Endress+Hauser Troubleshooting Guide for Flow, Level, Pressure, Temperature and Analytical Instruments

Flow Measurement Troubleshooting

Flow Meter Reading Too Low or Zero

• Check for empty pipe conditions or partially filled lines.
• Verify grounding and bonding for electromagnetic meters.
• Inspect electrodes for coating, scaling or fouling.
• Confirm correct installation orientation and straight-run lengths.
• Check for air pockets or entrained gas in the line.

Unstable or Noisy Flow Readings

• Verify flow profile and eliminate upstream disturbances.
• Check for vibration affecting Coriolis or vortex meters.
• Inspect process conditions for two-phase flow.
• Confirm correct grounding and shielding of signal cables.

Clamp-On Ultrasonic Issues

• Ensure correct transducer spacing and coupling gel application.
• Verify pipe wall thickness and material settings.
• Check for scale or buildup on the pipe exterior.

Level Measurement Troubleshooting

Radar Level Signal Loss

• Check for foam, heavy vapour or condensation on the antenna.
• Verify correct dielectric constant settings.
• Inspect for obstructions such as nozzles, ladders or agitators.
• Confirm correct mounting angle and orientation.

Guided Wave Radar Interface Errors

• Verify correct interface density settings.
• Check for buildup on the probe affecting signal propagation.
• Confirm correct probe length and installation depth.

Vibration Switch False Alarms

• Check for coating or buildup on the fork.
• Verify correct sensitivity settings.
• Inspect for excessive turbulence or aeration.

Pressure Measurement Troubleshooting

Pressure Transmitter Drift

• Check for diaphragm coating or corrosion.
• Verify temperature effects on the process connection.
• Inspect impulse lines for blockages or leaks.
• Confirm correct zero and span configuration.

Differential Pressure Issues

• Check for plugged impulse lines or condensate imbalance.
• Verify correct orientation of high and low pressure sides.
• Inspect remote seals for temperature or vacuum damage.

Hydrostatic Level Errors

• Verify stable density of the medium.
• Check for temperature-induced density changes.
• Inspect for trapped air in the measurement tube.

Temperature Measurement Troubleshooting

Slow Temperature Response

• Check thermowell dimensions and immersion depth.
• Verify correct sensor type (RTD vs thermocouple).
• Inspect for fouling or coating on the thermowell.

Temperature Drift

• Check for sensor aging or calibration drift.
• Verify correct transmitter configuration.
• Inspect wiring for noise or grounding issues.

Analytical Measurement Troubleshooting

pH Sensor Drift or Instability

• Check for coating or fouling on the glass membrane.
• Verify correct calibration and buffer integrity.
• Inspect reference junction for blockage.

Conductivity Measurement Errors

• Verify correct cell constant configuration.
• Check for scaling or fouling on electrodes.
• Confirm temperature compensation settings.

Turbidity Sensor Issues

• Inspect optical windows for fouling.
• Verify correct installation depth and flow conditions.
• Check for air bubbles affecting optical paths.

Application Engineering Across Industries

Mining & Minerals Processing

• Slurry measurement requires abrasion-resistant materials.
• Radar preferred for dusty or high-vibration environments.
• Ceramic pressure cells recommended for abrasive slurries.

Water & Wastewater

• Electromagnetic flow meters ideal for conductive media.
• Ultrasonic level suitable for open channels and reservoirs.
• pH, turbidity and chlorine sensors essential for compliance.

Oil & Gas

• Coriolis meters preferred for custody transfer and density.
• DP flow used for high-pressure gas and steam.
• Radar level required for high-temperature and high-pressure tanks.

Food & Beverage

• Hygienic RTDs and conductivity sensors required for CIP/SIP.
• Electromagnetic flow meters ideal for dairy and beverages.
• Non-contact radar preferred for hygienic level measurement.

Energy & Power

• Vortex meters ideal for steam measurement.
• High-temperature thermocouples required for boilers.
• DP transmitters used for feedwater and condensate monitoring.