Bin Master VR-90 User manual

Operating Instructions
Vibrating level switch
for granulated bulk solids
VR-90
VIBRATING ROD
Document ID: 29266
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Contents
VR-90 • Vibrating Rod
29266-EN-181126
Contents
1 About this document ............................................................................................................... 4
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety ......................................................................................................................... 5
2.1 Authorised personnel ....................................................................................................... 5
2.2 Appropriate use................................................................................................................ 5
2.3 Warning about incorrect use............................................................................................. 5
2.4 General safety instructions............................................................................................... 5
2.5 Safety label on the instrument .......................................................................................... 6
2.6 EU conformity................................................................................................................... 6
2.7 SIL conformity .................................................................................................................. 6
2.8 Installation and operation in the USA and Canada ........................................................... 6
2.9 Safety instructions for Ex areas ........................................................................................ 6
2.10 Environmental instructions ............................................................................................... 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 7
3.3 Adjustment ....................................................................................................................... 8
3.4 Storage and transport....................................................................................................... 8
4 Mounting................................................................................................................................. 10
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply................................................................................................. 15
5.1 Preparing the connection ............................................................................................... 15
5.2 Connection procedure.................................................................................................... 16
5.3 Wiring plan, single chamber housing.............................................................................. 16
6 Setup ....................................................................................................................................... 19
6.1 General information........................................................................................................ 19
6.2 Adjustment elements...................................................................................................... 19
6.3 Function table................................................................................................................. 20
7 Maintenanceandfaultrectication...................................................................................... 22
7.1 Maintenance .................................................................................................................. 22
7.2 Rectify faults................................................................................................................... 22
7.3 Exchanging the electronics module................................................................................ 23
7.4 How to proceed if a repair is necessary.......................................................................... 24
8 Dismount................................................................................................................................. 26
8.1 Dismounting steps.......................................................................................................... 26
8.2 Disposal ......................................................................................................................... 26
9 Supplement ............................................................................................................................ 27
9.1 Technical data ................................................................................................................ 27
9.2 Dimensions .................................................................................................................... 30
9.3 Industrial property rights................................................................................................. 32
9.4 Trademark ...................................................................................................................... 32
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Contents
VR-90 • Vibrating Rod
29266-EN-181126
Safety instructions for Ex areas
TakenoteoftheExspecicsafetyinstructionsforExapplications.
These instructions are attached as documents to each instrument
with Ex approval and are part of the operating instructions.
Editing status: 2018-11-22
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1 About this document
VR-90 • Vibrating Rod
29266-EN-181126
1 About this document
1.1 Function
This operating instructions provides all the information you need for
mounting, connection and setup as well as important instructions for
maintenance,faultrectication,theexchangeofpartsandthesafety
of the user. Please read this information before putting the instrument
into operation and keep this manual accessible in the immediate
vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained personnel.
Thecontentsofthismanualmustbemadeavailabletothequalied
personnel and implemented.
1.3 Symbols used
Document ID
This symbol on the front page of this instruction refers to the Docu-
ment ID. By entering the Document ID on www.vega.com you will
reach the document download.
Information, tip, note
This symbol indicates helpful additional information.
Caution: If this warning is ignored, faults or malfunctions can result.
Warning: If this warning is ignored, injury to persons and/or serious
damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
•List
The dot set in front indicates a list with no implied sequence.
→Action
This arrow indicates a single action.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.
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2 For your safety
VR-90 • Vibrating Rod
29266-EN-181126
2 For your safety
2.1 Authorised personnel
All operations described in this documentation must be carried out
onlybytrained,qualiedpersonnelauthorisedbytheplantoperator.
During work on and with the device, the required personal protective
equipment must always be worn.
2.2 Appropriate use
The VR-90 is a sensor for point level detection.
Youcannddetailedinformationabouttheareaofapplicationin
chapter "Product description".
