FLOMEC® Troubleshooting Guide: Loss of Pulse Part Two Page 1 of 8

FLOMEC® Troubleshooting Guide: Loss of Pulse Part Two

What To Do When
You Lose Your
Pulse!
Troubleshoot
Guide for OM
Pulse, UHP &
Electronic D-
Series Meters

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FLOMEC® Troubleshooting Guide: Loss of Pulse Part Two Page 2 of 8

We are back weekwith our second installment on Troubleshooting Pulse Meters.

Here we look at issues such as flow but no output, testing for pulse output with
display or digital multimeter.

Flow.. But No Output

Should the meter have fluid flow freely through it and there is still a fault, then it may
be due to how the meter translates the measurement into an electrical pulse.

Theory of a pulse board;

Pulse meters have 2 different ways of recording ‘pulses’ (every time the rotors spins,
the PCB records a pulse). It can either be via a ‘Reed switch’ (used in intrinsically
safe applications) also known as a 2 wire setup. The other method is using a Hall
Effect sensor (used in high pressure or high temperature applications), known as a 3
wire setup, however a standard board (like the one shown here) comes with both
Hall and Reed. Both these two methods are triggered by magnets passing near the
components on the PCB, which are hidden inside the rotors in the measuring
chamber.
Common faults with Hall Effect are mainly due to either being wired incorrectly or not
meeting the required voltage requirements (Hall Effect Sensors require between 5-
24vDC to operate).

Reed Switches are purely mechanical in nature as they consist of 2 pieces of metal
that are normally not touching and once a magnetic field comes near it, it causes the
two pieces of metal to touch creating a closed circuit. However because it relies on
the metal to flex, they can fail over a period of time due to metal fatigue. In general
they can exceed 2 billion actuations before failing provided it is switching 5vDC or
less, once they fail, they will not close and not give a signal. Reed switches can
handle up 24vDC (same as Hall Effect Sensors) however the higher the supply
voltage is, the shorter their lifespan becomes.

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Hall Effect Sensors are an NPN Solid state device which provides an unsourced
open collector output (no voltage is applied to the output from within the meter).
Because they are a solid state device, the lifespan of these devices are theoretically
infinite as they are can withstand voltage variations (up to 24vDC) and withstand
temperature and mechanical influences which is why they are the preferred choice if
the installation allows it.

The output of the Hall Effect must be pulled to a ‘high’ state with a pull-up
resistor between the signal output and the voltage supply. The pull up resistor
ties the open collector to the available DC voltage supply, in the form of a
square wave form that alternates between ground potential and the supplied
voltage at the signal terminal.
Many secondary flow instruments are fitted with an integral pull-up resistor. If it
does not contain an integral pull-up resistor, one must be externally added.
The pull-up resistor should be sized to limit the Hall Effect switching current to
less than 10mA (use ohms law to calculate this. The recommended minimum
value of a pull up resistor is 2.4k Ohm.

Using a Display To Test A Pulse Output Board

Should either the Hall or Reed switch fail, then a new PCB will be required for the
meter. It is recommended to check the wiring between the meter and the display to
ensure that the fault is not caused by a wiring fault.

A display can be used to measure the pulses out of each sensor independently.

If you are using a Reed Switch output to your receiving instrument and you
have no signal, the possible causes are;

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- The Reed Switch has failed

- Your wiring or receiving instrument has failed
- You are set up incorrectly/programmed incorrectly

Remove the wiring from the terminals of the Pulse Output Board and connect a
display directly to the pulse Output Board with short lengths of wire.

- This isolates the Reed Switch or Hall Effect. The display should be programmed to
have a K- Factor of 1 pulse/gallon or pulse/litre. The display’s total display will
show individual pulses as they are output from your flow meter.

Be sure to check if the display requires a pull-up resistor when using a Hall
Effect pulse.

- If your problem is eliminated, then the problem is with the wiring or the receiving
instrument.
- If your Reed switch output does not function when tested with a display, but you
find that your Hall Effect output functions correctly, then you need to replace the
pulse board.
- Likewise if your Hall Effect output does not function when tested, but your Reed
Switch output functions correctly, then you need to replace the pulse board.

Testing With A Digital Multimeter

A digital multimeter (DMM) can be used to check the condition of your wiring, the
presence of power at the Pulse Output Board terminals, or can be used to check the
operation or accuracy of an analogue loop (4-20mA signal) The DMM cannot be
used to check the presence of a pulse output.

When troubleshooting a Hall Effect output the DMM can be used to measure
the following;

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Input Voltage to your Pulse Output Board. This is done by connecting the
DMM across the +VDC and -0V (COM) terminals of the Pulse Output Board.
The measured voltage should be between 5-24VDC for correct function of the
Hall Effect sensor. If voltage is not present or is below 5VDC, then the Hall
Effect sensor will not function. Voltages above 28VDC will have caused over-
voltage failure, and over 24VDC may have caused failure if voltage spikes
have occurred.

In cases of over-voltage failure, replacement of the Pulse Output Board will be

required.

When troubleshooting a Reed switch with a DMM, you will need to measure
the resistance or continuity.

This is done by attaching the meter probes to the terminals of reed switch and
waving a small magnet over the reed switch on the board. When the magnet
comes into close proximity of the component, the DMM should display a value,
under (1ohm preferably)
If the magnet is near the Reed Switch and you do not get a reading, then a
new board is required.
If the meter shows low resistance without the magnet, check the position of the
meter probes and make sure nothing is bridging the circuit. If not, then the
reed switch has fused together, in which case a new board is required.

The other factors that can be checked using the resistance or continuity setting on
the DMM;
■ Check the presence of a pull-up resistor
■ Check resistance across the +VDC terminal and Signal terminal
■ Check the condition of the wiring

Pulse Meter With 4-20mA Output

When troubleshooting an Oval Gear flow meter fitted with a 4 – 20 mA module or
RT12
Electronic Instrument, the analogue output can be checked using a DMM in series.
The DMM acts as the receiving instrument, and will display the circuit current during
programming or operation. It is important that the series resistance shown be used.
This method isolates the instrument from the PLC or receiving instrument, and will
allow the user to attribute any faults to either the 4 – 20 mA module, or to the
receiving instrument.

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■ If the current measurement on the DMM is correct, then the PLC or receiving
instrument should be inspected for defects.
■ If the current measurement on the
DMM is absent, or inconsistent, then the 4 – 20mA module should be inspected for
defects.
■ The problem could be with the signal output from the flow meter to the 4 – 20mA
module

From the Technical Team here at GPI Australia, we hope this has been helpful.

Thank you kindly,

GPI AustraliaTechCorner

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