How to Deal with Malfunctions Encountered in the Use of Temperature Transmitters

Temperature transmitters are common instruments in modern industry, involving temperature measurement, signal transmission, and control. In the field of industrial automation control, temperature transmitters play a crucial role by providing accurate and reliable temperature data to the system and enabling temperature monitoring and control through signal transmission.

Temperature transmitters are widely used due to the diverse usage environments, field conditions, and accompanying instruments. Engineers, technicians, or maintenance personnel encounter various problems during the use. This article will introduce the functions of temperature transmitters and the troubleshooting methods.

How to Deal with Malfunctions Encountered in the Use of Temperature Transmitters


Temperature Measurement

Temperature transmitters are mainly used to measure temperatures in various industrial processes such as chemical production, manufacturing, and the energy industry. Its precise measurement capability makes it one of the key devices for monitoring and controlling temperature. With different types of sensors such as thermocouples, resistance thermometers, etc., temperature transmitters can accurately measure temperatures within different ranges, meeting the needs of industrial production processes from low to high temperatures.

Signal Conversion

Temperature transmitters can convert temperature signals measured by sensors into standard electrical signals output, such as 4-20mA, 0-10V, etc., which can be read and processed by industrial control systems. Through signal conversion, temperature transmitters enable temperature data to flow in the automation control system, providing a basis for subsequent monitoring and control.

Signal Amplification and Compensation

Temperature transmitters usually have signal amplification and compensation functions to ensure the stability and accuracy of the output signal. Problems such as signal attenuation and interference may exist in the sensor signal process. Temperature transmitters can enhance the strength and quality of the signal through amplification, filtering, etc., ensuring accurate and reliable temperature data output.

Isolation Protection

In industrial environments, temperature sensors may be subject to external interference or safety hazards such as electrical interference, voltage surges, etc. Temperature transmitters typically have isolation protection functions to effectively isolate sensors from the control system, preventing external interference from affecting temperature measurement and improving system stability and reliability.

Temperature transmitter(6)

Calibration and Adjustment

Before using the temperature transmitter, calibration and adjustment are necessary to ensure the accuracy and reliability of the temperature data output. Calibration of the temperature transmitter eliminates errors caused by factors such as sensors and circuits, ensuring the accuracy of temperature measurement. Additionally, temperature transmitters usually feature zero and span adjustment functions, allowing adjustment of the output signal according to actual requirements to meet the demands of different processes and systems.

Data Processing and Communication

Temperature transmitters can be paired with data processing units and communication modules to handle and transmit temperature data. Through modern communication technology, temperature data can be transmitted in real-time to monitoring systems, data loggers, or remote control centers, enabling remote monitoring and management of temperature for industrial production, providing more convenient and efficient solutions.

Self-Diagnosis and Alarm

Modern temperature transmitters typically come with self-diagnosis and alarm functions, enabling real-time monitoring of equipment status and operation. Upon detecting abnormal conditions such as sensor failure or circuit interruption, the temperature transmitter issues corresponding alarm signals, prompting operators to take timely action to ensure production safety and stability.

Energy Saving and Environmental Protection

Precise control and monitoring of temperature transmitters facilitate efficient energy utilization, reducing energy consumption and emissions. Temperature transmitters assist in regulating temperature parameters during production processes, optimizing production techniques, improving energy utilization efficiency, and achieving energy conservation and emission reduction goals, meeting the modern industry’s requirements for energy saving and environmental protection.

Temperature transmitter

Faults and Solutions

Fault One: Unstable or Drifting Output Signal

Possible Causes:

  • Power supply issues: Unstable power voltage or power noise;
  • Connection problems: Loose or poor connections;
  • Environmental interference: Electromagnetic interference or vibration;
  • Internal faults: Aging or damage to circuit components.


  • Check the power supply: Ensure stable power supply and use filters or voltage regulators to reduce noise;
  • Check connections: Reconnect the lines and ensure they are securely connected;
  • Anti-interference measures: Install the transmitter in a location with less electromagnetic interference and take isolation measures;
  • Repair or replacement: If necessary, conduct internal repairs or replace damaged components.

Fault Two: Missing or Abnormal Output Signal

Possible Causes:

  • Sensor failure: Temperature sensor damage or aging;
  • Signal processing issues: Faulty signal processing circuit;
  • External interference: External electromagnetic field interference or physical damage.


  • Check the sensor: Inspect whether the sensor is damaged or needs replacement;
  • Check signal processing circuit: Examine the operation of the signal processing circuit, and if necessary, perform repairs or replacements;
  • Isolate external interference: Take shielding measures or install the transmitter in a location with minimal interference.

Fault Three: Inaccurate Temperature Measurement

Possible Causes:

  • Sensor calibration issues: Incorrect or ineffective sensor calibration;
  • Environmental temperature changes: Environmental temperature changes causing measurement errors;
  • Measurement position issues: Improper sensor placement or existence of local hotspots.


  • Re-calibrate the sensor: Re-calibrate the sensor according to the manufacturer’s requirements;
  • Environmental control: Control environmental temperature changes as much as possible or take compensation measures;
  • Optimize installation position: Choose a suitable installation position to avoid the influence of local hotspots on measurement accuracy.

Explosion-proof Temperature transmitter


Fault Four: Temperature Transmitter Unable to Communicate or Communication Abnormal

Possible causes:

  • Communication line fault: Poor connection or damage to the communication line;
  • Communication protocol issue: Incorrect or mismatched communication protocol settings;
  • Interference or interference with other devices: Electromagnetic interference or other devices affecting communication signals.


  • Check communication lines: Reconnect communication lines to ensure good connection;
  • Check communication settings: Verify if communication protocol settings are correct and make adjustments if necessary;
  • Isolate sources of interference: Implement shielding measures or install devices in locations with less interference.

Fault Five: Damage or Water Ingress in Temperature Transmitter Housing

Possible causes:

  • Environmental damage: Physical damage to the transmitter housing;
  • Poor sealing: Inadequate sealing or aging leading to water ingress.


  • Replace housing: If necessary, replace damaged housing;
  • Reseal: Inspect the housing, reseal, or replace seals if necessary.

The above are common temperature transmitter faults and solutions. Timely detection and resolution of faults are crucial to ensuring the normal operation of temperature transmitters during routine maintenance and use. In addition, regular maintenance and proper installation location selection can effectively prevent and reduce faults, prolong the service life of temperature transmitters, and improve the stability and reliability of industrial production. In case of unresolved faults, it is recommended to promptly contact the manufacturer or professional repair personnel for assistance.


In summary, temperature transmitters play an important role in industrial automation control, not only enabling accurate temperature measurement and signal conversion but also providing various functions such as signal amplification, isolation protection, and self-diagnosis, offering reliable temperature monitoring and control solutions for industrial production. With the continuous improvement of industrial automation and technological innovation, temperature transmitters will play an increasingly important role in industrial production, making positive contributions to realizing intelligent manufacturing and green production.

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