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GREAT SYSTEM INDUSTRY CO. LTD Ultimo caso aziendale su Common Faults and Troubleshooting of VEGA and Endress Hauser Radar Level Meters
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Common Faults and Troubleshooting of VEGA and Endress Hauser Radar Level Meters

2025-08-01

Ultimo caso aziendale su Common Faults and Troubleshooting of VEGA and Endress Hauser Radar Level Meters
Radar level meters are widely used in industrial level measurement due to their advantages such as non-contact measurement, high precision, and strong adaptability. However, various faults may occur during use.

 

Common Fault Phenomena, Possible Causes, and Troubleshooting Methods:

 

I. Large Fluctuations/Instability in Level Display

 

  1. Attachments/condensation/crystals on the antenna or lens surface:
    • Cause: Volatilization, condensation, crystallization, or adhesion of media on the antenna surface, which interfere with the transmission and reception of radar waves.
    • Troubleshooting: Clean the antenna or lens surface regularly. Ensure the purging system (if applicable) works properly. Choose antennas with anti-condensation heating functions or use antenna shields.
  2. Severe liquid surface fluctuations or foam:
    • Cause: Severe fluctuations caused by stirring, boiling, or material feeding/discharging; overly thick or dense foam layers may attenuate or scatter radar waves.
    • Troubleshooting: Adjust the installation position (e.g., install in a bypass pipe or stilling well). Optimize radar parameters (e.g., increase filtering strength, adjust response time). Consider using Guided Wave Radar (GWR) to penetrate foam. If foam is an issue, try defoaming measures.
  3. Presence of interfering objects in the container:
    • Cause: Stirrers, heating coils, brackets, ladders, or other equipment reflect false echoes.
    • Troubleshooting: Use the False Echo Suppression function to shield the distance of fixed interferers. Re-select the installation position to avoid obstacles or ensure a sufficient safety distance. Adjust the antenna angle (e.g., install at an incline).
  4. Strong electromagnetic interference in the measurement environment:
    • Cause: Nearby high-power motors, frequency converters, high-voltage cables, etc.
    • Troubleshooting: Check if the instrument grounding is good and reliable. Use shielded cables for signal cables and ensure the shield layer is properly grounded at a single point. Keep away from interference sources or add isolation measures.
  5. Improper radar parameter settings:
    • Cause: Weak filtering settings, excessively fast response time, or unreasonable range settings.
    • Troubleshooting: Adjust filtering parameters and response time according to actual working conditions. Confirm and correctly set the upper and lower range limits.
  6. Steam/dust interference:
    • Cause: High-temperature or volatile media generate a large amount of steam or dust, affecting radar wave propagation.
    • Troubleshooting: Choose higher-frequency (e.g., 80GHz) radars, which have narrower beams and stronger anti-interference capabilities. Ensure good ventilation at the installation position. Consider using Guided Wave Radar (GWR) or antennas with purging devices.

 

ultimo caso aziendale circa [#aname#]
II. No Signal/Signal Loss/Excessively Low Signal Strength

 

  1. Severe fouling or blockage of the antenna:
    • Cause: Media with severe crystallization, polymerization, or viscosity completely covering the antenna.
    • Troubleshooting: Thoroughly clean the antenna. Evaluate working conditions and choose a less fouling-prone antenna type (e.g., planar antenna, scraper-equipped antenna). Increase maintenance frequency or consider level meters based on other principles.
  2. Excessively low dielectric constant of the measured medium:
    • Cause: Radar waves have weak reflection on the surface of media with extremely low dielectric constants (e.g., certain solvents, liquefied gases, light oils, or empty tanks).
    • Troubleshooting: Confirm the dielectric constant of the medium (usually required to be >1.8, higher is better). Choose a more sensitive radar (e.g., 80GHz is better than 26GHz). Select Guided Wave Radar (GWR), whose signals propagate along the waveguide rod and are less affected by dielectric constants. Ensure correct instrument parameter settings (e.g., low gain mode) for low dielectric constant applications.
  3. Radar beam blocked:
    • Cause: Improper antenna installation position, with fixed obstacles (e.g., manholes, beams) in the beam path.
    • Troubleshooting: Re-select the installation position to ensure no obstacles within the beam cone angle. Choose an antenna with a smaller beam angle (e.g., 80GHz).
  4. Empty tank or level below the blind zone:
    • Cause: No medium in the container or the level is below the measurement blind zone of the radar (a section near the antenna that cannot be measured).
    • Troubleshooting: Confirm the actual level status. If the tank is empty, ensure the instrument can correctly display the "empty tank" status (parameter support is required). Check if the blind zone settings are correct.
  5. Instrument power supply or wiring issues:
    • Cause: Power interruption, unstable voltage, loose or incorrect wiring, or blown fuses.
    • Troubleshooting: Check if the power supply voltage is within the rated range. Inspect all terminals for firmness and correctness. Check fuses (if any). Use a multimeter to measure the loop current.
  6. Fault in instrument electronic components:
    • Cause: Damage to circuit boards, transmitting/receiving modules.
    • Troubleshooting: Try powering off and restarting. If ineffective, contact the manufacturer's technical support for repair/replacement.

 

ultimo caso aziendale circa [#aname#]
III. Display Value Unchanged or Stuck at a Certain Value

 

  1. False echo locking:
    • Cause: The instrument mistakenly identifies the echo from a fixed interferer as the real liquid level echo.
    • Troubleshooting: Use the false echo suppression function to re-map and suppress interfering echoes. Optimize the installation position.
  2. Incorrect parameter settings:
    • Cause: Errors in settings such as tank height, range upper/lower limits, or damping time.
    • Troubleshooting: Carefully check and re-set correct parameters, especially tank height and reference points (flange surface/process connection surface).
  3. Crash or software failure:
    • Cause: Abnormal operation of the instrument's internal software.
    • Troubleshooting: Try powering off and restarting. If the problem persists, contact the manufacturer.
  4. Guided Wave Radar (GWR) probe stressed or fouled:
    • Cause: The probe is caught, bent, or severely fouled, affecting signal transmission.
    • Troubleshooting: Check the probe status, clean it, or correct its position.

 

IV. Display Full Scale/Overflow

 

  1. Strong reflectors under the antenna:
    • Cause: Overly long mounting flanges, welds, brackets, etc., are too close to the antenna, generating strong fixed echoes mistaken for full scale.
    • Troubleshooting: Use the false echo suppression function to suppress such echoes. Ensure the mounting flange length meets requirements. Inspect and remove overly close obstacles.
  2. Wiring errors or current output setting issues:
    • Cause: Incorrect wiring of the 4-20mA output loop (e.g., signal line shorted to ground) or wrong output mode settings (e.g., 20mA set to correspond to empty tank).
    • Troubleshooting: Check wiring. Confirm the output range settings (whether full scale corresponds to 20mA or 4mA).
  3. Instrument failure:

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