Weige (China) Instrument Co., Ltd
wangyan@vega.com
Room 218, Building 9, Jiaxing Advanced Manufacturing Industrial Base International Innovation Park (Phase II), No. 1188 Fenghua Road, Economic and Technological Development Zone, Jiaxing City, Zhejiang Province
As the core equipment for industrial liquid level measurement,VEGARadar level transmitters are known for their high precision and maintenance free characteristics, but scientific maintenance is still the key to ensuring their long-term stable operation. This article combines the characteristics of equipment structure and industry practice experience to systematically explain the hierarchical maintenance system, fault diagnosis methods, and spare parts management strategies.
1、 Hierarchical maintenance system: building a three-level protective net
1. Daily inspection (daily)/Shift)
Appearance inspection: Confirm that the explosion-proof shell is not deformed, the sealing strip is not aged or cracked, and the antenna cover is free of dust or condensation water
Data display verification: Compare the displayed values of the transmitter withDCSSystem data, liquid level fluctuation exceeds±5%Start troubleshooting when needed
Environmental assessment: Check if there are strong electromagnetic interference sources (such as frequency converters, high-power motors) around the equipment
Case: A petrochemical enterprise discovered the accumulation of condensation water in the antenna cover through daily inspections, and promptly activated the heating and dehumidification function to avoid measurement errors caused by changes in the refractive index of the medium.
2. Monthly in-depth maintenance
Sensor cleaning: Use a soft bristled brush to clean the surface of the antenna, and wipe with isopropanol for viscous media conditions
Electrical performance testing:
Verify the output voltage of the power module（24VDC±5%）
Measure circuit resistance（≤500Ω）
Check the grounding resistance（≤4Ω）
Communication testing: simulation4G/LoRaNetwork interruption, verify local data storage and breakpoint resume function
Tool recommendation:FLUKE 87VMultimeter, Phoenix Grounding Resistance Tester
3. Annual professional maintenance
Explosion proof performance verification:
Verify the pressure resistance of the shell using an explosion-proof detector（1.5Multiple rated pressure)
Check the tightening torque of the wiring terminals（0.6-1.0N·m）
Antenna system calibration:
Perform waveguide flatness testing on horn antenna（≤0.1mm）
Verify the surface roughness of the planar antenna（Ra≤0.8μm）
Software Upgrade: ThroughVEGA ToolsPlatform updates signal processing algorithms and optimizes anti-interference capabilities
2、 Typical fault diagnosis and disposal
| Fault phenomenon | Diagnostic process | Solution |
| Data jump | Check if the antenna cover is damaged→Verify the refractive index of the medium | Replace the antenna cover→Adjust the temperature compensation parameters during the adjustment process |
| Weak echo signal | Clean the surface of the antenna→Check the verticality of the antenna | recalibrate→Adjust the transmission power（10-25dBm） |
| Communication interruption | Check the antenna connection→verifySIMcard status | Restart the communication module→Replace the antenna orSIMcard |
| power failure | Measure input voltage→Check the fuse | Replace the power module→Tighten the wiring terminals |
Principles of emergency response:
When abnormal measurements are detected, immediately activate the backup level gauge data
When the explosion-proof shell is damaged, designate an isolation zone and initiate emergency power-off procedures
Before thunderstorms, check the grounding system in advance
3、 Spare parts management and life prediction
Key spare parts list:
Antenna components (recommended)3Annual replacement)
Power module（5Annual replacement cycle
Explosion proof junction box (to be replaced with equipment overhaul)
Life prediction method:
passVEGA ToolsAnalyze historical fault data and establishMTBFmodel
Monitor the attenuation rate of transmission power (normal should be<)0.5dB/Year)
Track the trend of return loss changes (>15dBTimely warning is required)
Case: A certain power company conducted an annual maintenance by analyzing power attenuation in advance2It was discovered that the radar module was aging within a month, which prevented an unplanned shutdown.
4、 Maintain value and industry trends
Implementing standardized maintenanceVEGARadar level transmitter, with an average service life of up to10Over years, with an annual failure rate below0.3%With the development of industrial Internet, a new generation of equipment has been integratedAIDiagnostic function can automatically generate maintenance work orders and predict spare parts requirements. After a certain chemical group applied predictive maintenance system, the inventory cost of spare parts decreased40%The device availability has been increased to99.7%.
In the context of increasingly stringent safety production requirements, a scientific maintenance plan is not only the foundation for ensuring equipment reliability, but also a key link for enterprises to achieve digital transformation.VEGAContinuously optimized maintenance tools and service systems are helping global users build'prevention-diagnosis-optimizeenhanceimprove