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The Essential Role of Sensors and Controls in Commercial and Industrial Heating Systems

In the realm of commercial and industrial heating systems, efficiency is paramount. As businesses strive to optimize their operations and reduce costs, the role of sensors and controls in maintaining heating systems becomes increasingly vital. In this blog post, we will delve into how these components contribute to the efficient operation of heating systems and provide insights into their maintenance.

Sensors and controllers in heating systems with Tubman Heating

Understanding the Functionality of Sensors and Controls:

Sensors and controls are essential components of commercial and industrial heating systems. Sensors act as the eyes and ears of a heating system, collecting data on various parameters such as temperature, pressure, and humidity. This data is then sent to the controller, which acts as the brain, analysing the information and making decisions on how to adjust system parameters to achieve optimal performance. For example, if a sensor detects that the temperature in a room is too high, it will send a signal to the controller, which will then adjust the heating system to reduce the temperature. Sensors and controllers work together in a continuous feedback loop, constantly monitoring and adjusting system parameters such as temperature, pressure, and airflow, and adjust system operation accordingly. This ensures that the system operates at optimal efficiency, reducing energy consumption and minimizing wear and tear on components.


There are several types of sensors and controls used in commercial and industrial heating systems that Tubman Heating source, supply, maintain and install. These include:

Flame rod’s and UV sensors are critical components of heating systems that detect the presence of a flame in burners. They ensure that the burner is functioning correctly and that the flame is stable and consistent. Flame sensors help prevent the release of unburned fuel and ensure safe and efficient combustion.


Speed sensors, also known as rotational speed sensors or tachometers, monitor the rotational speed of components such as fans, blowers, or pumps within the heating system. They help ensure that these components are operating at the correct speed for optimal efficiency and performance.

QRBI UV sensor
QRBI UV Sensor
Dungs air pressure switch
Dungs Air Pressure Switch

Flue gas sensors are used in combustion systems to monitor the composition of flue gases. They measure parameters such as oxygen, carbon dioxide, and carbon monoxide levels to ensure proper combustion and efficient heat transfer. Flue gas sensors help prevent the release of harmful pollutants and optimize fuel efficiency.


Air pressure switches monitor the air pressure on a combustion fan. They are used as a safety device to ensure the burner has optimal air flow.


Gas pressure switches monitor the pressure of the fuel gas on a gas train. They ensure that the gas pressure remains within the specified range for safe and efficient combustion. Gas pressure switches help prevent issues such as flame instability or incomplete combustion.

UV cells are used in heating systems that utilise ultraviolet light for combustion. They monitor the UV intensity of the flame to ensure safe operation of the burner.


Temperature controllers are central control units that regulate the operation of heating systems. They receive input from various sensors and issue commands to control components such as boilers, pumps, and valves to maintain desired temperatures and optimize energy usage.


Water level controllers are used in boilers and other water-based heating systems to maintain the proper water level. They monitor the water level and adjust the feedwater supply to ensure that the boiler operates safely and efficiently.

Siemens temperature controller
Siemens Temperature Controller
Siemens burner controller
Siemens Burner Controller

Burner controllers regulate the operation of burners in heating systems. The burner controller ensures the safe operation of the burner by switching on the fuel source, ignition and air flow in the correct sequence, and monitoring the flame to ensure correct operation.


VSD’s, or variable speed drives, regulate the speed of components such as fans, pumps, or blowers in heating systems. They adjust the speed based on input from sensors to optimize energy usage and system performance.


Controller relays are used to switch electrical circuits on or off based on input from controllers. They help control various components in heating systems, such as pumps, valves, or actuators, to achieve desired operating conditions.

TDS controllers, or total dissolved solids controllers, are used in steam boilers to monitor and control the concentration of dissolved solids in the boiler water. They help prevent issues such as scaling and corrosion, which can reduce boiler efficiency and lifespan.


Pressure transmitter provides a pressure indication to a controller which adjusts the process value, to optimise the heating system.


Boiler to cascade controllers are used in systems with multiple boilers to control their operation in a cascading sequence. They ensure that boilers are brought online or taken offline as needed to maintain optimal system efficiency and balance the load between boilers.

Pressure transmitter
Pressure Transmitter

Maintenance of Sensors and Controls:

Proper maintenance of sensors and controls is essential for the reliable operation of commercial and industrial heating systems. Here are some best practices for their maintenance:

  • Regular Inspection: Sensors and controls should be visually inspected regularly for signs of damage or wear.
  • Cleaning: Sensors and controls should be kept clean and free from dirt and debris that could affect their performance.
  • Testing: Sensors and controls should be tested periodically to ensure they are functioning correctly.
  • Replacement: Sensors and controls that are damaged or malfunctioning should be replaced promptly to prevent system downtime.

Sensors and controls are critical components of commercial and industrial heating systems, and their proper maintenance is essential for the efficient operation of these systems. By following best practices for maintenance and having your heating system serviced regularly, businesses can ensure that their systems continue to operate reliably and efficiently, reducing energy costs and minimizing downtime.


You can contact your local branch below, to set-up a service schedule:

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