems, building automation, heating loops, chilled water lines, and energy monitoring applications.

✅ Wind sensors

Wind sensors

Wind sensors are devices used to measure wind speed and direction or both. That help monitor environmental conditions and provide essential data for safety, control, and automation systems.
Common types include anemometers, wind vanes, and ultrasonic wind sensors. By providing accurate real-time wind information, wind sensors help optimize system performance, protect equipment, and support decision-making in various outdoor and industrial environments.

Method of Installation

Install on the façades exposed to the main wind direction. Make sure the sensor is accessible (for inspection/testing).
Do not install under eaves.
Do not install in recesses.

Applications

weather stations, HVAC systems, building automation, renewable energy sites (like wind turbines), marine applications, and industrial safety monitoring.

✅ Solar sensors

Solar sensors

Solar sensors are intelligent devices that detect and measure sunlight levels for use in automation, monitoring, and energy management systems. They work by converting sunlight into electrical signals, allowing controllers to understand solar intensity, brightness, and daylight availability.
Solar sensors help optimize energy usage, improve system efficiency, and support renewable energy operations. Because they rely on natural sunlight, they are highly efficient, low-maintenance, and suitable for long-term outdoor applications.

Method of Installation

1. Install solar sensors on the façades behind which the associated control system is operative.

2. Install the sensor where it is easily accessible (for inspection/testing).

3. Avoid shade (from trees or neighbouring houses etc.)

Applications

solar power plants, HVAC daylight control, smart lighting, agriculture, shading systems, and weather monitoring.

🏁 Conclusion

This second part of the Temperature Sensor Installation Series explored room sensors, outdoor sensors, strap-on sensors, frost protection sensors, wind sensors, and solar sensors. Proper installation of each sensor type ensures accurate temperature measurement, reliable HVAC operation, and efficient building automation performance.

In the next part, we will continue with more specialized sensor types and installation guidelines to support technicians, engineers, and students in mastering temperature measurement methods.

Stay connected with Insight Control System for more technical and educational automation content.💡