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How a Pressure Sensor Can Affect Equipment Reliability

Likewise, your equipment is only as good as each of its components.

You know the old cliché: a chain is only as strong as its weakest link.

Choose Equipment Reliability...Every year, your customers must overcome a number of obstacles that threaten their operations: increasing material costs, unpredictable weather, government regulation, and unplanned equipment downtime. You can’t control the weather, but you can help them by ensuring the reliability of your equipment.

Monitoring = Safe and Efficient OperationPressure sensors play an important role in the safe and efficient operation of a wide range of mobile hydraulic equipment. They monitor a variety of functions, such as controlling operating pressure, load pressure, brake pressure, valve pressure, filters, flow rates and fluid levels.

CRITICAL TO FUNCTION (CTF)Measure pressure to control critical systems

CRITICAL TO SAFETY (CTS)Measure pressure to provide warning of unsafe conditions

BASIC MONITORING Measure pressure to ensure consistent performance

Combustion engine

Cooling system

Suspension system

Hydraulic traction drive Brake safety

Main hydraulics

ECU – Electronic control unit

Steering system

1Call 855-362-9452 or visit www.WIKA-Sensors.com

4 trucks and their drivers stop working...

Dozer and its operator stop working...

You lose tens of thousandsof dollars per hour

Your customerdemands anexplanation

One of your excavatorsbreaks down...1

2

34

5

True Cost of Failure: Mining

2 Call 855-362-9452 or visit www.WIKA-Sensors.com

Downtime is more than one machine—it’s your entire production line. Breakdowns can cost a lot more than the parts and labor needed to fix the machine and return it to work. As seen in the hypothetical example below, downtime in one machine affects the rest of production.

4 trucks and their drivers stop working...

Dozer and its operator stop working...

You lose tens of thousandsof dollars per hour

Your customerdemands anexplanation

One of your excavatorsbreaks down...1

2

34

5




Selecting a Sensor: MiningShock and VibrationShock and vibration can eat away at a pressure transmitter. Having a sensor that cannot withstand these forces could lead to unnecessary downtime.

Electrical InterferenceEMI/RFI interference on a mining site, or on any site, can cause signal instability and inaccuracy in the pressure transmitter.

TemperatureEquipment using mobile hydraulic systems are typically exposed to environments ranging from the frozen tundra of Alaska to the deserts of Australia. These rapid temperature changes affect pressure transmitters as they do any electronics.

Water IngressIt’s important that you have a pressure transmitter that can weather the high pressures and temperatures that are present during a high pressure wash down. Not to mention being able to stop water from entering the unit in all kinds of wet environments.

In addition to personal injury costs, an accident affects production. These indirect costs can include schedule delays, repairs to damaged property, maintaining insurance coverage, and added administrative time, not to mention losing the trust of your mostvaluable customers.

$7,0001

Without LostWork Day

$28,0001

With LostWork Day

$152,0001

Indirect Costs

$910,0001

WithOccupational

Death

$225/hr.2

equipmentrental cost

alone

DownMachine

OSHA found that an accident can cost your company +$1,000,0001

True Cost of Failure: Construction

Pressure transmitters help indicate that the application is within safe operating parameters. A failed or inaccurate sensor can also lead to equipment downtime, which will impact productivity.


In addition to personal injury costs, an accident affects production. These indirect costs can include schedule delays, repairs to damaged property, maintaining insurance coverage, and added administrative time, not to mention losing the trust of your mostvaluable customers.

$7,0001

Without LostWork Day

$28,0001

With LostWork Day

$152,0001

Indirect Costs

$910,0001

WithOccupational

Death

$225/hr.2

equipmentrental cost

alone

DownMachine


1 OSHA average costs, includes both direct and indirect costs, excludes property damage.2 WIKA industry research


Selecting a Sensor: ConstructionLong-Term StabilityThe performance of a transmitter on day one is obviously essential, but its performance in year two, three and beyond is even more important.

Shock and VibrationIs this a pressure transmitter that is going to be able to withstand the shocks and vibrations that are commonly present in a construction site? What about internal stresses such as changing loads and cavitation?

Pressure SpikesYou can have huge pressure spikes when you open and close a valve. Also, large equipment may experience propagated waves of pressure that come back and hit the pressure sensor. Your sensor needs to be able to withstand these variations.


