How long could I do an exposure without risking overheating my sensor?
I have seen this happen but unfortunately there is no simple answer. Each sensor in each camera model is setup differently and generates a different amount of heat. I would go so far as to say high end full frame cameras would possibly be able to go indefinitely but I wouldn't try it based on my word.
The camera in question was a 350D which took a 40 minute startrail I think it was, and then never recovered. I took a hour long startrail one day and aside from the picture being garbage due to the purple thermal effect of a CCD that's heating up the camera survived. But my D200 was burning hot to the touch so I won't ever try one that long again.
Sensors generate heat when they are on, and DSLR sensors are not heatsinked. Sensors for telescopes and other dedicated long exposure equipment have large heatsinks or peltier units to keep them cool.
50 Exposures at 30 seconds to 2 minutes within 4 hours.
Not an issue because the camera would have time to cool between shots. Worst case your sensor was off and on for 100 minutes out of 240, I'd expect any camera to do this without even getting warm.
Something like star trails will take 15 minutes or more. I've done those with no apparent ill effects.
I would also say 15 min is not an issue. I'd be worried getting longer than half an hour though, but then again modern cameras *may* last longer still. The 350D is a bit old.
The temperature was around 20 degrees or 68 farenheit. Used a Canon 450D, ISO 100, F8. The camera body istelf was a little warm but nothing to worry about.
The 450D is plastic! The sensor is in the very middle of the camera away from the body! If your camera is warm I would say it IS something to be worried about. If it was an all metal camera with good heat transfer I say non issue, but some thick hardened plastics can almost have the heat transfer characteristics of styrofoam.
Do you have access to a laser temp meter? I'd be interested if you do this again if you quickly flip the camera into cleaning mode and take a reading on the sensor.
For those interested in doing startrails the best way to do it on a DSLR is by stacking images. I have taken a exposure made up of 120 30second exposures with a 5 second gap between each one totalling 70minutes. The camera wasn't anywhere near as warm as my one hour continuous shot, and the image had zero noise as this was averaged out due to the stacking process, not to mention no purple thermal effects.