What Are ExProof Differential Pressure Sensors?

ExProof Differential Pressure Sensors are ex-proof field sensors that measure the pressure difference between two points and transmit this value to automation systems as an analogue or digital signal.

In ATEX-zoned facilities where standard differential pressure sensors are not suitable from a safety perspective, models with enclosures, connections, and electrical protection designed for explosive atmospheres are preferred.

Operating Principle

A differential pressure sensor detects the pressure difference between the positive and negative pressure connection points. The sensor electronics convert the measured value into a 4–20 mA, 0–10 V, or another output signal.

This signal enables parameters such as filter contamination, fan flow, duct pressure, room pressure, airflow, or process pressure difference to be monitored on the automation screen.

Applications

• ATEX-zoned ventilation systems
• Ex-proof air-handling units
• Filter contamination and pressure-loss monitoring applications
• Fan-operation and airflow-control scenarios
• Duct-pressure and flow-monitoring systems
• Clean-room and controlled-area pressure monitoring
• Chemical, petrochemical, paint, and solvent facilities
• Battery rooms and areas with a hydrogen risk
• Dust-collection and process-exhaust systems
• PLC, BMS, and SCADA automation systems

Technical Features

• Ex-proof enclosure and safe connection structure
• Model options suitable for ATEX areas
• Product alternatives for different pressure-measurement ranges
• 4–20 mA, 0–10 V, or other output-signal options
• 24V AC/DC or a supply voltage suitable for project requirements
• Configuration suitable for filter, fan, duct, and room-pressure applications
• Panel, field, duct, or device-mounting alternatives
• Durable enclosure suitable for the required IP protection class
• Integration capability with PLC, BMS, SCADA, and alarm systems

System Advantages

• Provides safe differential-pressure measurement in areas with a risk of explosive atmospheres.
• Helps continuously monitor filter contamination and pressure loss.
• Supports monitoring pressure differences in fans, ducts, rooms, and processes.
• Provides measurable data to automation systems through an analogue output.
• Offers reliable monitoring for early warning, alarms, and maintenance planning.
• Contributes to energy efficiency in ex-proof HVAC and process-ventilation systems.
• Supports operational safety, equipment protection, and process continuity.

Selection Criteria

When selecting a sensor, not only the measuring range but also the application type, output signal, zone classification, ambient conditions, mounting point, supply voltage, and automation infrastructure should be evaluated together.

• Differential-pressure range to be measured
• Filter, fan, duct, room, or process application
• Requirement for 4–20 mA, 0–10 V, or digital output
• ATEX zone classification and certification requirement
• Supply voltage and control-panel connection
• Pressure connection nipple, hose, and mounting detail
• Ambient temperature, humidity, dust, and chemical-vapour conditions
• PLC, BMS, SCADA, or alarm-system integration
• Calibration, maintenance access, and ease of field inspection

Use in Filter and Fan Systems

In filter systems, differential pressure sensors help monitor the contamination level by measuring the pressure difference between the inlet and outlet points of the filter. As the filter becomes dirty, the pressure difference increases, and the maintenance requirement can be monitored on the automation screen.

In fan systems, airflow, fan performance, and duct pressure can be monitored. This allows conditions such as fan failure, low flow, or filter blockage to be detected earlier.

Clean Room and Controlled Area Applications

In clean rooms, laboratories, production areas, and controlled spaces, differential pressure is a critical parameter for contamination control and airflow direction.

Differential pressure sensors help keep positive- or negative-pressure scenarios under control by enabling continuous monitoring of the pressure difference between rooms or sections.

Use in ATEX Areas

Differential pressure sensors used in areas with a risk of explosive atmospheres must have an appropriate ex-proof protection structure. Since standard measuring equipment may create an electrical risk in these areas, products suitable for the zone classification should be selected.

In facilities with risks from chemical vapours, solvents, hydrogen, paint, gas, or dust, pressure-measurement equipment should be selected in accordance with ATEX requirements and installed correctly.

Automation Integration

The measurement signal received from differential pressure sensors can be transferred to a PLC, BMS, SCADA, fan control panel, filter-monitoring system, or alarm panel.

Through this integration, filter contamination, fan performance, duct pressure, and room pressure difference can be monitored in real time. When threshold values are exceeded, an alarm, maintenance warning, or automatic control scenario can be activated.

Maintenance and Calibration

For reliable measurement, pressure hoses, connection nipples, cable connections, output signals, control-panel connections, and mounting points should be inspected regularly.

For critical processes, sensors should be checked periodically, measurement values should be verified, and calibration should be performed when necessary.

Airtes ExProof Pressure Measurement Solutions

Airtes supports the correct product selection for ExProof Differential Pressure Sensors used in ATEX-zoned facilities by evaluating the application area, measuring range, output signal, zone classification, and automation infrastructure together.

Through a project-based approach, safe differential-pressure measurement solutions can be created for ex-proof HVAC, process ventilation, filter monitoring, fan control, clean-room pressure monitoring, and SCADA integration.

Why Airtes?

• Technical experience in ATEX-area and ex-proof equipment applications
• Correct product selection according to pressure range, output signal, and application type
• Project-based evaluation for filter, fan, duct, and room-pressure control
• Technical support suitable for PLC, BMS, SCADA, and alarm-system integration
• A solution approach for HVAC, process ventilation, and clean-room applications
• Professional support for site surveys, technical analysis, and quotations

Frequently Asked Questions

What are ExProof Differential Pressure Sensors used for?

ExProof Differential Pressure Sensors measure the pressure difference in filters, fans, ducts, rooms, or process systems in ATEX areas and transmit a signal to automation systems.

What is the difference between a differential pressure sensor and a differential pressure switch?

A differential pressure sensor transmits the measured value as an analogue or digital signal. A differential pressure switch provides a contact output at a predefined threshold value.

Can it be used to monitor filter contamination?

Yes. By measuring the pressure difference between the inlet and outlet points of the filter, filter contamination, pressure loss, and maintenance needs can be monitored.

How should the product be selected?

Selection should be made by evaluating the pressure-measurement range, output signal, zone classification, supply voltage, application type, and automation infrastructure together.

Contact Airtes for ExProof Differential Pressure Sensors Suited to Your Project

Selecting ExProof Differential Pressure Sensors without accurately analysing the measuring range, application point, zone classification, output signal, supply voltage, and automation infrastructure at your facility is not appropriate. The Airtes technical team provides professional support for a differential-pressure measurement solution suited to your operation.

Contact us for detailed information, a site survey, and a project-based quotation.