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Reasons and Solutions of Differential Pressure Switch Failures


Differential pressure switch could be called as differential pressure controller, it is an indispensable sensor element in tens of thousands of equipment from refrigeration system to filter. The differential pressure switch converts the applied pressure into electrical signal, and then transmits it to PLC (programmable logic controller), recorder or digital instrument and other equipment to analyze the electrical signal and use it to display, record or modify the pressure of the equipment.

differential pressure switches for the auto flushback filter

Differential Pressure Switches for the Auto Backflush Filter
(made by A.YITE TECH, GE-511 series)



Although most electronic differential pressure switches are solid-state devices, their service life is indeed limited and they are vulnerable to damage from various sources.
Causes of differential pressure switch failure



Use Wrong Media

In view of the wide variety of differential pressure switches, it is not surprising that one of the most common causes of electronic pressure sensor failure is improper application. Misuse means that the wrong type of differential pressure sensor is used in an inappropriate application. Some common erroneous applications include the use of differential pressure switches that are not compatible with the system medium.


Vibration or shock
Vibration actually splits the equipment. Over time, impact or impact on the equipment will only make the problem worse. electronic differential pressure switch is specially designed to resist shock and vibration. Each of these solid electronic differential pressure switches has 20 mechanical tests in the factory before leaving the factory.


Over Use Pressure and Over Pressure Instantaneously
Any type of differential pressure switch used in equipment, if the pressure is higher than its recommended pressure range, it will have the risk of bursting and the service life may be shortened. The instantaneous peak pressure is also very common in some applications. At the moment when the water pump is opened, the pressure will be very high, which may exceed 2 times of the normal operation pressure, thus damaging the differential pressure switch. As a result of these applications, all "A.YITE" brand electronic differential pressure switches are fully tested, including impact resistance and case stability.


Digital Differential Pressure Switches with 2 set points

Digital Differential Pressure Switches with 2 set points
(made by A.YITE TECH, GE-209 series)




Temperature too high or too low
The electronic equipment is designed to operate within the specified temperature range. Long term use above or below specification may lead to early failure. Repeated expansion and contraction during the temperature cycle will degrade the gasket and even the transmitter housing, resulting in cracking and forming a leak path. Any experienced hydropower engineer should understand the importance of using differential pressure switches to cope with extreme temperatures.


Water in electrical components
Everyone knows to avoid water in electronic equipment, but in many applications, it is almost inevitable to come into contact with water accidentally. Most importantly, all electronic differential pressure switches shall be fully sealed. As part of our quality control process, we have conducted more than 50 environmental tests, and all Hong Kong A.YITE brand differential pressure switches have undergone thorough waterproof tests.


Electrical interference
Although electronic equipment may encounter electronic interference problems due to the proliferation of electronic interference sources, most electronic devices have good shielding performance today. However, when the shielding layer is lowered, electromagnetic or radio-frequency interference will cause problems in the differential pressure switch, such as signal instability or signal inaccuracy. Aite brand electronic differential pressure switch is subject to 10 separate electrical tests, including overvoltage resistance and load sudden drop.


Chemical damage
Whether it is the fertilizer and pesticide sprayed from the caustic process medium or agricultural machinery, the differential pressure switch will almost inevitably be exposed to corrosive chemicals, which will eventually shorten the service life of the equipment. An easy way to solve this problem is to make sure that the pressure sensor you choose is made of a material that is compatible with the chemicals it contacts.

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