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056-092 Best Practices For Wiring Resistive Sensors
056-092 Best Practices For Wiring Resistive Sensors
Resistive Sensors
1 OVERVIEW
This training document is intended to assist with wiring resistive sensors to DSE modules. Outlined below are the DSE
recommended wiring practices, as well as examples of common mistakes made when installing sensors. It is
assumed that all personnel carrying out the work described have a sufficient level of technical knowledge to assess
and complete the job to a competent level.
NOTE: The diagram shows a generic earthing configuration. For further information on earthing
conventions, such as floating or positive earth, refer to the relevant DSE operators manual.
DSE recommendations for wiring resistive sensors are outlined below in bullet notation. All points are intended solely
as a guideline, and as such each installation must be evaluated individually from both an operational and safety
perspective.
o Sensor ground connections wired directly between the sensor body and engine block.
o Analogue input common used solely as ground reference, and not providing a ground connection for any other
device.
o Analogue input common circuit unsusceptible to voltage increase as a result of current flow from another device,
for example return current from a battery charger.
o Consideration for the sensor cable lengths, cross-sectional area and quality made to ensure voltage drop across
the cable remains within acceptable limits. Refer to relevant DSE Operator Manual and manufacturers
specifications for the sensor.
o Battery negative connected to earth.
Analogue
Input
Common
wired directly
to earth point
with no other
connections.
Correctly
specified
cable used.
o PTFE Tape Around Sensor Threads. Often used to aid sealing, the PTFE tape also acts as electrical insulation.
This is a problem on resistive sensors designed to use the surface they are screwed into (usually the engine
block) as the earth connection. The PTFE tape creates a high resistance between the sensor and earth, causing
incorrect values/loss of sensor readings.
o Incorrect Washer/Seal Used with Sensor. Similarly to the PTFE tape, the wrong type of washer or seal for the
selected sensor may cause a high resistance to the sensor common. Manufacturers guidelines must always be
followed regarding sealing requirements.
o Sensor Failure. The majority of resistive sensors utilise internal moving parts to provide variable readings. As
with all moving components, these are subject to wear and will fail in time. Environmental factors such as water
ingress may serve to additionally shorten the lifespan of such parts. A typical failing resistive sensor may display
high readings, before becoming permanently open circuit.
o Poor Termination. Incorrectly terminated sensor wires may cause high resistance, and thus incorrect readings.
Furthermore, the connections are likely to be weaker and may fail sooner than expected, especially if attached to
vibrating machinery such as an engine.
o Oil Pressure
o Generator Frequency
o Engine Speed
o Charge Alternator Voltage
o Generator Voltage
If the engine is physically verified to have stopped, and the alarm is present, the most likely cause is a fault in the Oil
Pressure Sensor circuit. This may be due to any of the faults or incorrect wiring practices described elsewhere in this
document. The Oil Pressure value is checked on the front panel of the DSE module or using the SCADA section of the
DSE Configuration Suite PC software. Carrying out this quick and easy test may avoid a lengthy fault finding process.