How to – Understanding Pressure Sensors

How to – Understanding Pressure

Sensors

Ref #: tdoc000259
Rev: 1.0 1
Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors

Safety Alert Symbol

This is the safety alert symbol. It is used in this manual to alert you to
potential personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.

Before you start

The information included in this document is intended for experienced personnel familiar with this type of
equipment.

Only trained and competent personnel should perform the work outlined in this document.

If there are any questions regarding the information provided or the application of the provided information, please
contact, techtraining@terex.com

Operation and maintenance of the machine must be done in accordance with the instructions in the operation
manual for the machine.

Review the safety, operation, and maintenance sections of the operation manual prior to performing this work.

Ref #: tdoc000259
Rev: 1.0 2
Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors

Lockout / Tagout
WHEN CARRYING OUT MAINTENANCE OR ADJUSTMENT THE FOLLOWING
LOCKOUT / TAGOUT PROCEDURE MUST BE FOLLOWED:

NOTE: SOME MAINTENANCE PROCEDURE STEPS MAY REQUIRE SOME OR ALL ENERGY SOURCES TO
BE ENGAGED. IN SUCH CASES ONLY POWER THE MACHINE AFTER THE MACHINE HAS BEEN TAGGED
FOR MAINTENANCE AND ENSURING EVERYONE IS CLEAR.

1. Ensure the machine is empty prior to shut down.

2. Disengage each machine component (e.g. conveyors, etc.) using the control levers.
Note: Turning off all machine components at once causes a pressure spike in the hydraulic circuit.
A slight pause between disengaging each component can prevent this spike from taking place.
3. Turn components off in the order:
A. Component one (e.g. Feeder)
B. Component two (e.g. Side Conveyor or Main Conveyor)
C. Component three (e.g. Crushing Chamber or Screenbox/Fines Conveyor)
D. Component four (e.g. Product Conveyor or RH/LH Side Conveyor)
4. Switch off engine and remove ignition key. Carry the key with you.
5. Engage emergency stop.
6. Use padlock to secure machine isolator at powerunit to prevent restart.
7. Place appropriate maintenance warning sign.
NEVER WORK ALONE

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Rev: 1.0 3
Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors

Stay Safe
• ALWAYS use gloves or barrier cream when working with fuels and lubricants.

• ALWAYS Lockout / Tagout machine prior to carrying out any work.

• ALWAYS immediately clean up any spilled hydraulic oil with correct absorbent material.

• NEVER work alone.

• NEVER use your hands to check for leaks (skin injection risk).

• REMEMBER: Hydraulic systems use fluids under high pressure which can cause major injury or death.

• REMEMBER: STAY SAFE, STAY ALIVE

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Aut: C Walker
How to – Understanding Pressure Sensors

Personal Protective Equipment (PPE)

Your personal safety is the number one priority. Before performing any task or procedure you should wear the
following personal protective equipment as required:

• Safety glasses
• Steel toed safety boots
• Hearing defenders
• Hard hat
• Gloves (heat resistant gloves if performing hot work)
• Tight fitting overalls (fire retardant overalls if performing hot work)
• High visibility vest
• Fall restraint system (if working at height)

Ref #: tdoc000259
Rev: 1.0 5
Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors

Pressure Sensors are a reliable solution for hydraulic and pneumatic pressure sensing
The pressure sensor uses a mA signal to inform the PLC of the pressure in the system
It uses a 4…20 mA signal for this measurement
The software then converts this mA signal into a pressure to display on the PDM
In the below diagram you can see the internals

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How to – Understanding Pressure Sensors
An example of a pressure sensor on a Machine
In the picture below you can see the sensor positioned before an inline filter
The sensor in the picture is monitoring the hydraulic pressure of a PVG
They can be used in many applications with regards to hydraulics

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Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors
Testing the sensor

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Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors

Lockout/Tagout
Test 1 – Testing for power to the sensor
Step 1 – Lockout/Tagout

Remove key LOTO

Ref #: tdoc000259
Rev: 1.0
Date: 25 JUL 19
Aut: C Walker
How to – Understanding Pressure Sensors
Lockout/Tagout
Step 2 – Locate sensor connection plug and remove
Remove sensor connection and locate pins for testing
Pin numbers vary on different machine types, always refer to your electrical schematic

Location of sensor Remove connection from sensor

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Aut: C Walker
How to – Understanding Pressure Sensors

Lockout/Tagout Removed
Step 3 - Remove Lockout/Tagout and key on machine to first position

Isolator on position Key on to first position

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 4 – Select the Volts DC function on your multi-meter

Select Volts DC

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 5 – Pull back sensor cover
Ensure to do this carefully as the wiring can be delicate

Sensor connection Expose connection screws

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How to – Understanding Pressure Sensors

Lockout/Tagout
Step 6 – Connecting the multi-meter
Ensure red probe is connected to the supply wire to the sensor
Place

Red probe on supply wire Black probe on negative

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How to – Understanding Pressure Sensors

Lockout/Tagout
Step 7 – Check findings on multi – meter
You will see 24v-28v
If you do not see 24v-28v consult your electrical schematic and investigate further

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How to – Understanding Pressure Sensors
Lockout/Tagout
Test 2
Step 1 – Lockout Tagout the machine
Ensure that LOTO is correctly fitted and ignition key is removed from panel

Key removed
LOTO

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 2 – Locate sensor on your electrical schematic
This will vary on different machine types
In this example it is a sensor on a Jaw Crusher

Pressure Sensor

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 3– Locate Wiring for testing in electrical panel
Locate signal wire X7 14x11
You will conduct a mA test on this wire

Section X7 Wire 14x11

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 4 – Select the mA function on your multi-meter
Ensure you select the correct range
The sensor uses a 4-20mA range

mA function

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How to – Understanding Pressure Sensors
Lockout/Tagout
Step 5– Attach crocodile clips to both wires on DIN rail
The multi-meter is now reading the return signal in series
The positive and negative can be connected either way to the wires

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How to – Understanding Pressure Sensors

Lockout/Tagout Removed
Step 6 - Remove Lockout/Tagout and key on machine to first position

Isolator on position Key on to first position

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How to – Understanding Pressure Sensors

Lockout/Tagout Removed
Step 7 –Start machine and check mA reading on your multi meter
When you start the machine you will see the mA value change on the multi-meter
In this example below you can see the mA value on the left
This will vary on different machine types due to different stand by pressures

mA value PVG pressure

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Aut: C Walker
How to – Understanding Pressure Sensors

Lockout/Tagout Removed
Step 8 –Operate a function on the PVG block and check Ma reading
Operating a function on the PVG block will have an effect on the mA reading
This is because the pressure is changing within the block
The sensor is now seeing this change and sending the information back to the PLC

mA value PVG pressure

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Date: 25 JUL 19
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How to – Understanding Pressure Sensors
mA Conversion Table
What is the expected mA reading when 40bar is present?

2
20 600 0-600 (range of sensor) = 600
350
19 340
330
18 320
310
3
17 300
290

16 280 = 16/600 = 0.02666

1 270
260
4 to 20 has a range of 16 15 250
240
14 230
220
13 210
200
190 4 40bar is the value on PDM
12 180
170
11 160
150
10 140
130
5
9 120
110 40 x 0.02666 =1.06
100
8 90
6
80
7 70
60 1.06+4=5.06mA
6 50
40
5 30
20
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Rev: 1.0 4 24
Date: 25 JUL 19
Aut: C Walker