Undefined output signals, zero shifts, and even complete failure of measuring equipment are phenomena that cause great inconvenience to users. The good news is that these errors can be easily corrected if the cause is correctly identified.
This article presents a number of typical errors that users may encounter in practice, and which can generally be avoided using just a little information. If your error is not on the list, please contact our specialists.
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Error |
Cause |
Solution |
|
No output signal |
Line damage
|
Check the cable for damage and ensure it is properly positioned. |
|
Connection error |
Check the cable connector compatibility and, if necessary, refer to the installation and operation manual. |
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Incorrect polarity |
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The display shows too low pressure |
The incoming pressure is too low due to contamination of the inlet port |
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The pressure transmitter leaks at the process connection |
Check the sealing gasket for tears or damage (verify gasket material compatibility with the measured medium). |
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The signal is constant but does not exceed a certain value even when pressure increases |
The inlet port is blocked |
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Temperature too low (below -40 °C) |
The measuring cell of the piezoresistive pressure sensor contains a liquid that may freeze at temperatures below -40 °C. In this case, a pressure transmitter optimized for low temperatures should be selected. |
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The output signal shows a high value and remains unchanged |
The allowable measurement range is exceeded. When operating beyond the range, the sensor will not fail but will not display correct measurement results. The output signal has reached the maximum mark and cannot exceed it. |
A pressure transmitter suitable for the measured range must be selected. |
|
The output signal shows too low a value and does not exceed it even when pressure increases |
Input pressure too low |
The inlet port is blocked (see above). |
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Current signal load too high (electronics connected to the sensor draw too much current) |
Reduce the current signal load using the specification/manual. |
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Voltage signal load too low |
Increase the voltage signal load using the specification/manual. |
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Operating voltage too low |
The operating voltage should be increased according to the manual. |
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Pressure transmitter measurement range too wide |
A device matching the measurement range must be selected. The measurement range should be about 75% of the device's capability. |
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Zero shift (signal zero mark too high) |
Membrane deformed by excessively high pressure |
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Membrane deformed or torn by pressure spikes |
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Excessive tightening force during sensor installation (measuring cell damaged) |
This problem is more typical for low-pressure range devices. Pay attention to the maximum tightening force during installation (see Installation Instructions). |
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The output signal changes significantly under the influence of temperature |
Atmospheric pressure supply is blocked (mainly in devices with a low pressure range up to 25 bar) |
Check for contamination in the atmospheric pressure supply. Also make sure the installation was done correctly. |
|
Strong fluctuations in the output signal |
Contacts are damaged |
The cable or connector is damaged. |
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Strong vibrations or pulsation during operation |
The sensor is resonating. Ideally, before selecting a sensor, it is necessary to clarify the allowable shock load. Shock-resistant devices are characterized by sealed electronics and have no adjustable potentiometers. |
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Output signal interference |
Too much electromagnetic interference |
Make sure the cables are shielded. Electromagnetic interference can be prevented by proper installation. |
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Potential difference between the measuring device and the process |
Check the grounding of the pressure transmitter. |
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The output signal disappears after some time of operation |
Electronic components are damaged due to high operating temperature |
The process medium must be sufficiently cooled by a temperature separator, for example, an element with cooling fins or a cooling section. Keller high-temperature pressure sensors: 35 HTT, 35 HTC, M5 HB |
Many of the errors described above occur due to incorrectly selected pressure transmitters. To avoid such errors, it is necessary to take the process of selecting suitable devices for your task as seriously as possible. The optimal option is a free consultation on sensor selection with our specialists. Also, we have a good overview article on choosing pressure transmitters.
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