Duweyintelli Manufacturer During the long-term operation of turbine flowmeters, two types of faults, mechanical structure and electronic device, are prone to occur, which in turn lead to problems such as measurement inaccuracy, no display on the device, and abnormal signals. Now, the common fault phenomena, fault causes, and corresponding troubleshooting methods of the device are sorted out as follows to facilitate maintenance personnel to quickly locate and solve problems, ensuring the stable operation of the device.
Malfunctions and Handling Methods of the Mechanical Part of the Flow Meter
Mechanical failures are mostly caused by wear from media impurities, component aging, and seal failure, mainly affectingflow metersmedia flow and impeller operation, directly resulting in flow measurement deviations.
Equipment leakage, large deviation in measured flow rate
Fault Phenomenon: The flow data of the device operation shows obvious deviation.
Troubleshooting and handling: Focus on checking the overall installation tightness of the flowmeter, inspecting whether there are issues such as leakage, loose seals, and aging or damage of gaskets at positions such as flanges, gaskets, and joints, and promptly replacing sealing components and tightening the installation structure to ensure the equipment is well-sealed.
Rectifier blockage, sudden drop in flow pressure
Fault Phenomenon: The pipeline flow rate and medium pressure show a significant decline, and the flow output is abnormal.
Troubleshooting: This fault is mostly caused by the upstream rectifier being blocked by medium impurities and particulate matter. It is necessary to shut down the machine, disassemble and clean the internal debris of the rectifier to restore the normal flow of the medium. Subsequently, it is necessary to regularly check the operating conditions of the filter to avoid blockage again.
Impeller damage, inaccurate measurement readings
Fault Phenomenon: The flowmeter reading deviation exceeds the standard, and the flow measurement is unstable.
Troubleshooting and Handling: After long-term operation of the equipment, the impeller is prone to problems such as wear, breakage, and deformation, which cause uneven rotation of the impeller when the medium flows through, making it impossible to accurately collect flow data. After confirming the damage to the impeller, the flow sensor needs to be directly replaced, and the parameters need to be recalibrated before it can be put into use.
Bearing wear and component aging failures
Fault Phenomenon: The impeller runs laggy and makes abnormal noises, and the measurement accuracy continuously declines, which is the most common mechanical wear-and-tear fault of flow meters.
Troubleshooting and Handling: The bearing is a vulnerable core component that is prone to aging and damage due to the impact of medium scouring and long-term friction. Based on equipment operation and maintenance experience, it is recommended to conduct a special cleaning or overall replacement of the bearing every two years to proactively avoid measurement failures caused by laggy operation and wear.
Magnetic induction element damaged, Data Acquisition failed
Fault Phenomenon: The device fails to properly collect the medium flow rate, with the readings remaining unchanged, data being distorted, and unable to accurately reflect the actual flow rate value.
Troubleshooting and Handling: After confirming that the magnetic induction element is damaged, the corresponding element needs to be replaced in a timely manner to restore the device’s flow signal acquisition and transmission functions.
Faults and Treatment Methods of the Electronic Device Part of the Flowmeter
Electronic failures are mostly caused by abnormal power supply, wiring errors, poor grounding, component damage, and improper parameter settings, mainly manifested as problems such as no display, no signal, flow fluctuations, and non – metering of small flows.
General Electric Protection Requirements
The electronic device of the flowmeter must be reliably grounded, strictly match the power supply specified by the equipment, and it is strictly prohibited to supply power irregularly or have poor grounding to avoid voltage abnormalities and electrostatic interference that could burn out internal electronic components.
No signal output after the device is powered on
Troubleshooting steps: ① Check whether the power supply and output wiring of the device are correct and whether there is any looseness or disconnection; ② Appropriately increase the medium flow rate to ensure that the actual flow rate reaches the starting working flow rate of the flowmeter; ③ Verify the parameter settings of the device’s pulse output mode to ensure that the selected model matches the working conditions.
