Posted on Wednesday, December 15, 2021 by Mads Wraa Hyttel

How to avoid problems with condensation in cooling meters – Part 2: Best practices for installation

Right installation plays an important role in minimizing the risk of breakdown due to condensation in cooling meters. Read this blog to learn from our product expert about the best installation practices o avoid condensation in your cooling/thermal energy meter.
Condensation is a significant problem within cooling meters and typically results in reduced lifetime of the cooling meter. In the previous blog, we discussed how selecting the right products can make a significant difference towards reducing the problems related to condensation. In this blog, we will look into how installation of the cooling meter should be done to minimize the risk of breakdown due to condensation.We will start by looking at installation of the calculator. While the flow and temperature sensors must be installed on the pipes with chilled water, it is important that the calculator is not mounted on any of the pipes since this can potentially create condensation inside the calculator. The calculator should instead be placed on a wall. Furthermore, it is important that the calculator is placed above the flow sensor. By doing this, you avoid that any condensation created at the pipe is transferred to the calculator. If possible, the calculator should be placed in a different room or cabinet with less condensation.

For the flow sensor, it is important that the cable between the flow sensor and the calculator is installed as shown below to avoid continuous transfer of condensation to the flow sensor. The cables should hang freely downwards after cable connections to form a drip nose for drainage of water and condensation. ULTRAFLOW® 44 is unique in the sense that the electronics box is separated from the flow sensor with a 1.2 m cable, which makes it possible to mount the electronics box at a significant distance away from the flow sensor or pipes where condensation occurs. The electronics box should therefore not be mounted on the flow sensor or any pipes but should instead be mounted horizontally on the wall using a grating and cable strips.

To get the highest possible energy efficiency, ULTRAFLOW® 44 should be insulated as shown below.

When it comes to temperature sensors, it is important to install them from below. If a temperature sensor is installed from above, there is a high risk of water being accumulated inside the temperature sensor. Instead, the temperature sensor should be installed from below so that gravity is used to remove water and condensation from the temperature sensor. Again, the cable should form a drip nose for drainage of water. Since Kamstrup TemperatureSensor 63 & 83 are both IP68 approved, it is recommended to insulate the temperature sensors to achieve the highest possible energy efficiency.

Wrong installation

Correct installation

To sum up

Correct installation is a critical part of ensuring a long lifetime of a cooling meter used in hot and humid environments with condensation. This is based on our more than 15 years of experience with cooling meters used in these environments. In this blog, we have covered in detail how the calculator, flow sensor and temperature sensors should be installed to minimise ingress of water in the cooling meter. All other aspects of installation of our cooling meters can be found in the corresponding technical descriptions and our manual for insulation of flow and temperature sensors. Condensation is a significant challenge within application of cooling meters, but with the right combination of cooling meters designed to minimise ingress of water and subsequent correct installation of the cooling meter, it is possible to achieve a smooth operation and low total cost of ownership.


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