Operational reliability is ensured only if the instrument is properly
usedaccordingtothespecicationsintheoperatinginstructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to
application-specichazards,e.g.vesseloverllordamagetosystem
components through incorrect mounting or adjustment.Thus dam-
age to property, to persons or environmental contamination can be
caused. Also the protective characteristics of the instrument can be
inuenced.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and directives.The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsi-
ble for the trouble-free operation of the instrument.When measuring
aggressive or corrosive media that can cause a dangerous situation
if the instrument malfunctions, the operator has to implement suitable
measures to make sure the instrument is functioning properly.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.Forsafety
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2 For your safety
VR-90 • Vibrating Rod
29266-EN-181126
reasons,onlytheaccessoryspeciedbythemanufacturermustbe
used.
To avoid any danger, the safety approval markings and safety tips on
the device must also be observed and their meaning read in this oper-
ating instructions manual.
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 EU conformity
ThedevicefullsthelegalrequirementsoftheapplicableEUdirec-
tives.ByaxingtheCEmarking,weconrmtheconformityofthe
instrument with these directives.
YoucanndtheEUconformitydeclarationonourwebsiteunder
www.vega.com/downloads.
2.7 SIL conformity
VR-90 meets the requirements of functional safety according to IEC
61508. Further information is available in the Safety Manual
"VEGAVIB series 60".
2.8 Installation and operation in the USA and
Canada
This information is only valid for USA and Canada. Hence the follow-
ing text is only available in the English language.
Installations in the US shall comply with the relevant requirements of
the National Electrical Code (ANSI/NFPA 70).
Installations in Canada shall comply with the relevant requirements of
the Canadian Electrical Code.
2.9 Safety instructions for Ex areas
PleasenotetheEx-specicsafetyinformationforinstallationandop-
eration in Ex areas. These safety instructions are part of the operating
instructions manual and come with the Ex-approved instruments.
2.10 Environmental instructions
Protection of the environment is one of our most important duties.
That is why we have introduced an environment management system
with the goal of continuously improving company environmental pro-
tection.Theenvironmentmanagementsystemiscertiedaccording
to DIN EN ISO 14001.
Pleasehelpusfullthisobligationbyobservingtheenvironmental
instructions in this manual:
•Chapter "Packaging, transport and storage"
•Chapter "Disposal"
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3 Product description
VR-90 • Vibrating Rod
29266-EN-181126
3 Product description
3.1 Conguration
The scope of delivery encompasses:
•VR-90 point level switch
•Documentation
– This operating instructions manual
– Safety Manual "Functional safety (SIL)" (optional)
– Supplementary instructions manual "Plug connector for
level sensors" (optional)
–Ex-specific"Safety instructions" (with Ex versions)
–Ifnecessary,furthercertificates
The VR-90 consists of the components:
•Housing lid
•Housing with electronics
•Processttingwithvibratingrod
1
2
3
Fig. 1: VR-90 with plastic housing
1 Housing lid
2 Housing with electronics
3 Processtting
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
•Article number
•Serial number
•Technical data
•Article numbers, documentation
•SILidentication(withSILratingexworks)
With the serial number, you can access the delivery data of the instru-
ment via "www.vega.com", "Search".Youcanndtheserialnumber
on the inside of the instrument as well as on the type label on the
outside.
3.2 Principle of operation
VR-90 is a point level sensor with vibrating rod for point level
detection.
It is designed for industrial use in all areas of process technology and
is preferably used for bulk solids.
Scope of delivery
Constituent parts
Type label
Application area
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3 Product description
VR-90 • Vibrating Rod
29266-EN-181126
Typicalapplicationsare overfill and dry run protection. Thankstoits
simple and robust measuring system, VR-90 is virtually unaffected by
the chemical and physical properties of the bulk solid.
It also works when subjected to strong external vibrations or changing
products.
Solid detection in water
If VR-90 was ordered for solid detection in water, the vibrating rod is
calibrated to the density of water. If covered by water (density: 1 g/
cm³/0.036 lbs/in) VR-90 signals "uncovered". Only if the vibrating
element is also covered with solids (e.g. sand, sludge, gravel etc.) will
the sensor signal "covered".
