When All The Pieces Fit Just Right!
The Flexar® continuous level measurement system is a smart
guided wave radar device used for monitoring the level of powders,
granules and other bulk solids. It is also suitable for use with
a multiplicity of liquids. It is used in a wide assortment of
vessels and industries for measuring levels up to 200ft (60m)
in height.
Bringing the Pieces Together: Manufactured at our facility
in Elburn, IL, we uniquely combine this proven and strategically
acquired technology with almost five decades of expertise and
focus in powder and bulk solids applications, and with our
SiloTrack™ inventory
management software interface. Monitor Technologies uniquely
provides the best solutions in level measurement and inventory
management of powders and bulk solids.
The Flexar sensor requires
no field calibration or re-calibration and can be setup easily
by customer personnel without the use
of any special tools or training. Flexar units are suited
for almost any application, can operate with process temperatures
up to 392° F (200°C), can be provided with a variety of process
connections and can work reliably with materials having a
wide
range of bulk densities and dielectric constants.
Flexar is
available with a choice of two outputs. The standard output
is a “smart” interface for use with SiloTrack™ Version
3.5 PC-based inventory management software. This network-ready
software provides a flexible graphical interface for up to
128 “smart” output
sensors. In lieu of this “smart” output, an optional
analog output is also available.
Flexar® smart guided wave radar sensors operate using
TDR (time domain reflectometry) principles that were first
developed in the middle part of the 20th century for use in
the geological field. Further development of TDR led to its
use in the telecommunication industry for detecting breaks
in cables. Flexar technology was pioneered in the mid-late
1990’s when TDR was applied to level measuring applications
within the process measurement industry.
In the application
of TDR for process level measurement micro-pulses are continuously
transmitted along a probe or “wave guide” at
the speed of light. As soon as the pulses reach the material
surface they reflect back to the sensor electronics unit. The
time-of-flight of the pulses is calculated and directly related
to the distance from the point at which the sensor is mounted
on the top of the vessel to the material surface (level). The
output from the electronics is continuously updated as the
level of the material surface changes.
Flexar smart guided
wave radar sensors are equipped with two
different measuring modes. In the Direct measuring mode the
pulses directly reflect off the material surface back to the
electronics
unit. This mode is used in applications where the material
being measured has a dielectric constant as low as 2.1 for
single-cable/rod
probes and 1.8 for twin-cable probes.
For materials with dielectric
constant below the above mentioned limits, down to as low
as 1.4, the second measurement mode
is used. This is the TBF (tank bottom following) mode, which
is
used due to the inability of the pulses to adequately reflect
off of the surface of very low dielectric materials. In this
measuring mode the Flexar sensor has a “short circuit” at
the bottom of the probe at a precisely known distance from
the sensor’s mounting point.
In the TBF mode the pulses travel through air at the speed
of light and then pass through the material in the vessel at
a slower speed, dependent on the specific dielectric constant.
The pulses are reflected at the short circuit back up the probe.
Flexar sensors in the TBF mode measure the time between the
emission and reception of the pulses from the probe short circuit.
Because the return time of a pulse when no material is present
(through air) is known, we can determine the difference in
time between the time-of-flight when empty and the time-of-flight
when filled as being directly proportional to the material
level in the vessel.
Applications
The Flexar® smart guided
wave radar continuous level measuring system can be used in
a wide variety of applications, including powders, coarse/fine
granular solids, liquids, foodstuffs and even some corrosive
substances. Flexar sensor technology is proven in many difficult
applications including those where dust levels make it difficult
for other technologies to perform reliably, especially at long
ranges.
Typical Applications include, but
are not limited to:
Feeds
Grains
Aggregates
Cement
Carbon Black
Oils
Coal Dust
Silica
Fly Ash
Lime
Bulk Chemicals
Flour
Powders
Plastic Pellets
PVC Powder
The maximum range for solids applications is
limited to 100ft (30m) due to load limits possible from heavy
materials
in long
ranges. Liquid applications can extend up to 200ft (60m).
Any application requiring a continuous level measurement
update
where the process temperature does not exceed 392° F (200°C)
and 580psig
(40bar) is possible. The 316 stainless steel probes and threaded
or flanged process connections make the Flexar continuous
level measuring system ideal for almost any bulk solid and
liquid
application. To ensure a successful and reliable application,
consult with
the Monitor Technologies factory-based technical support
group to see if Flexar is right for your application.
