APPLICATION NOTE

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Dew point sensing technologies and their

performance differences in compressed air
applications
until condensation forms. A gas
sample passes over a metallic
mirror surface which is chilled by
a cooler. Light is then directed
at the mirror allowing an optical
sensor to measure the amount of
reflected light. When the mirror
is cooled to the point at which
condensation begins to form on
its surface (i.e. the dew point has
been reached), the amount of light
reflected by the mirror diminishes
which is in turn detected by the
optical sensor. The rate of cooling
is then carefully regulated by a
temperature sensor on the mirror.
Once a state of equilibrium has
been reached between the rate
of evaporation and condensation,
Moisture is a constant issue in Different sensing the mirror temperature is equal to
compressed air systems. When dew technologies the dew point. Due to the chilled
point sensors are working optimally, mirror’s optical measurement
measures can be taken to avoid The three most common types of principle, the sensor is highly
malfunctions, inefficient operations sensors for measuring dew point sensitive to the presence of dirt,
or poor quality end product. are chilled mirrors, metal oxide, oil, dust, and other contaminants
However, the measurement of dew and polymer sensors. on the mirror surface. Similarly,
point in compressed air systems accurate chilled mirror devices
can present many challenges that Chilled mirror technology can tend to be expensive and are
lead to erroneous readings, poor offer the highest accuracy over often employed when absolute
stability, and even sensor failures. a wide range of dew points. The accuracy is essential and frequent
The most common issues with dew operating principle is based on maintenance and cleaning can be
point sensors in compressed air are the fundamental definition of dew performed.
usually centered on the following: point – cooling a volume of air

• Response time
• Reliability of the reading Sensor Wide High Immune Immune to Long- Reason-
• Recovery from water spikes or technology measure- accuracy to dust conden- term able
condensation ment range and dirt sation stability price
• Exposure to compressor oil Chilled
+++ +++
Mirror
To better understand these Capacitive
challenges, it is worth first exploring ++ ++ ++ + + ++
Metal oxide
the performance differences
between the most common sensor Capacitive
++ ++ +++ +++ +++ ++
Polymer
technologies.
Next are capacitive metal oxide layer (polymer vs. metal oxide), a During auto-calibration, the sensor
sensors, including aluminum capacitive polymer sensor is also is heated and allowed to cool
oxide technology, which are bonded together with a resistive while the humidity and monitored
designed for very low dew temperature sensor. The polymer readings of the sensor are
point measurement in industrial sensor measures the humidity monitoring and plotted. This data
processes. While the types of (amount of water molecules in is analyzed and used to adjust the
materials used in construction the measured gas) in terms of reading of the humidity sensor.
can vary, the sensor structure relative humidity (RH) while the
and operating principle generally temperature sensor measures The key to this accurate calibration
remain the same. These capacitive the temperature of the polymer is that the sensor’s output is
sensors are built in a layered sensor. From these two values, the equivalent to relative humidity
structure sandwiching together microprocessor in the transmitter (RH), which changes in relation to
a substrate base layer, a lower electronics calculates the dew the temperature. This well-known
electrode, a hygroscopic metal- point temperature. An auto- physical dependence allows the
oxide middle layer, and a water calibration feature, also invented auto-calibration to evaluate if the
permeable upper electrode. The by Vaisala, is used to measure low humidity reading at 0% RH is
capacitance across the upper and accurate dew point values in very correct. Any possible drift is then
lower electrode changes based dry conditions with the polymer automatically corrected by the
on the amount of water vapor sensor. When relative humidity microprocessor. This results in an
absorbed by the metal oxide layer approaches zero, rather small accuracy of better than ±2ºC even
(the dielectric of the capacitor), changes in humidity will result at low dew points.
which is a function of dew point. in quite large changes in dew
While providing excellent low point readings. For example, dew Polymer technology, which is the
dew point measurement accuracy points of -40°C and -50°C at room result of years of testing and careful
to -100°C and lower, they tend temperature correspond to relative material selection, combined with
to offer poor long-term stability humidities of 0.8% RH and 0.3% intelligent electronics offer a high-
in processes with varying dew RH, respectively. With the typical performance solution in applications
points at the higher ranges (e.g. ±2% RH accuracy specification of where minimal maintenance
refrigerant dried systems). Metal polymer sensors, an accuracy of is required for the dew point
oxide sensors can also be easily ±2°C dew point can be achieved transmitter.
damaged by high humidity levels down to -9°C. Auto-calibration
and condensation. This drift in the extends this accuracy from ±2ºC
output reading means frequent down to -80°C.
calibration, which can typically be
done only at the manufacturer’s
calibration lab.

