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Radar Wave Level Indicator with Strong Wave Penetration

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Radar Wave Level Indicator with Strong Wave Penetration

Radar level gauge technology principle

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Radar level gauge technology principle

The transmitted pulse propagates in space at the speed of light, encountering the surface of the measured medium, and part of the energy is reflected back and received by the same antenna. The time interval between the transmitted pulse and the received pulse is proportional to the distance from the antenna to the surface of the measured medium, thereby calculating the distance from the antenna to the surface of the measured medium.

1

 

 

Radar level gauge technical features

* The frequency is high and the beam angle is smaller;

* The antenna size is small, the signal gain is large and the energy is concentrated;

* The influence of debris in the tank is small, and it is not easy to produce false echoes;

* The blind area is small, and the small tank measurement effect is good;

* The effect of powder solid interface reflection is good;

* Strong wave penetration, applicable to steam and extra-strong dust conditions;

* The antenna size is not easy to be affected by condensation and hanging materials;

* Large liquid fluctuations, large block measurement is better than high frequency.

 

Radar propagation mode

2

 

 

Radar wave level gauge antenna type

3

 

 

PTFE insulated rod antenna

4

 

 

Conical horn antenna

5

 

 

Parabolic antenna

6

 

 

Guided radar antenna

7

 

 

Obstacle avoidance method

8 9

 

 

 

 

Universal joint, purge environment selection

10

 

 

Installation of special conditions

11

 

 

Radar level gauge field installation diagram

12

 

 

Measurement error--handling

Case number one

Description of working conditions:

Medium - flour

Feeding method - pneumatic conveying

Tank height - 20 meters (cone height 3 meters)

Straight diameter - 5 meters

Temperature - normal temperature

Pressure - micro negative pressure

Fault condition:

  1. The product is measured normally for most of the time, but the measured value occasionally jumps to a certain uncertainty near the highest position.
  2. The material level information that the customer wants to measure by radar is converted into the tonnage of the flour, even if the level measurement is stable.

      Maximum conversion error of 10 tons

13

 

 

 

 

Cause Analysis:

The cause of fault 1 - from the echo curve, the coordinates have interference echoes to the left, and the amplitude is higher than the reflected echo of the material.

Causes the internal program to choose the echo disorder, which occasionally jumps to the left echo (expressed to the measured value)

That is, jump to the vicinity of the maximum value of the material level).

Troubleshooting method - check the product antenna to find that there is flour agglomeration on the dust cover. If conditions permit, the material can be cleaned regularly. In addition, the product blind zone can be increased. The secondary site will set the blind zone to 1.75 meters, which can make the internal program. Automatically abandon all echo signals within the blind zone, thus no longer fluctuating

The cause of fault 2 - the customer system is converted into tonnage according to the height of the material level, and does not take into account the taper at the bottom of the tank.

Simply convert according to the linearity of the cylindrical barrel, the error is naturally large

Troubleshooting method—(1) Since the customer system does not have a nonlinear volume conversion function, a large virtual tank height is set, thereby reducing the influence of the error of the cone in the entire virtual volume, and finally the system tonnage display error Control within 3 tons; (2) long-term plan allows customers to prepare our secondary table, and use 20-point nonlinear tank volume conversion function.

In other words: powdery materials such as cement and pulverized coal, when they are attached to the dust cover to a certain thickness, it is possible

The condition described in fault 1

For the conical tank of solid materials, it should also be noted that: at the same time, if the joint is not adjusted, there will be fluctuations or

Display an incorrect level value

 

Display output fluctuations - fault handling

Description of working conditions:

Medium - various feed ingredients powder

Feeding method - pneumatic conveying

Tank height - 11 meters (cone height 2 meters)

Straight diameter - 2.5 meters

Temperature - normal temperature

Pressure - atmospheric pressure

Fault condition:

The field shows fluctuations, and the echo curve is shown in Figure 1.

cause of issue:

The field DN50 extension tube is up to 1m long, forming a higher interference echo as shown in the left of Figure 1, and weakening the strong echo of the material; the dielectric constant of the material itself is very low (1.2<εr<3), plus The influence of material adhesion, the final material reflected echo is very low on the curve (1)

Troubleshooting method:

Since the installation cannot change the installation environment, only the signal

The threshold (Figure 3) drops to 20mV

 

Choosing the wrong bypass pipe - troubleshooting

Description of working conditions:

Medium - steel pickling solution

Feeding method - pneumatic conveying

Tank height - 2 meters (plastic bypass pipe installation)

Straight diameter - DN125

Temperature - normal temperature

Pressure - atmospheric pressure

Barrier status:

In the empty bucket, the central control room displays the maximum value, the field radar display value is normal, but the E14 error code appears.

cause of issue:

The bottom of the plastic bypass tube is weakened by microwave penetration. When the error is reported, the default fault current is 22 mA, so the central control shows the maximum value.

Troubleshooting method:

Replace with metal bypass

 

Easy Crystallization Medium--Fault Treatment

Description of working conditions:

Medium - 30% hydrochloric acid

Feeding method - bottom pumping

Tank height - 8 meters

Straight diameter - 3 meters

Temperature - normal temperature

Pressure - atmospheric pressure

Fault condition:

The liquid level display is unstable, and it is occasionally displayed to the full scale from the central control room; from the field instrument, occasionally the full scale is displayed or E14 is displayed, and the echo curve is as shown on the right.

cause of issue:

The field is still in the test phase, the tank is not completely sealed, causing volatile HCL and moisture in the air to form small droplets of hydrochloric acid attached to the emitter, creating a top interference echo and occasionally E14.

