Core Judgment Logic: If the abnormal signal persists after wiring checks and calibration adjustments, the sensor is considered damaged. A three-step quick troubleshooting method can confirm the diagnosis:
1. Step One: Eliminate External Issues (Elimination Method to Narrow Down the Scope)
First, check for external issues such as loose wiring, abnormal power supply, and module malfunction:
Reconnect and reconnect the wiring, confirm the power supply voltage is normal. If the abnormal signal persists, wiring issues are ruled out.
Relocate the sensor to a working mounting position of the same specification. If the abnormality persists, the control system and the hot runner itself are ruled out.
2. Step Two: Check for Key Abnormal Indicators that Suspect Damage
If any of the following conditions are met and cannot be repaired after calibration adjustments, damage can be determined:
Under zero pressure, the output deviates from zero by more than 10% FS, and repeated fine-tuning of the zero-point potentiometer cannot bring it back to the acceptable range;
When the pressure changes, the output signal does not change at all (remains fixed at 0 or full scale), or the jumps are completely irregular;
After calibration, the deviation exceeds the limit again in less than a week, the zero point continues to drift, and it cannot be stabilized.
3. Third Step: Cross-validation for Final Diagnosis. Replace the original sensor (of the same specifications) with a known working one in the same mounting position. If production returns to normal and the signal stabilizes, then replace the original sensor with the working one. If the original problem persists, then it can be confirmed with 100% certainty that the original sensor is damaged.
This method can quickly distinguish between "interchange error requiring calibration" and "the sensor itself is faulty," avoiding misjudgments and wasted costs.
