Common Failure Types of Diffused Silicon Pressure Sensors and Solutions

In industrial flow control systems, the stable operation of pressure transmitters such as CFUEIIIERC1 and BSCYG9010-1.0 is directly related to production safety and efficiency. As the core component, diffused silicon sensors often show faults such as abnormal display, signal fluctuation, or accuracy deviation. Based on 15 years of industry service experience, Xi'an Shenghongchuang Instrumentation Co., Ltd. has summarized the following 5 typical faults and their troubleshooting methods to help contract operators respond quickly to on-site issues.

1. Zero Drift and Abnormal Display（Fault Code E1）

When transmitters such as KYB-Z04 and CS-PT1200V show irregular fluctuations or zero return failure, first check whether the sensor diaphragm is contaminated by medium crystallization. Diffused silicon sensors are sensitive to corrosive gases such as H2S and CL2, and it is recommended to clean and calibrate the diaphragm with isopropanol. If the EDYBT-49 transmitter displays a value exceeding ±0.5%FS under no-load conditions, the zero-point parameters need to be recalibrated through the HART protocol. It is worth noting that a long-term vibration environment will cause imbalance in the Wheatstone bridge resistance of the ZWP-L61-K sensor, and the vibration damping performance of the mounting bracket should be checked at this time.

2. Abnormal Full-Scale Output（Fault Code E2）

When the BAR-GP1 transmitter shows nonlinear output in the high-pressure section, it is often related to overload of the diffused silicon chip. Use a multimeter to measure the excitation voltage（usually 10VDC±5%）, and if the KYB18G07M1P4C3-I sensor output signal remains saturated, the medium pressure may have exceeded the upper limit of the 20MPa range. For the HQ-HQ1002 model, it is also necessary to check whether AC interference has been introduced into the 24V power supply circuit, and add a signal isolator if necessary. According to the GB/T 34036-2017 standard, after overload recovery, the diffused silicon sensor must undergo 3 full-scale cycle tests.

3. Accuracy Deviation Caused by Temperature Drift

If the CEMPX215-GATCA1 transmitter output fluctuation exceeds 0.1%FS/℃ when the ambient temperature changes by ±10℃, it indicates failure of the temperature compensation circuit. High-quality diffused silicon sensors should have a built-in PT1000 compensation resistor, which can be verified by comparing the temperature-output curve in the manual. Xi'an Shenghongchuang's solution is to use laser trimming technology, enabling the CS-PT1200V sensor to maintain ±0.25% accuracy within the -40~125℃ range. If shutdown is not possible on site, it is recommended to install a constant-temperature protective cover and carry out online calibration every quarter.

4. Troubleshooting Electrical Connection Faults

According to the IEC 61508 standard, wiring errors in pressure transmitters can lead to more than 30% false alarms. Focus on checking the 4-20mA loop of the ZWP-L61-K sensor:

5. Medium Compatibility Failure

When measuring chlor-alkali media, pitting corrosion may occur on the 316L diaphragm of the EDYBT-49 sensor. It is recommended to select the HQ-HQ1002 transmitter made of Hastelloy C276 material, which has passed NACE MR0175 sour environment certification. For viscous media, the BAR-GP1 model needs to be equipped with a flush diaphragm and cleaned regularly with ultrasound. The customized services provided by Xi'an Shenghongchuang can optimize the sensor sealing structure according to different media characteristics, extending MTBF to more than 100000 hours.

Why Choose Shenghongchuang Instrumentation

As a high-tech enterprise in Xixian New Area, we provide the following for the full range of pressure transmitters such as KYB-Z04 and CFUEIIIERC1:

• 72-hour emergency response service, including on-site diagnosis and spare parts replacement
• Calibration laboratory compliant with GB/T 17614.3-2018
• 10-year aging test database for diffused silicon sensors
• Support for customized protocol development such as RS485/MODBUS

Call 029-8456XXXX now to obtain the "Diffused Silicon Sensor Maintenance Manual" and exclusive technical service solutions, ensuring the continuous and stable operation of your flow control system.