Differential Pressure Sensing in HVAC: Mechanical Gauges vs Wired Transmitters vs Wireless IoT Sensors (LoRaWAN, NB-IoT/LTE-M, Wi-Fi)

Executive summary

Differential pressure (ΔP) measurement sits at the intersection of energy, IAQ, compliance, and reliability in HVAC. It’s used for filter loading, duct static pressure, airflow inference, fan performance, and room pressurization (cleanrooms / isolation rooms).

Three types of sensor dominate the market:

• Mechanical gauges: lowest cost and simplest deployment, but usually local-only visibility unless you add switches or manual rounds.

• Wired electronic transmitters: the default when ΔP feeds control loops or needs deterministic BAS trending.

• Wireless sensors (LoRaWAN / NB-IoT / LTE-M / Wi-Fi): fastest path to retrofit monitoring at scale where pulling cable is the real cost driver.

The practical decision isn’t “which sensor is best,” it’s measurement quality + installation + integration + operating cost over a 3–10 year lifecycle.

How to read specs like an instrumentation engineer

If you want this article to sound “expert,” anchor it on how pros actually evaluate ΔP instrumentation:

Range and resolution

Low ΔP (10–250 Pa) is where devices separate. Multi-range sensors can be excellent if your selected range matches your true operating band.

Accuracy statement (and why marketing comparisons often fail)

Accuracy can be stated as:

• % of Full Scale (FS) (common in mechanical and many transmitters)

• % of span / selected range (common in multi-range digital)

• % of reading (less common in HVAC ΔP)

Example: Synetica’s Status-DP2 states ±0.1% of auto-selected range and supports multiple calibrated ranges (25 Pa up to 2500 Pa). That can outperform a “good” %FS device when you’re operating in a narrow band.

Stability and drift

For filter trending and critical spaces, zero stability + temp compensation often matter more than headline accuracy.

Overpressure, porting, and installation physics

Most field “accuracy problems” are actually:

• tubing routing (water traps)

• port leaks

• clogged barbs/ports

• poor reference placement

  So compare port design, overpressure tolerance, and installation guidance at least as much as sensor element specs.

Environmental rating

Mechanical rooms are harsh (dust + condensate + cleaning chemicals). Rooftops demand UV stability + IP65+.

The market landscape: the three archetypes

1) Mechanical gauges (and switches)

Mechanical gauges remain a baseline because they’re simple and robust. Dwyer’s Series 2000 Magnehelic datasheets commonly cite ±2% FS accuracy  and versions described as weatherproof to IP67.

Where they win

• Lowest up-front cost, almost no commissioning

• No power, no network, no cybersecurity review

• Excellent for “walk-by” filter checks

Where they struggle

• No native trending / analytics (problems discovered late)

• Remote alarms require add-ons

• “Accuracy” in real life is often dominated by installation and zeroing

Best-fit use cases

• Basic filter monitoring where manual checks are acceptable

• Small sites where remote visibility isn’t required

2) Wired electronic transmitters (BAS workhorses)

Wired ΔP transmitters are still the default when:

• ΔP participates in a control loop (duct static control)

• you need high-confidence trending inside the BAS

• you want deterministic response and simple troubleshooting

Representative devices (by class)

• Entry / general-purpose: Dwyer 668 is widely used and lists ±1% FS accuracy (plus standard loop-output integration).

• Higher-accuracy / established reference: Setra 264 datasheets commonly specify multiple accuracy options (e.g., ±0.25% FS class variants).

• Ultra-low pressure specialty: Greystone EUP submittals position it for ultra-low ΔP with enclosure and output flexibility; documentation shows an IP65 / NEMA 4X enclosure reference.

Where they win

• Best for control and deterministic alarms

• Mature commissioning & calibration practices

• BAS-native outputs (4–20 mA / 0–10 V) simplify integration

Where they lose

• Retrofit at scale becomes expensive when the job is “mostly conduit and labor”

• Coverage gaps for distributed assets (filters across many buildings)

3) Wireless ΔP sensors (split by comms technology)

A) LoRaWAN (campus/building network)

LoRaWAN shines when you control the physical environment (campus, large building portfolios, industrial sites). Devices vary widely in enclosure and accuracy.

Examples and spec patterns

• Adeunis Delta P (ARF8283AA): datasheet calls out IP68 and long-life battery positioning (often quoted as multi-year / 10+ years depending on config).

• Synetica Status-DP2: multi-range (25 Pa to 2500 Pa), ±0.1% of selected range, battery life 3+ years, enclosure IP40 standard / optional IP67 gasket.

• Sensocon WS-DP: datasheet cites ±1% FS, IP65, and battery-life guidance depending on interval (often framed as multi-year).

• Sontay RF-LW-DP1: highlights 0.1% of selected range accuracy class and broad range options.

