VEGA has extended its already proven VEGAPULS family for continuous level sensing and indication in bulk solids and liquids, to make them more affordable than ever. They are designed to deliver even more flexibility, safety, confidence and reliability to bulk grain and feed processing and handling businesses. The new non-contact level sensors are based on the latest FMCW 80-GHz technology combined with a specially developed VEGA radar-level microchip to deliver an affordable, yet high quality level sensor, it represents a real alternative to ultrasonic level technology in the feed and milling industry. It makes it highly economical for those applications found in the sector, from small hoppers, conveyor levels, small or large storage silos and transfer stations. These low-cost compact loop-powered radars are available in two versions: a standard compact connection housing and with an ultra-compact fixed cable connection (IP68) and measuring/sensing range up to 30m. They all offer safer, easier and faster Bluetooth set up and monitoring via the free, award winning VEGA TOOLS App.
Strong focusing ensures measurement without the jumps
Why 80-GHz technology? This enables the radar beam to be much more focused and aimed at the surface level to be measured with pinpoint accuracy. Thanks to this strong signal focusing, build up and deposits on the container wall or on the sensor face itself are no problem. This technology offers a non-contact solution for accurate, consistent level indication, even in narrow shafts, when there are deposits on hopper or vessel walls, or where silo internals such a braces and reinforcing can create false signals to the sensor and readings that ‘jump’ around. The free VEGA TOOLS App even features an easy-aiming tool to optimise the sensor angle to facilitate a measurement to the bottom of your silo.
No dead zones for measurement in confined spaces
One special advantage of these new affordable radar sensors is they also have a smaller dead/blanking zone, thus enabling them to measure closer to the top of the vessel. Typical areas of application are areas where head-space is limited, like mills, feeders or hoppers when capacity is at a premium. They even feature a right-angle cable option for when installation head-space is tight and the sensor sizes are much smaller too.
Handles build up and noise
Many non-contact sensors constantly struggle with the problem of short or long term dust and build-up – maintenance call outs to ultrasonic, laser or infra-red devices, ‘needing a wipe’, are commonly reported. This is because contamination or condensation on the sensor face can greatly affect the reliability of the sensing or measurement signal, resulting in unreliable indication or control. Cable based devices can be used, but cable wear, contamination and roof loading then all become considerations. Using non-contact radar technology, the situation is different, a combination of the microwave based measuring principle and optimized signal processing, enables these radar sensors to better ignore the interference caused by build-up on their antenna system. This means bulk grains, powders and feeds can be measured and controlled reliably with radar – with no effect from dust or even acoustic noise generated during the process. This is because they are highly resistant to the individual, or combined, effect of condensation and dust, noise and dirt thus reducing nuisance outages and cleaning.
Liquids, Chemicals and EX approval
Storage and buffer tanks supply oils, ingredients and special chemicals for various plant applications. The new radar sensors exploit their strengths here too, as they can be installed in very confined spaces and on small process fittings. Or they can look through plastic tanks and safely measure the liquids inside. Even if the medium generates gases, or condensation, the sensors remain unaffected and deliver reliable measuring results. In addition, they have an Ex approval for flammable media. So it makes them highly versatile for use in a wide range of applications.
Reliable level independent of process and environmental influences
Due to their physical measuring principle, traditional ultrasonic sensors are easily affected by ambient conditions: for example, strong air and dust movement can all affect measurement reliability. Strong winds, rain, or even fog, extremes of temperature can affect the transducer efficiency, damp the emitted sound waves and restrict their measuring range, for example when out measuring on open heaps or hoppers. Radar sensors, however, are not affected by these conditions – or even temperature change, pressure, vapours, gases or vacuums – they continue with accurate readings.
In other areas, such as effluent plants, collection and treatment tank levels need control, open channel flow measurement needs to be made for accurate dosing and measurement of final effluent discharge. Even here, radar sensors offer the highest possible accuracy and stability, combined with an economical price.
Low power for remote sites and telemetry
There are also devices that can be completely battery powered and use wireless networks, GPS and mobile networks to send their data, with measuring ranges for bulk solids up to 30m silos, or IBC’s over 1m and offering up to 10 years battery life, depending on how often the measurements are made and reported.
Simple wiring, with optional controllers and Bluetooth built in
Radars do not require an external control box, unlike long-range ultrasonic sensors with dedicated cables and big diameter transducers. Radar can operate from a single, standard 24V DC two core cable, with a capability of sensing the level up to 120m away, using the ‘big brother’ VEGAPULS 69, yet still with a 3”/80mm antenna. But in some cases an optional controller is desirable for local display, extra outputs and level alarms. Both sensors and controllers can be easily and safely adjusted remotely via Bluetooth with a smartphone or tablet using the award winning VEGA TOOLS App – ideal for harsh environments, tall silos, operational safety or Ex areas. All your PIN codes are also securely, safely and automatically stored in the cloud, if you register for a free ‘myVEGA’ account.
If you would like a personal video demonstration, distanced site visit, discuss a requirement or a free trial unit to test, please contact us.