Remote Inventory Monitoring
If material levels need to be monitored at one or many
locations (i.e. your facility, a location down the street,
or a plant
on the other side of the world) the Flexar system can
provide continuous, reliable and accurate measurements. Using
SiloTrack™ Version
3.5 software, inventory monitoring from remote locations
has never been easier.
Features
Solid-State Performance,
No Moving Parts.
Unlike weight and cable based systems of old, Flexar® guided
wave radar sensors are state-of-the-art and use a time-proven
electronic method for continuous measurement of a material
level. This non-mechanical means of measurement helps ensure
low maintenance.
Measure Materials
With Dielectric > 1.4
(TBF Mode). Flexar sensors are capable of sensing and measuring
the level of most any material. Materials with dielectric
constants below 1.8-2.1 require the use of our TBF (tank
bottom following) measuring mode.
Unaffected By Dust
And Changes In Material Properties.
The technology employed in Flexar
units has been proven to be unaffected by airborne dust
even during pneumatic filling operations. Unlike through-air
technologies such as ultrasonic, through-air radar and
laser, Flexar can reliably measure in dusty environments
without sacrificing performance or reliability.
Range Of Probes.
In order to handle the assortment of applications possible
with Flexar, Monitor offers a range of probe styles including
single-cable, twin-cable and single-rod. All probes are
constructed of 316 stainless steel, have traction load
handling capabilities suitable for their respective applications
and are easily field replaceable. Consult with Monitor’s
factory-based technical support personnel to select the
right probe style for your application.
Assortment Of Process Connections.
To meet the required bulk solids and liquid applications
we have prepared a selection of process connections that
will ensure a smooth and simple installation. Flexar
sensors can be provided with 1-1/2” NPT, 1-1/2” BSP
G, 2” ANSI or DIN DN50PN40 flange connections.
Probe type will determine the available process connections.
Dual Compartment Enclosure.
The Flexar smart guided wave radar sensor uses an enclosure
with two compartments, each with its own access cover.
This allows separation of access for wiring and setup/display.
The setup/display compartment is provided with a cover
window allowing local viewing of the LCD display. In
addition, every unit is provided with either two 1/2” NPT
conduit entrances (NPT threaded and ANSI flanged process
connections) or M20 cable connectors (BSP threaded and
DN flanged process connections).
Local LCD Display And Setup.
Each sensor includes a built-in user interface consisting
of a three-line backlit LCD display, three pushbuttons
and three magnetic sensors (used to perform setup and
interact with the unit without having to remove the display
cover).
Universal Power Supply.
Power supply choices include a universal high voltage option
100-240 VAC and a low voltage 24 VAC/VDC option.
Choice of outputs.
The standard output for all Flexar guided wave radar units
is a “smart” RS-485 communications interface
for use with SiloTrack™ Version 3.5 inventory management
software. In lieu of this “smart” interface
an analog 4-20mA output is available.
Remote electronics available.
The standard unit includes the electronics integrally mounted
with the sensor. However, remote mounted electronics
is optionally available for applications where the electronics
are desired to be mounted away from the probe due to
extreme vibration, temperature or for convenient access
to the local operator interface. The remote electronics
version includes a pre-wired 16.4ft (5m) interconnecting
cable.
Hazardous location approvals
available.
All units include the CE mark and are approved for use in
ordinary locations. When required, Flexar sensors can be
provided approved for use in hazardous areas worldwide. Flexar
is available with ATEX and CSA(US/C) approvals for hazardous
areas.
Probe Styles
Single Cable 0.16” (4mm)
Single Cable 0.31” (8mm)
Single flexible 316 SS cable with counterweight
Single Flexible 316 SS cable with counterweight
Vessel height < 150ft (45m); Liquids; Some solids
(consult Monitor)
Vessel height < 100ft (30m);
Powders and other bulk solids (consult Monitor)
Twin Cable 0.16” (4mm)
Single Rod 0.38” (10mm)
Two flexible 316 SS cables with spacers between them at
intervals, w/ counterweight
Vessel height < 10ft (3m); Liquids; Some powders
(consult Monitor)
PC-Based Inventory Management Software
SiloTrack™ Version
3.5 Inventory Management Software provides users with
an unsurpassed, flexible graphical interface for Flexar® smart
guided wave radar sensors. Together, SiloTrack Server
and Client software can provide inventory monitoring
and management to a virtually unlimited number of users,
both internal and external to your facility. This allows
easy implementation of remote monitoring and vendor managed
inventory programs.
