The CONSENSOR is tightly and intimately connected thermally to your cold water inlet pipe near the heat exchanger. It has an internal “Test Surface” that is designed to be very sensitive to the onset of the condensation process. This Test Surface will be thermally the same as your pipe surface. It’s exposed to the same atmosphere. Consequently, the CONSENSOR’s Test Surface will “sweat” at the same instant the pipe begins to “sweat”. In less than a second, coolant flow is stopped … typically before any condensate is visible … but never before the condensation process has actually started.
At most, the pipe will get no more than a light mist of condensate on its surface … usually, not that much. This means that it will quickly dissipate as soon as the conditions allow. Then the CONSENSOR’s indication returns to the normal state – coolant flow resumes. There is no undue delay of the resumption of coolant flow - and the pipe and heat exchanger are dry.
Coolant flow is never interrupted before it’s necessary, and never longer than necessary. Cooling capacity is never needlessly diminished. This is precisely what the customer needs.
See the YOUTUBE video at the end of this material.
COMPANION CIRCUITRY All condensation sensors require a companion electronic circuit to provide a useful signal or output. Most of these circuits are very rudimentary.
In our CG -ICM series, the CONSENSOR is mated with our "ICM", an integrated companion circuit that includes a powerful micro-processor with a sophisticated program. It processes information from its internal Test Surface many times a second and decides if condensation is occurring. It is also able to determine if the overall sensor is functioning properly. If it isn’t, a “SENSOR FAULT” condition will be indicated by the CONSENSOR's on-board LED. It constantly indicates just what is happening at its location. It indicates 3 states:
POWER ON .... CONDENSATION CONDITION ... SENSOR FAULT
No condensation occuring Condensation onset is detected The Sensor is unreliable
This is a great aid for the installer and for on-site troubleshooting.
FAIL SAFE TECHNOLOGY All CONSENSORs incorporate the best "Fail Safe" design techniques. If an internal failure (a Sensor Fault) is detected, the output signal goes to a CONDENSATION state. The CONSENSOR will not allow coolant flow to continue while it is unreliable. The CONSENSOR's current condition will always be indicated by its on-board LED.
COST Cost is always a factor. When all factors are considered ... installation, accessories, etc., THE CONSENSOR MODEL CG -ICM series may cost a bit more than the inexpensive sensors, but in nearly all applications, they are in effect, an insurance policy ... almost always to protect costly equipment, furnishings, etc. from water damage. In the overall system cost, they are almost a trivial cost factor.
The CONSENSOR has become the industry standard in the HVAC industry. Our customers include SIEMENS, JOHNSON CONTROLS, TRANE, HONEYWELL,etc., etc. Many architect firms specify it. Some chilled beam manufacturers suggest it to customers.
THE CUSTOMER The primary advantage of the CONSENSOR approach goes to the customer. The customer always gets full performance from the installed system. There is no fear of condensation "rain". Heat transfer is never diminished because of wet heat exchangers, and cooling capacity is never needlessly cut off when it’s needed most. Use of the CONSENSOR improves system performance under the most critical conditions.