Rounding out the sensor types,

capacitive polymer sensors
measure accurately over a wide
humidity range in addition to H² O
offering excellent long-term
stability. Since January 1997,
when Vaisala launched the first 1
ever polymer sensor for dew
point measurements, DRYCAP ® 2 5
technology has been used in a
wide variety of industrial and 3
meteorological applications. New
innovations have enabled polymer 4
sensors to be utilized in low dew
point applications as well. While
the capacitive operating principle
is similar to that of metal oxide,
there are a few key differences. Layer construction of the DRYCAP® sensor. 1. Water vapor permeable
Beyond the obvious material upper electrode 2. Humidity sensitive polymer layer 3. Bottom electrode
difference in the hygroscopic 4. Sensor substrate 5. Connection pins
Issue #1: How can I ensure
fast response time?

When installing a dew point probe

that has acclimated to ambient dew
points into a -40°C compressed
air line, the response time required
for traditional sensors to stabilize
at this -40°C value can often take
from several hours to several days
for equilibrium to be reached.
This is due to the fact that other
capacitive sensor technologies
must rely on the relatively slow
process of using the dry process
air to passively dry the hygroscopic
(water absorbing) layer of the
sensor.

A better solution is to use a

capacitive polymer sensor with a
purge function. Vaisala's DRYCAP ®
sensor reacts immediately when it
senses a decrease in dew point of The graphs above are derived from an ongoing test in which two Vaisala
10°C or more by initiating a sensor DRYCAP® DMT242 dewpoint transmitters were installed in a compressed
air line seven years ago and have not been recalibrated or adjusted. The
purge cycle that applies heat to the
line conditions are representative of instrument air. x-axis represents
sensor. This expels water molecules years, y-axis represents difference to the reference value at periodic
from the polymer layer, drying the checks.
sensor, and providing a stabilized
reading within 5-6 minutes.

Issue #2: How can I ensure installed at the same installation number of variables that can affect
the reading is correct? point but they’re all reading the reading: process conditions,
different values – how do I know installation method, how the signal
The most frequently asked which one is correct?” is being read, accuracy of sensors
question about dew point from installed, and length of time since
compressed air technicians is – “I This question is usually the most last calibration.
have several dew point instruments difficult to answer due to the
While it is widely known that every
dew point sensor drifts, the critical
questions are – by how much and
how quickly?

Well-established high quality

polymer sensor with auto-
calibration provides a high level of
accuracy due to a self-calibration
method that activates once every
hour in a stable environment
(more frequently in varying
conditions) to ensure the absolute
minimum sensor drift – providing
years of maintenance-free, reliable
measurements you can rely on.
Vaisala DRYCAP® Capacitive polymer sensor structure
Issue #3: How does the Issue #4: Can the In brief
sensor recover from water sensor withstand
spikes or condensation? exposure to entrained ▪ Chilled mirror technology
offers the highest accuracy
compressor oils? over a wide range of dew
Occasional high-humidity water points, but its performance can
spikes or exposure to water Trace amounts of compressor be limited by the presence of
droplets are an unavoidable oil suspended in compressed contaminants.
phenomenon in the normal air can spell disaster for some ▪ Capacitive metal oxide sensors
operation of a compressed air sensor technologies. Fortunately, provide very low dew point
system. Whether your dew point the structure of some polymer measurement, but they can
sensor can survive and recover sensors, like Vaisala DRYCAP ®, be damaged by high humidity
from these events depends on the have been specifically designed levels and condensation.
type of sensor installed. to be selective to only water ▪ Capacitive polymer sensors
molecules. This is achieved by with auto-calibration
Metal oxide sensors continue to a specially designed permeable functionality operate over
oxidize in the presence of water, upper electrode with a pore size a wide humidity range, are
resulting in a structural change allowing only water vapor to pass unaffected by condensation
in the porous oxide layer. This through it. By comparison, much and ensure long term stability.
translates into measurement larger hydrocarbon molecules (i.e.
inaccuracy and sensor drift. oils) are unable to pass through
Polymer sensors, on the other these pores, thereby eliminating
hand, are immune to water due to any cross-sensitivity to oils. Clearly
their inherent inert characteristics. by design, chilled mirror optics
When a polymer sensor with auto- and reflective surfaces need to
calibration functionality senses a remain clean in order to maintain
water spike, it initiates an auto- their performance – and thus
calibration cycle as normal dry have a minimal tolerance for oil
air returns to the line, returning to contamination.
normal operating values within
a few minutes.

Auto-calibration function.

Please contact us at Ref. B211092EN-B ©Vaisala 2020

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