• Netvox R718Y: manual shows a measurement range of -500 to +500 Pa and references battery-life calculators rather than a single fixed number.

• and of course, ellenex PDT2-L, stands as one of the most reliable LoRaWAN differential pressure sensors in the market for differential pressure sensing in HVAC sector and critical assets monitoring.

Where LoRaWAN wins

• Very low power (battery-first designs)

• No carrier dependency (private networks)

• Excellent economics at building/campus scale once gateways exist

• Ease if integration to BMS (building Management Systems)

Where LoRaWAN can lose

• Gateways + coverage planning become “real work,” especially in concrete/steel interiors

• Integration varies (some devices are great; others require significant platform work)

B) NB-IoT / LTE-M (carrier network)

Cellular LPWAN is often the fastest way to scale across distributed sites because you avoid deploying gateways.

Examples and spec patterns for some of the options for differential pressure sensing in HVAC

• Efento NB-IoT differential pressure logger: datasheet positions battery life “up to” multi-year and uses BLE for local configuration.

• Dragino differential pressure sensor family: documentation highlights battery capacity (e.g., 8500 mAh) and OTA/BLE capabilities depending on model.

• PDT2-N class finished devices: With stable sub-Pascal accuracy with built-in temperature sensor, stands as one of the most reliable options in the market for the long term operation in harsh environment.

Where cellular LPWAN wins

• No gateway install

• Great for national rollouts service models

• Centralized provisioning + cloud workflows become scalable

Where cellular LPWAN can lose

• Coverage and in-building penetration vary by carrier/site

• SIM/eSIM/data-plan economics and security requirements must be managed

C) Wi-Fi / Ethernet (IT-managed networks)

Wi-Fi solutions often align with compliance-driven environments (healthcare, labs) where the organization is comfortable routing device data through IT networks.

Examples

• Dickson supports a differential pressure sensor accessory (e.g., RS081) within its logging ecosystem.

• SensoScientific publishes Wi-Fi transmitter spec sheets oriented around secure Wi-Fi collection and transmission.

Strength

• Works where Wi-Fi is ubiquitous and power is available

• Often packaged with mature cloud portals and reporting

Weakness

• IT onboarding/cyber reviews can be a gating factor

• Battery-first deployment is less common (often mains-powered)

  
  

Durability and outdoor deployment: what fails in the field

Common field failures

• Condensation ingress via tubing and reference ports

• Dust/lint clogging on ports (false ΔP “stuck” readings)

• UV + thermal cycling degrading housings and seals on rooftops

• Battery behavior in cold (capacity reduction, passivation considerations)

This is why IP ratings matter:

And why “finished devices” designed for outdoor deployments become attractive.

Accuracy vs usefulness: pick by use case, not by spec-sheet ego

Filter performance monitoring (ΔP across filters)

Typically 25–250 Pa bands → wireless becomes compelling when you want alarms and portfolio analytics, while wired makes sense if you already trend everything in BAS.

Duct static pressure control

Control loops generally prefer wired transmitters into controllers (deterministic behavior, predictable failure modes).

Critical room pressurization

Prioritize stability, repeatability, and documented calibration. Wi-Fi ecosystems and high-quality wired transmitters are common; LoRaWAN/NB-IoT can work when the deployment is designed for auditability and maintenance discipline.

Distributed facilities portfolios

NB-IoT/LTE-M is often the fastest to scale (no gateway installs). LoRaWAN wins where you control the network and can standardize deployments.

Where ellenex PDT2-class of devices works well

A newer category is emerging between “instrumentation” and “IoT”: purpose-built ΔP transmitters already provisioned for cloud/BMS workflows via LoRaWAN or cellular.

The differentiation is rarely just the sensing element. It’s the full deployability stack:

• enclosure + ports + sealing

• power model (battery life under realistic duty cycles)

• provisioning workflow

• firmware/update posture

• integration options (BMS/cloud)

This class is compelling when:

• you’re retrofitting many points and installed labor dominates

• you need alarms + analytics without expanding the BAS footprint

• you need outdoor-capable hardware

• you want a single finished SKU vs assembling sensor + radio + enclosure + power

  
  

Selection checklist

• ΔP range(s) needed + expected operating band (and transient spikes)

• Accuracy format (%FS vs %span vs %reading) + temp compensation + zero stability

• Overpressure rating + port type + tubing best practices

• Environmental rating (IP/NEMA) + UV resistance (if rooftop/outdoor)

• Power plan (24 V vs battery) + maintenance interval

• Integration plan (BAS analog, gateway, cloud API, MQTT/LwM2M, etc.)

• Cyber/security requirements (identity, credentials, update policy, data path)

• Commissioning workflow (zeroing/calibration, provisioning, labeling, swap process)