Nexisense Temperature Sensor Common Installation Methods Explained: A Comprehensive Guide from Selection to Practice

Temperature sensors are widely used in industrial automation, environmental monitoring, and process control. Their installation methods directly affect measurement accuracy and device lifespan. Different environments and media require different fixing methods. From pipeline threaded connections to indoor wall mounting, choosing the right method can significantly reduce errors. The Nexisense temperature sensor series features flexible designs that support multiple installation methods and adapt to various scenarios. Starting from the basics, this article details common installation methods and practical points.

Definition and Role of Temperature Sensors

A temperature sensor is a device that converts temperature changes into electrical signals, mainly used for real-time monitoring of medium or ambient temperature. It integrates temperature-sensing elements (such as PT100 or thermocouples) and outputs standard signals for easy integration into control systems.

Nexisense products emphasize durability and compatibility, providing reliable data in chemical, food, HVAC, and other industries, supporting predictive maintenance and process optimization.

Working Principle Analysis

Most temperature sensors are based on changes in resistance or electromotive force. Resistance temperature detectors (such as PT100) change resistance linearly with temperature, while thermocouples generate voltage using the Seebeck effect. Signals are processed through internal circuits with non-linearity compensation to ensure accurate output.

The installation method affects the heat transfer path, and proper fixing minimizes lag and error.

Internal Structure Analysis

The structure of Nexisense temperature sensors includes a probe, a protective tube, and a junction box. The probe encapsulates the sensing element, typically made of 316L stainless steel. The protective tube can be equipped with threaded, flange, or clamp interfaces. The wiring section supports shielded cables with a protection rating of IP65 or above.

The design focuses on modularity, facilitating on-site replacement and maintenance.

Key Advantages Highlighted

Nexisense sensors offer diverse installation methods with strong adaptability. Compact size and light weight make them suitable for deployment in confined spaces. Multiple interface options reduce retrofit costs while ensuring sealing and vibration resistance.

These designs simplify construction and improve overall system reliability while maintaining measurement accuracy.

Detailed Explanation of Common Installation Methods

Temperature sensor installation varies by environment. The following are several mainstream methods.

Threaded Connection Method

Threaded connections are suitable for non-corrosive medium pipelines, featuring compact size and easy installation. Common specifications include M20×1.5 (length 18mm), G1/4 (length 15mm), and G1/2 (length 18mm). Pipelines are often equipped with welded thermowells, typically with M20×1.5 threads, to ensure sealing.

This method provides firm fixing, is suitable for medium- and low-pressure environments, and allows easy disassembly.

Flange Connection Method

Flange connections are suitable for high-temperature, high-pressure, or corrosive media in medium- and low-pressure pipelines and equipment. The probe is fixed via a flange plate, and sealing gaskets ensure airtightness.

Advantages include wide applicability, strong corrosion resistance, and easy maintenance, making it suitable for large storage tanks or reactors.

Clamp Connection Method

Clamp connections (including sanitary tri-clamp types) are simple to operate and do not require welding, saving time. Ordinary workers can master them after training without altering the original characteristics of the pipeline.

This method is particularly suitable for industries with high hygiene requirements, such as food and pharmaceuticals, offering easy cleaning and quick assembly and disassembly.

Wall-Mounted Installation Method

Wall-mounted installation is used for indoor environmental monitoring, such as buildings or equipment rooms. Sensors are compact and lightweight, installed vertically (text facing forward) at a height generally within the human sitting height or main activity area (1.4–1.6 m).

This method is aesthetically pleasing and unobtrusive, suitable for HVAC systems or cleanrooms.

Diverse Application Scenarios

Threaded and welded thermowells are common in chemical pipelines; flanges are used in oil storage tanks; clamps dominate food and brewing lines; wall-mounted types are widely used in smart buildings. Nexisense products cover these scenarios and support customized interfaces.

Measurement Methods and Installation Precautions

Installation location selection is critical. Choose points with sensitive and representative temperature changes, avoiding valves, weld seams, dead zones, or areas near strong magnetic fields. Probes must be fully immersed, inserted to the center flow velocity zone in pipelines.

Use protective sleeves in high-pressure environments and protective boxes outdoors. Power must be cut off before installation, performed by professionals to ensure sealing and grounding.

Maintenance and Care Guidelines

Regularly check fixing tightness and clean probe surfaces to prevent fouling. Calibrate annually and verify insertion depth. Replace protective tubes promptly in corrosive environments. Store in dry conditions and avoid vibration. These measures extend lifespan and maintain accuracy.

Technical Parameters Overview

Frequently Asked Questions

What if threaded installation leaks?
Check seal integrity and add PTFE tape or sealant.

What pressure is flange connection suitable for?
Depending on specifications, medium and low pressure up to 10 MPa; ultra-high pressure requires customization.

Why are clamp connections popular?
Fast, non-destructive installation compliant with hygiene standards.

Is there a standard wall-mount height?
Around 1.5 m, avoiding heat source interference.

How to choose welded thermowells?
Based on pipe diameter and medium, stainless steel is preferred.

Conclusion

Temperature sensor installation methods are diverse, and selecting the appropriate method is the foundation for accurate measurement. Through flexible design, Nexisense supports full-scenario applications from threaded to wall-mounted installations. Standardized installation, careful location selection, and proper maintenance maximize equipment value and drive more reliable and efficient process control. In the wave of industrial upgrading, mastering these practices will help your system operate more stably and deliver more precise data.