Common faults and solutions of float level gauges

Common faults and solutions

1. The liquid level indication is abnormal

Phenomenon: The displayed value deviates from the actual liquid level, such as continuous full-scale range, zero or large fluctuations in the value.

Causes: The float is detached, broken or the counterweight is out of balance, and the catheter is blocked, causing the float to get stuck; Deterioration or damage to sensors or circuit components.

Solution: Check and replace the broken float and clean up the impurities in the catheter; Calibrate sensors, repair or replace faulty circuit components.

2. The float is stuck or does not move

Phenomenon: The float is fixed or moves slowly, and cannot change with the liquid level.

Cause: foreign matter or media impurities (such as iron filings, dirt) blocking the float; High viscosity liquid or magnetic tank adsorption floats.

Solution: Regularly clean the float and guide rod, install a filter device to intercept impurities; For magnetic tanks, add fixing clamps or adjust the installation spacing.

3. The signal output is abnormal

Phenomenon: No signal output, current fluctuations or false alarms.

Cause: Power failure or loose wiring; magnetic field interference (e.g., strong electromagnetic equipment in the vicinity); The reed switch is overloaded or damaged.

Solution: Check the power supply voltage (24V±20%), tighten the terminals; Use shielded cables and reliably ground, install signal isolators if necessary; Replace the reed switch assembly with a voltage/current compatibility.

4. Leakage issues

Phenomenon: Liquid seepage at flanges and threaded interfaces.

Causes: Aging or corrosion of gaskets; Not tightened according to standard torque during installation.

Solution: Regularly replace the seals that are resistant to medium corrosion; Re-tighten the bolts evenly to avoid seal failure caused by force on one side.

5. Interference from environmental factors

Phenomenon: Temperature or air bubbles cause measurement errors.

Causes: The density of liquids is affected by temperature changes; The medium contains air to form bubbles that interfere with the buoyancy of the float.

Solution: Add real-time calibration of temperature sensors as much as possible; Install a defoamer or add a defoamer to reduce the effect of air bubbles.

Preventive maintenance recommendations

1. Regular cleaning: Clean the impurities in the float, guide rod and catheter every quarter to avoid jamming.

2. Seal inspection: check the status of seals every month and replace aging parts in time.

3. Calibration and debugging: calibrate the sensor and signal output every six months to ensure accuracy.

4. Environmental optimization: avoid strong magnetic field, high temperature or severe vibration environment, and install protective devices if necessary.

Float level gauge failures are often caused by mechanical jamming, electrical aging, or environmental disturbances, and targeted maintenance can significantly extend the life of the equipment. For complex faults, it is recommended to contact professional technicians or original factory support to ensure safe and efficient resolution.