True Cost of Failure: Agriculture

A failed pressure sensor on a cutting boom control could mean the boom fails to remain at a consistent height, hurting productivity all because of a small sensor. An inaccurate or failing sensor could also lead to applying too little or too much chemicals or fertilizer, leading to negative outcomes.

Nutrient inputs are responsible for between 30-50% of crop yield 1...

If a sensor’s not working properly, then you can end up applying too much or too little material in a certain area...

Resulting in the possibility of excess run-off and EPA fines...

As well as decreasing your crop yield.


1 http://www.ipni.net/ppiweb/ppinews.nsf/0/7DE814BEC3A5A6EF85256BD80067B43C/$FILE/Crop%20Yield.pdf2 Industry studies

Selecting a Sensor: Agriculture

Shock and VibrationSomething as simple as a running engine can actually shake apart the sensor over time. You need a sensor that’s robust enough to withstand the constant vibration so you don’t have a failed unit in the field.

Chemical CompatibilityYou want to make sure the sensor is compatible with the material your customer will be applying. Chemicals and fertilizers can degrade the sensor over time.

Survive the EnvironmentYou need a pressure sensor that can survive the environment in which your equipment is used. If your unit is unable to withstand the elements—such as torrential rainfall—then water will get into the sensor. This may disrupt the electronics and skew the output.

Down machine cost =$7,000/hr. in rental cost alone.2


Why WIKA?At WIKA, we maintain control over every facet of our manufacturing, including making our own thin film sensor. This way, we can ensure our products give you the durability and reliability you—and your customers—demand.

It’s all a part of who we are at WIKA.

We build it WIKA tough…

So you never have to apologize to a customer with a machine down.


From design to delivery to after-sales support, we’ve structured ourselves to ensure you get the most

efficient use of our products as possible.

Collaborative Design Real-World Testing Customization Supply Chain Customer Care

During WIKA’s Value Innovation

Workshop, we bring our engineers together with the engineers of key industry leaders

to develop new, game-changing

products.

WIKA conducts more than 80 different tests—including

mechanical, environmental, and electrical tests—to

make sure our products can withstand

your real-worldenvironment.

We can custom configure items such

as signal output, pressure range,

connections, and special design features

to make sure you have the right product

for your specific application.

WIKA partners with your company to

choreograph logistics that reduce order fulfillment time,

and accommodate your needs.

We provide the support you need

to ensure you have the most efficient

experience with our products.


By manufacturing our products, we can ensure you

get an exceptional

qualityproduct

customizableproduct

And by working directly with the manufacturer,

you benefit from a totally

innovationsproduct

We can also work with you and your team to help your

Every Product is a PromiseThe WIKA promise means that we will not allow anything less than the best products to leave our factory. It all starts with our WIKA Production System, which is based on KAIZEN, Lean and Six-Sigma principles. Attention to detail is a typical “German” trait, and we bring this scrutiny to every phase—from design to process development and process qualification to production.

Real-World Results

Innovative Product Design Quality Materials High Degree

of Automation Process Control Rigorous Testing


Sensors are at the heart of your monitoring device.

While others may outsource this function to avoid the millions in capital expenditures, we refuse to relinquish control of something so important.

By manufacturing our own sensors, we help decrease defect rates and improve durability and quality.

We Do Things DifferentlyWe believe that all relevant processes and technologies must be under our control. For instance, we make our own sensors to ensure we deliver reliable products.


WIKA Real-World TestingWIKA takes the same set of 10 sensors and runs them through a battery of tests to help ensure reliable performance in all real-life conditions. Putting them through one test after another helps ensure they perform in an array of real-life conditions, not just one or a few.

20 Mechanical TestsSuch as Connector Accuracy, Housing Stability

and Impact Resistance

Batch of 10Electrical Sensors

50 Environmental TestsSuch as Continuous Shocks, Ice Water, Vibration,

Resistance to Chemicals and High Pressure

10 Electrical TestsSuch as Overvoltage Resistance,

Load Dump and Radiates Field

Tests to ensure reliabilityand functionality



The result is a better product to handle the rigors of mobile hydraulics applications...

20 Mechanical TestsSuch as Connector Accuracy, Housing Stability

and Impact Resistance

Batch of 10Electrical Sensors

50 Environmental TestsSuch as Continuous Shocks, Ice Water, Vibration,

Resistance to Chemicals and High Pressure

10 Electrical TestsSuch as Overvoltage Resistance,

Load Dump and Radiates Field




Durable thin film sensor technology provides excellent long-term stability in applications producing frequent pressure cycles.