Instantaneous flow shows zero
Troubleshooting: When the device is powered on normally, there is medium flowing through the pipeline, but the instantaneous flow reading is zero, focus on checking the operating status of the preamplifier, troubleshooting amplifier malfunctions and signal transmission interruption issues, and promptly repair or replace it.
The instantaneous flow value fluctuates unstably
Cause of failure: mainly caused by poor grounding of the equipment, external signal interference, or laggy operation and unstable rotation speed of the sensor impeller.
Troubleshooting and handling: Re-standardize grounding operations, investigate and avoid surrounding interference sources; inspect and clean debris from the impeller, overhaul bearings to ensure the impeller operates at a uniform and stable speed.
No signal under low flow conditions
Troubleshooting: When the device measures large flow rates normally but has no signal output for small flow rates, it is necessary to check the lower limit cut-off frequency parameter of the flowmeter, optimize the parameter settings as needed, and adapt to the small flow rate measurement conditions.
LCD screen shows no display, device screen goes black
Troubleshooting and Handling: ① First, check the device’s battery level. If the battery is low, recharge it or replace the battery in a timely manner; ② When the battery is normal, check if the LCD screen is damaged or malfunctioning, and replace the damaged screen; ③ Check for wiring connection issues. If the main circuit board is burned out, the circuit board needs to be directly replaced to restore the normal display and operation of the device.
Note: Various fault phenomena, causes, and corresponding troubleshooting methods of turbine flowmeters can be accurately checked against the equipment fault comparison table to achieve rapid maintenance and quick resumption of operation.
Common faults and troubleshooting methods of turbine flow meters are shown in the table:
| Fault Phenomenon | Possible Causes | Exclusion Method |
| No output signal after power is turned on | 1. No medium flowing in the pipeline or the flow rate is lower than the starting flow rate:2. Incorrect connection between power supply and output line:3. Pre-amplifier damaged: (integrator does not count, instantaneous value is 0)4. The drive amplifier circuit is damaged (integrator is normal). | 1. Increase the medium flow rate or replace the flowmeter with a smaller diameter to meet the requirements of the flow range:2. Correct wiring:3. Replace the preamplifier:4. Replace the damaged components in the driver amplifier |
| The flowmeter outputs a signal when there is no flow | 1. Poor grounding of the flowmeter or interference with the wiring of high-voltage and other ground wires:2. Amplifier sensitivity is too high or self-excitation occurs:3. Unstable power supply, poor filtering, and other electrical interference.4. Pipe vibration causes the impeller to shake accordingly, generating false signals | 1. Properly connect the ground wire to eliminate interference; 2. Replace the preamplifier;3. Repair or replace the power supply and eliminate interference.4. Reinforce pipelines or install brackets before and after sensors to prevent vibration. |
| Instantaneous flow value display is unstable | 1. Medium flow rate is unstable:2. The amplifier sensitivity is too high or too low, resulting in overcounting or undercounting of pulses:3. There are foreign objects inside the housing:4. Poor grounding:5. Flow rate is below the lower limit value:6. The sealing ring has protrusions extending into the pipeline, creating disturbances. | 1. Measure after the flow stabilizes:2. Replace the preamplifier:3. Sweep and remove dirt:4. Check the grounding circuit to ensure it is functioning properly. |
| The indicated cumulative flow does not match the actual cumulative amount | 1. The meter factor of the flowmeter is incorrectly entered.2. The user’s normal flow rate is lower or higher than the normal flow rate range of the selected flow meter. | 1. Enter the correct meter factor:2. Adjust the pipeline flow to make it normal or select a flowmeter of appropriate specifications: |
| Display is abnormal | Converter button has poor contact or is locked | Replace the display panel |
| After replacing the battery Freeze occurred | The power-on reset circuit is abnormal or the oscillator circuit fails to oscillate | Reinstall the battery (reinstall after discharging for 5 seconds) |
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