Selecting the Right Media-Isolated Pressure Sensor for Industrial OEM Applications
- John Valentini
- Jan 17
- 4 min read
Industrial OEMs designing systems for harsh gases and liquids face a common challenge: how to measure pressure accurately while protecting the sensing element from corrosive, contaminated, or high-energy media. Oil-filled, media-isolated pressure sensors remain one of the most proven and reliable solutions for these environments—provided the sensor’s mechanical interface, packaging, and electrical output are aligned with the system architecture.
AVSensors offers a family of media-isolated, oil-filled pressure sensors engineered specifically for industrial OEMs, covering a wide range of mechanical formats while maintaining consistent sensing performance. Understanding how these families differ—and where they are intentionally the same—can significantly reduce design risk, qualification effort, and long-term lifecycle cost.
Why Media Isolation Matters in Industrial Systems
In industrial applications such as HVAC&R, pneumatic controls, wastewater processing, refrigeration, and hydraulic systems, direct exposure of a silicon pressure die to process media is often unacceptable. Moisture, particulates, refrigerants, oils, and corrosive gases can degrade unprotected sensors, leading to drift, hysteresis, or outright failure.
Media-isolated pressure sensors solve this problem by using:
A 316L stainless steel isolation diaphragm
Silicone oil to hydraulically transfer pressure to the silicon sensing element
A sealed structure that prevents media contact with electronics
This architecture allows OEMs to measure pressure reliably while maintaining compatibility with a wide range of industrial fluids and gases suitable for 316/316L stainless steel.
Three Media-Isolated Sensor Formats — Three OEM Design Approaches
While accuracy, temperature compensation, and pressure capability are broadly consistent across AVSensors’ oil-filled families, mechanical packaging and porting strategy define how each sensor integrates into an OEM system.
Compact O-Ring, Embedded Designs — MIOF-154CC Series
The MIOF-154CC Series is designed for OEMs that want to embed the pressure sensor directly into a manifold or housing using a compact O-ring seal.
Key characteristics
19 mm diameter O-ring sealed package
Gage and absolute pressure ranges up to 500 PSI
Constant-current excitation with gain-set resistor for ±1% field interchangeability
Form-fit replacement for legacy MEAS / TE Connectivity 154-style sensors
Best suited for
Pneumatic control modules
Embedded pressure transmitters
Environmental and building controls
OEM designs with custom machined ports and limited space
This format gives OEMs maximum control over sealing geometry while minimizing overall sensor footprint.
Process-Threaded, System-Level Integration — MIOF-85CC Series
The MIOF-85CC Series targets OEMs that prefer a ready-to-install pressure sensor with standard process fittings, reducing mechanical design effort.
Key characteristics
0.500-inch diameter body
Wide range of industry-standard threaded ports and weldable options
Optional snubber for protection against pressure spikes
Direct replacement for MEAS / TE Connectivity 85-series sensors
Best suited for
HVAC and refrigeration equipment
Hydraulic and pneumatic controls
Wastewater and industrial process monitoring
OEM platforms requiring fast mechanical integration
By offering multiple port styles and snubber options, the MIOF-85CC family simplifies system-level design in dynamic pressure environments.
Larger O-Ring Format for Rugged Assemblies — MIOF-86CC Series
The MIOF-86CC Series provides a larger O-ring sealed format for OEMs that prioritize mechanical robustness and sealing margin.
Key characteristics
0.625-inch diameter O-ring package
Gage and absolute pressure ranges up to 500 PSI
High mechanical stability under vibration and thermal cycling
Designed to replace MEAS / TE Connectivity 86-series sensors
Best suited for
Industrial control assemblies
Hydraulic subsystems
OEM designs requiring a larger sealing footprint
Applications where mounting tolerance and robustness outweigh size constraints
Common Electrical Options Across All Three Families
A key advantage of AVSensors’ media-isolated portfolio is that mechanical format does not lock the OEM into a single electrical output architecture. Across the MIOF-154, MIOF-85, and MIOF-86 families, OEMs can select from multiple electrical output options while retaining the same oil-filled isolation structure.
High-Level Analog Voltage Outputs
For OEMs that prefer simple system integration, AVSensors offers high-level, normalized analog voltage outputs derived from the same media-isolated sensing platform.
These configurations:
Operate from a constant voltage supply
Provide a normalized output span (e.g., percentage of supply voltage)
Reduce analog design effort compared to low-level mV outputs
Improve noise immunity in electrically harsh industrial environments
This approach is ideal for OEMs using PLCs, data acquisition modules, or microcontrollers with standard ADC inputs.
Digital Pressure and Temperature Outputs (I²C & SPI)
For OEMs moving toward higher levels of integration and system intelligence, AVSensors also offers digital output versions built on the same mechanical and media-isolated foundation.
These options provide:
Digitally calibrated pressure output
Integrated digital temperature output
Industry-standard I²C or SPI communication
Reduced analog signal routing and calibration complexity
Improved consistency across production and temperature
Digital outputs are especially attractive for OEMs developing connected equipment, smart controls, or platforms where firmware-based compensation and diagnostics add value.
One Mechanical Platform — Multiple Electrical Paths
The important takeaway for industrial OEMs is this:
The choice of mechanical format does not limit the choice of electrical interface.
Whether the application requires a compact embedded sensor, a threaded process connection, or a rugged O-ring seal, AVSensors can support:
Low-level mV outputs
High-level analog voltage outputs
Fully digital pressure and temperature interfaces
This commonality allows OEMs to scale product families, upgrade electronics over time, or support multiple customer tiers without redesigning the pressure sensor interface.
Media Isolated Pressure Sensor Family
Milli Volt Output Family Series
High Level Analog Output Family
24 Bit Digital Output Series
John Valentini, Business Development AV Sensors (business.development@avsensors.com)
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