Cavitation Dampening System protects unit from pressure spikes and cavitation.

Cable version provides environmental protection to IP 69K for resistance to high-pressure steam wash-down cleaning procedures.

EMI properties in accordance with EN 61326 offer consistent operation even when exposed to severe interference.

Welded sensor cell provides a leak- free seal that eliminates the need for additional soft-sealing materials.

Can customize to your needs, including special pressure ranges and configurations and a Private Label service with no additional minimum quantity requirements and at a very low set-up cost.

Mobile Hydraulic Pressure TransmitterWIKA’s MH-2 mobile hydraulic pressure transmitter is one of the most rugged pressure transmitters available today. This pressure transmitter, offers extreme shock and vibration resistance, high-pressure steam wash down protection, and the WIKA CDS system (cavitation dampening system). The MH-2 has a plastic body, with a metal liner for EMI/ RFI protection.

MH-2


Pressure TransmitterThe unique WIKA countersunk sensor design coupled with the CDS system for protection against pressure spikes makes the MH-1 one of the most durable, accurate pressure transmitters available today. Its all-stainless steel body and bullet-proof construction make the MH-1 suitable for the most severe environments.

MH-1

CDS system includes an arc eroded pressure channel for additional protection against pressure spikes and pulsations.

Sputtered technology provides excellent long-term stability in applications producing frequent pressure cycles.

Provides ingress protection from IP 65 to IP 69 K (steam jet protection).

All-welded thin film measuring cell eliminates need for additional soft- sealing materials that may deteriorate over time.

Thin film sensor is recessed into the hex to provide mechanical protection against system fluid loss in case the transmitter body is damaged.


Pressure TransmitterThe MHC-1 combines outstanding temperature characteristics, excellent accuracy specifications and an instrument concept that has been designed and tested for the severe operating conditions of mobile applications. And it is available with either CANopen® or J1939 protocol.

You can order these instruments preconfigured so that they can be installed without further effort.

MHC-1

High EMC protection shields unit from electrical interference.

Offers IP 6K9K ingress protection.

Version with integrated Y-connector offers easy and secure installation.

Available with either CANopen® or J1939 protocol.

* CANopen is a Community Trademark of CAN in Automation.


Pressure TransmitterWIKA’s MHS-1 pressure transmitter offers the first integrated dual pressure sensors, manufactured specifically for safety-critical and safety-related applications in mobile hydraulics. It includes dual (2 channel) pressure measurement, separate electrical signal processing and two independent 4-20mA output signals enable control-side redundant monitoring for pressure measurement points. A random hardware or software error of the safety-critical load monitoring system can be detected by monitoring the dual pressure sensors in the control system, and the actuator can be set to a safe condition if a hazardous condition is detected. This reduces the probability of a dangerous failure and increases process security, not to mention reducing the cost of buying two individual sensors.

MHS-1

Hermetically-sealed, welded, dry thin-film measuring cell with its sputtered Wheatstone bridge offers long-term stability in applications with high dynamic load changes.

Robust stainless steel housing and the IP 69K high pressure steam washdown rated electrical connection are designed and extensively tested to withstand extreme conditions.

Thin film sensors feature excellent resistance to pressure spikes.

Cost effective—mechanical and electrical installation costs are lower than installing two individual pressure sensors.

Channel 1 can be a pressure sensor with measuring range 0-3000 PSI with a 4-20mA proportional electrical output signal and Channel 2 can be 0-5000PSI for 4-20mA.

Arc eroded pressure port and cavitation damping system integral to the process connection minimizes the possibility of pressure sensor failure.


B031-0000 06/13 WIKA® is a registered trademark of WIKA Alexander Wiegand SE & Co. KG., used under license by WIKA Instrument, LP. Copyright 2013 WIKA Instrument, LP. All Rights Reserved.

We Make It WIKA Tough...So You Never Have To Say You’re Sorry.

No one want to receive a phone call from a customer with a machine down. So, why chose a sensor from a general industrial catalog when you have a mission-critical application?

To learn more about how we have designed and tested our pressure sensors to withstand the real-world conditions your equipment faces, see our video at WIKA-Sensors.com.

Wika instrument, lp1000 Wiegand BoulevardLawrenceville, GA 30043Tel (855) 362-9452Email: [email protected]

Date post:	21-Mar-2018
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