Nexisense Differential Pressure Sensor Types and Comprehensive Analysis

Definition of Differential Pressure Sensor

A differential pressure sensor is an industrial detection device used to measure the difference between two pressures. By sensing the pressure difference between the high-pressure and low-pressure ports, it converts the physical quantity into a standard electrical signal output to achieve precise monitoring.

Differential pressure sensors are commonly used to monitor pressure differences before and after pipelines, equipment, or components, and are widely applied in HVAC systems, industrial control, medical equipment, and hydraulic systems.

According to the measured medium, range, structural form, and material, differential pressure sensors can be divided into multiple models and types to meet the requirements of different operating conditions.

Working Principle of Differential Pressure Sensors

The core of a differential pressure sensor is a diaphragm-type or chip-type piezoresistive element. Its working principle mainly includes:

Diaphragm Deformation Principle

The high-pressure and low-pressure ports act on both sides of the diaphragm, causing slight deformation. The diaphragm displacement is converted into an electrical signal through strain gauges, silicon chips, or capacitive sensing elements.

Signal Processing

The electrical signal is internally amplified, filtered, and linearized, then output as a standard industrial signal such as 4-20mA, 0-10V, or RS485 digital signal.

Pressure Measurement Conversion

According to different application requirements, the differential pressure sensor can convert the measured pressure difference into secondary measurement data such as flow rate, liquid level, or pressure, providing real-time feedback for control systems.

Analysis of Common Differential Pressure Sensor Models

CCY11 Differential Pressure Sensor

Applicable media: Gas and compressed air
Interface type: Barbed fitting (Φ8mm tube) or quick connector (Φ6mm tube)
Diaphragm material: Silicon chip
Housing material: LY12 aluminum (barbed fitting) or nickel-plated copper (quick connector)
Features: Suitable for gas differential pressure measurement, easy installation, stable signal transmission

CCY15 Differential Pressure Sensor

Applicable media: Liquids, gases, and process industries
Wiring method: Hirschmann connector, fast and reliable installation
Diaphragm material: 316L stainless steel
Housing material: 304 stainless steel
Static pressure capacity: Up to 25 times the differential pressure range
Features: Suitable for high-precision measurement of liquids and gases, resistant to high static pressure, stable and reliable signal output

CCY18 Differential Pressure Sensor

Applicable media: Gas and compressed air
Installation method: Wall-mounted or DIN-rail mounted
Diaphragm material: Silicon chip
Housing material: PVC engineering plastic
Interface type: Φ6 barbed fitting, copper material
Features: Suitable for industrial gas differential pressure measurement, lightweight structure, adaptable to various installation scenarios

Different models of differential pressure sensors have different measurement ranges. Users can select appropriate products based on operating conditions. Parameters can be customized for special applications to meet specific requirements.

Structural Composition of Differential Pressure Sensors

Differential pressure sensors mainly consist of the following components:

• Diaphragm or piezoresistive chip: senses pressure difference and generates micro-deformation

• Signal conversion and processing unit: amplification, filtering, and linearization

• Housing and interfaces: protect internal components and provide connection methods

• Output ports: 4-20mA, 0-10V, or RS485 digital signals

Some industrial models are also equipped with corrosion-resistant, waterproof, and dustproof structures to adapt to complex field environments.

Technical Advantages

High Accuracy and Stability

• Accurate differential pressure measurement with controllable error within 0.1%–0.5% FS

• Strong stability, suitable for long-term continuous operation

Wide Media Compatibility

• Suitable for gases, liquids, and industrial fluids

• Optional materials such as silicon chip, 316L stainless steel, and PVC

Multiple Output Options and Compatibility

• Analog outputs: 4-20mA, 0-10V

• Digital output: RS485 (Modbus RTU)

• Compatible with DCS, PLC, and industrial IoT platforms

Flexible Installation

• Barbed fittings, quick connectors, DIN-rail mounting, or wall mounting

• Adaptable to different installation requirements

Application Scenarios

• Industrial automation: pipeline flow monitoring and differential pressure control

• HVAC systems: air duct and air-conditioning differential pressure monitoring

• Medical equipment: ventilators, airflow regulation, and negative pressure environment monitoring

• Process industries: pressure monitoring and alarm of liquid and gas pipelines

• Environmental monitoring: cleanrooms, warehouses, laboratories differential pressure control

Measurement Methods

• Direct hose connection: high and low pressure ports connected directly to measuring points without brackets

• Transmitter measurement modes:

• High-pressure port measured, low-pressure port vented to atmosphere → positive differential pressure measurement

• Low-pressure port measured, high-pressure port vented to atmosphere → negative differential pressure measurement

• Gradual pressurization and depressurization to avoid instantaneous high pressure damaging the sensor

Installation and Maintenance Notes

• Ensure the equipment is depressurized and powered off before installation

• Select environments with minimal temperature gradients

• Keep high and low pressure interfaces level to avoid measurement errors

• Media compatibility: avoid corrosive or incompatible media contacting the diaphragm

• Lightning and overvoltage protection: add protective devices between power supply and sensor in harsh environments

• Cabling requirements: as a weak-current device, wiring should be separated from strong current lines and comply with GB/T50312-2016

• Do not disassemble the diaphragm without authorization to prevent sensor damage

Technical Parameters Reference

Frequently Asked Questions (FAQ)

Q: Can differential pressure sensors operate continuously for long periods?
A: Yes. Industrial-grade design supports 24-hour online operation, provided pressure and power supply remain within allowable ranges.

Q: What media can differential pressure sensors measure?
A: Gases, compressed air, liquids, and most industrial process media, provided compatibility with the diaphragm material is ensured.

Q: Does installation location significantly affect measurement accuracy?
A: Yes. It is recommended to choose areas with stable temperature and minimal pressure gradients, keep interfaces level, and stay away from high-voltage or strong electromagnetic interference sources.

Conclusion

Differential pressure sensors are indispensable core devices in industrial automation and precision measurement, directly affecting equipment safety, flow control, and production efficiency. Nexisense differential pressure sensors meet diverse operating requirements through multiple models, materials, and output options.

With high accuracy, long-term stability, and strong adaptability to multiple scenarios, they are widely used in industrial, medical, HVAC, and process control fields. Through proper installation, reasonable maintenance, and regular calibration, differential pressure sensors can provide reliable, stable, and traceable pressure difference data, ensuring efficient system operation and data security.