Different pressure sensors are essential components of many industrial measuring and control systems. They monitor filter states, control air and gas currents or serve as safety monitoring in pressure-critical processes. A defective sensor can not only lead to incorrect measurement results, but also have serious consequences for system availability, product quality and even operational safety.
This article shows how to defects in differential pressure sensors - such as the PTH-3202 by Seickom Electronic - reliably recognize what causes most often occur and which test measures have proven themselves in practice.
Why differential pressure sensors should be checked regularly
In many industrial applications, the differential pressure is used as a control size, for example at:
- the Filter monitoring in ventilation systems or cleaning in
- the Flow control of air, gases or liquids
- the Monitoring of pressure conditions Between production rooms
A defect in a differential pressure sensor can therefore immediately lead to warning messages are triggered too late or even undetected system errors appear. In security -critical areas - for example in explosive environments - this can have fatal consequences. Therefore, a regular functional test of sensors such as that is PTH-3202 by Seickom Electronic expressly recommended.
Typical causes of defects in differential pressure sensors
Despite robust construction, differential pressure sensors can be damaged by various influences or impaired in their measurement accuracy:
-
Constitious pressure connections: Disposal of dust, moisture or process media in the pressure connections can hinder the pressure forwarding.
-
Mechanical overload: Short -term overpressures, for example by pressure surges, can permanently deform the membrane and thus lead to drift or total failure.
-
Condensation: Especially in the case of air or gas currents in moist environments, condensation can penetrate the measurement cells and cause corrosion or insulation errors there.
-
Electrical disorders: Overvoltages, earthing problems or EMC influences can damage the internal electronics.
-
Temperature stress: Frequent or extreme temperature fluctuations accelerate aging and can damage seals or electronic components.
Signs of a defective differential pressure sensor
A differential pressure sensor that no longer works correctly can often be seen from the following symptoms:
- Spring measured values or permanently show the maximum or minimum value
- Missing switching signals, although the process pressure was clearly achieved
- drift the starting values over time
- Delayed reaction on pressure changes
- No output signals (at 4–20 mA or 0–10 v)
In practice, it is advisable to use sensors in ongoing operation with a calibrated handmare machine to check or temporarily replace it with a reference device.
The PTH-3202 by Seikom Electronic-reliable differential pressure monitoring
The Different pressure sensor PTH-3202 from Seickom Electronic is specially designed for industrial requirements and offers reliable monitoring of air and gas pressure differences- for example for filter status control or fan monitoring.
Device highlights:
- Measuring ranges from ± 50 PA to ± 2,500 PA selectable (alternatively other devices even with a clear larger measuring range)
- Output signals 0–10 V or 4–20 MA
- Robust IP54 housing For the switchboard installation or wall mounting
- Response time <1 second For dynamic processes
- Long -term stability <± 1 % FS/year
Thanks to the capacitive measuring cell, the PTH-3202 is insensitive to temperature fluctuations and ages extremely slowly. Nevertheless, the following also applies here: Without regular visibility and function control, the risk of consequential damage in the overall system increases.
How to check difference pressure sensors in practice
A proven test concept for repairers and security personnel includes the following steps:
-
Visual control
Check the connection lines, screw connections and housings for visible damage, corrosion or leak. -
Signaling
Compare the measured differential pressure values with a calibrated handmy. Pay attention to linear signal processes for defined pressure levels. -
Zero -point control
If the condition is free of pressure, the output should display 0 PA (or 4 MA or 0 V). Deviations indicate an offset shift. -
Review of the response time
In the event of quick pressure changes, the output signal should follow in less than 1 second. Delays can indicate membrane deformations or electronics defects. -
Isolation test (optional)
In frequent failures, a test of the electrical insulation between signal lines and housing mass is worthwhile.
Security is going on - preventive maintenance is worthwhile
The regular testing of differential pressure sensors not only protects against unplanned stills and maintenance costs, but is even in safety -relevant applications legally required (e.g. according to TRBS or VDI 6022).
Practice tip: Systematically capture test cycles and results in a maintenance plan - this is how you recognize trends at an early stage before failure occurs.