SiloTrack capabilities
include:
Monitor up to 128 sensors/with up to
5 sensors per vessel
Easy
to setup and use
Network-ready
Remote
monitoring via LAN, Internet/WAN or dial-up
3-line; Backlit LCD; 3 pushbuttons;
3 magnetic sensors for setup without cover removal
Materials of Construction:
Enclosure:
Aluminumm, powder coated
Threaded/Flange Connection:
316 Stainless Steel
Process Insulator:
Teflon (PTFE)
O-Ring Seal:
Viton
Probes:
316 Stainless Steel
Remote Electronics:
16.4’ (5m) pre-wired interconnection cable
Dead Zones:
Single Cable/Rod
Dielectric = 80 (water)
Top = 15.75” (400mm)
Bottom = 0.8” (20mm)
Dielectric = 2.4 (oil)
Top = 19.7” (500mm)
Bottom = 3.9” (100mm)
Twin Cable
Dielectric = 80 (water)
Top = 9.8” (250mm)
Bottom = 0.8” (20mm)
Dielectric = 2.4 (oil)
Top = 13.0” (330mm)
Bottom = 0.8” (20mm)
Enclosure Rating:
NEMA 4, IP66
Approvals:
Integral Electronics Only
Ordinary Location
CE Mark
Hazardous Location
CSA(US/C) Class I, Div 1,2, Groups B, C, D;
Class II, Div 1,2, Groups E, F, G; Class III
ATEX II 1/2 GD T75...150C
Remote Electronics
Ordinary Location
CE Mark
Hazardous Location
ATEX II 1/2 GD T75...150C
Warranty
Monitor Technologies LLC warrants
each Flexar® guided wave radar continuous level measurement
system it manufactures to be free from defects in material
and workmanship under normal use and service within two (2)
years from the date of purchase. The purchaser must give notice
of any defect to Monitor within the warranty period, return
the product intact and pre-paid transportation charges. The
obligation of Monitor Technologies LLC under warranty is limited
to repair or replacement at its factory. This warranty shall
not apply to any product which is repaired or altered outside
of the Monitor Technologies LLC factory, or which has been
subject to misuse, negligence, accident, incorrect wiring by
others or improper installation.
Monitor Technologies LLC reserves the right to change the design
and/or specifications with our prior notice.
353A.3.0606
Global Flour Processor Uses Flexar® Guided Wave Radar
A large global flour processor and food products company recently began using the Flexar® guided wave radar in a total of eighteen (18) silos and bins to manage their finished product inventory. Readings from these continuous level sensors is reported as being reliable and accurate, even during pneumatic filling, contrary to their previous measuring system. A previous non-performing ultrasonic system was replaced by the Flexar level sensors. Flexar guided wave radar level sensors were chosen as the best for pneumatically filled dust laden flour silos.
Eight (8) Flexar level sensors are installed in load-out silos that fill bulk trucks with processed and finished flour. These silos are 12ft in diameter and 35ft tall. The finished flour is pneumatically conveyed into these silos. During filling the internal environment of the silos is very dusty and turbulent. The finished flour in these silos is used for loading bulk transport trucks for distribution. In addition, ten (10) Flexar level sensors are installed in 40ft high bins that contain bran. This material is also sent by bulk transport to end users.
All of the Flexar level sensors are equipped with an RS485 digital communications output that is connected to a PC with a graphical user interface for inventory management purposes. Monitor’s SiloTrack™ inventory management software is used by the facility to monitor and manage material inventories of both the finished flour and the bran. SiloTrack allows for multiple user viewing and data access via LAN and this is how the facility will be using the software that provides a flexible, graphical user interface, alarms, report generation and history analysis functions.
Guided wave radar is especially well suited to level measurement applications of dusty powder materials even when measuring during pneumatic filling. Flexar guided wave radar utilizes TDR (time domain reflectometry) technology. Radar pulses are continuously transmitted down the sensor’s probe and guided to the material surface where they are reflected back to the electronics along the wave guide. The time-of-flight of the pulses is measured and directly related to the distance to the material surface and its level.
SiloTrack™ Version
3.5 Inventory Management Software provides users with
an unsurpassed, flexible graphical interface for Flexar® smart
guided wave radar sensors. Together, SiloTrack Server
and Client software can provide inventory monitoring
and management to a virtually unlimited number of users,
both internal and external to your facility. This allows
easy implementation of remote monitoring and vendor managed
inventory programs.
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