As for the appearance of multiple peaks with similar spacing in the curve, it is due to multiple reflections of the echoes through the liquid surface to form "multiple echoes".

Troubleshooting method:

Increase the blind zone appropriately, shield the interference wave on the left side of the coordinate, and the product will return to normal.

 

Easy to block media - fault handling

Description of working conditions:

Medium - industrial naphthalene

Feeding method - bottom pumping

Tank height - 6 meters

Straight diameter - 4 meters

Temperature - 80 ° C

Pressure - atmospheric pressure

Fault condition:

The field display value is not accurate, and the error signal E14 (weak echo) is displayed as shown in Figure 1. The echo curve is shown in Figure 2.

cause of issue:

The product was removed and inspected, and it was found that the inside of the antenna was blocked by the dielectric crystal, which caused the microwave energy to be unable to be transmitted and received, so the code showing the weak E14 echo was displayed.

Troubleshooting method:

  • Regular cleaning of crystals; 2) Adding a purge device

 

There are obstacles in the barrel - fault handling

Description of working conditions:

Medium - rice husk feeding method - pneumatic conveying

Tank height - 4 m / 20 m straight diameter - 6 m

Temperature - normal temperature pressure - micro negative pressure

Fault condition:

The field measurement is normal for most of the time, but the measured value occasionally fluctuates to a certain fixed value. After a certain period of time, the measured value will return to normal. When the actual material level is higher than this position, it will be stable.

cause of issue:

Obviously, the interference signal is a fixed point, and there may be interference such as brackets in the barrel; it is recommended that the customer check the inside of the barrel.

In the installation situation, it was found that there is a DN100 transverse reinforced steel pipe directly under the horn antenna, which cannot be removed.

Troubleshooting method:

Since the interference source cannot be excluded, only the false echo learning function can be used; when the empty bucket is on site (or all the interference sources are exposed), enter the false echo learning, and input the true empty height value at this time. After learning, the product will record all the interference sources in the current barrel and filter them out on the curve, which will also cause a small range of stagnation and mutation when the material is just close to the interference source.

 

On-site maintenance work guidelines

1, safety first

      Industrial control instruments are mostly used in production line, full of various risk factors; field operators must be equipped with relevant safety equipment (safety helmets, gas masks, masks, protective glasses, etc.), and learn safety protection knowledge and operate according to specifications.

2, first prepare and then set off

      Before going to the site for maintenance, you should confirm the product failure and working conditions in advance, and prepare tools, spare parts, on-site service documents, etc.

3, first move the mouth and then start? For faulty equipment, do not respond to hands-on, should first ask before and after the failure and failure phenomenon. ?4. First external and internal? First check the equipment for obvious cracks and defects, understand the maintenance history, service life, etc., and then check the machine. Before dismantling, the surrounding fault factors should be checked and determined to be disassembled after the internal fault. Otherwise, blind disassembly may worsen the equipment.

  1. Electrical and mechanical first? Only after confirming that the mechanical parts are not faulty, perform an electrical inspection. When checking the circuit failure, the detection instrument should be used to find the fault location, and after confirming that there is no contact failure, the operational relationship between the line and the machine can be checked in order to avoid misjudgment.
  2. First clean and repair. For heavily polluting equipment, first clean the buttons, wiring points and contact points, and check if the external control keys are malfunctioning. Many faults are caused by dirty and conductive dust, which is often ruled out after cleaning.
  3. After the power supply, the power failure rate of the power supply part is high, so it is often more effective to check the power supply first. ?8. First, after the inside and outside? Do not rush to replace the damaged electrical components. When confirming that the peripheral circuit is normal, consider replacing the damaged electrical components.
  4. First debug after failure? For the equipment and equipment that coexist with debugging and fault, the fault should be eliminated first, and then debugging. The debugging must be carried out under the premise of normal operation of the equipment.
  5. Leave after verification

        For well-maintained instruments and equipment, further on-line operation must be carried out on site. After observing at least one operating cycle, confirm that the product is stable after confirming the stability.

 

Instrument failure analysis methods and operational practices:

  1. Observation

     It is a method of checking and judging faults by means of watching, smelling, and listening according to the external performance of electrical faults. ? Inspection steps: Inquire the operator and the fault presence personnel, including the external performance of the fault, the approximate location, the environmental conditions at the time of the fault, if there is abnormal vibration, heat source, electromagnetic interference, etc.; observe whether the near-high-power appliance is corroded or not. Intrusion of sexual gas, presence or absence of water leakage, whether someone has repaired it, the contents of repairs, etc. ?2. Measurement method

     The measurement method is to measure the power supply and input and output signal values ​​of the instrument and equipment by using standard instruments (such as a calibrated multimeter), and compare it with the theoretical calculation value to quickly confirm the fault location. Exclusion

     When there are multiple possible factors for the failure, they can be verified one by one and eliminated one by one.

  1. Comparison, replacement method? (1) Contrast method:

        When multiple similar products are installed on site, before determining the fault, carefully observe whether there is any difference in the application environment of each product, which is often caused by the difference.

(2) Replacement method:

        When multiple products of the same model are installed on site, and individual products fail, but the faulty part cannot be confirmed, the working product and the faulty product can be exchanged for the installation position, and the fault location can be quickly determined.

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