Function monitoring
The electronics module of VR-90 continuously monitors the following
criteria:
•Correct vibrating frequency
•Linebreaktothepiezodrive
If one of the stated malfunctions is detected or in case of voltage
supply,theelectronicstakesonadenedswitchingstatus,i.e.the
contactless electronic switch opens (safe state).
Thevibratingrodispiezoelectricallyenergisedandvibratesatits
mechanicalresonancefrequencyofapprox.360Hz.Whenthevibrat-
ing rod is submerged in the product, the vibration amplitude changes.
This change is detected by the integrated electronics module and
converted into a switching command.
VR-90 is a compact instrument, i.e. it can be operated without
external evaluation system. The integrated electronics evaluates the
level signal and outputs a switching signal. With this switching signal,
a connected device can be operated directly (e.g. a warning system,
a pump etc.).
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Adjustment
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
•Signal lamp for indication of the switching condition (green/red)
•Potentiometer for adaptation to the product density
•Mode switch for selecting the switching condition (min./max.)
3.4 Storage and transport
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
The packaging of standard instruments consists of environment-
friendly, recyclable carton material. The sensing element is additional-
ly protected with a cardboard cover. For special versions, PE foam or
Functional principle
Voltage supply
Packaging
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3 Product description
VR-90 • Vibrating Rod
29266-EN-181126
PE foil is also used. Please dispose of the packaging material through
specialised recycling companies.
Transport must be carried out in due consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
•Not in the open
•Dry and dust free
•Not exposed to corrosive media
•Protected against solar radiation
•Avoiding mechanical shock and vibration
•Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
•Relative humidity 20 … 85 %
With instrument weights of more than 18 kg (39.68 lbs) suitable and
approved equipment must be used for lifting and carrying.
Transport
Transport inspection
Storage
Storage and transport
temperature
Lifting and carrying
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4 Mounting
VR-90 • Vibrating Rod
29266-EN-181126
4 Mounting
4.1 General instructions
Make sure that all parts of the instrument coming in direct contact
with the process, especially the sensor element, process seal and
processtting,aresuitablefortheexistingprocessconditions,such
as process pressure, process temperature as well as the chemical
properties of the medium.
Youcanndthespecicationsinchapter"Technical data" and on the
nameplate.
The instrument is suitable for standard and extended ambient condi-
tions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1.
In general, VR-90 can be installed in any position. The instrument
only has to be mounted in such a way that the vibrating element is at
the height of the desired switching point.
Use the recommended cables (see chapter "Connecting to power
supply") and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cablegland.Rainandcondensationwatercanthusdraino.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g. through cleaning processes) or
on cooled or heated vessels.
To maintain the housing protection, make sure that the housing lid is
closed during operation and locked, if necessary.
Makesurethatthedegreeofcontaminationspeciedinchapter
"Technical data" meets the existing ambient conditions.
Fig. 2: Measures against moisture ingress
Do not hold VR-90 on the vibrating element. Especially with flange
andtubeversions,thesensorcanbedamagedbytheweightof the
instrument.
Remove the protective cover just before mounting.
Suitability for the process
conditions
Suitability for the ambient
conditions
Switching point
Moisture
Transport
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4 Mounting
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29266-EN-181126
Theprocessttingmustbesealedifthereisgaugeorlowpressurein
the vessel. Before use, check if the seal material is resistant against
the measured product and the process temperature.
Themax.permissiblepressureisspeciedinchapter"Technical
data" or on the type label of the sensor.
The vibrating level switch is a measuring instrument and must be
treated accordingly. Bending the vibrating element will destroy the
instrument.
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Use the hexagon above the thread for screwing in.
Metric threads
In the case of instrument housings with metric thread, the cable
glands are screwed in at the factory. They are sealed with plastic
plugs as transport protection.
You have to remove these plugs before electrical connection.
NPT thread
In the case of instrument housings with self-sealing NPT threads, it is
not possible to have the cable entries screwed in at the factory. The
free openings for the cable glands are therefore covered with red dust
protection caps as transport protection.
Prior to setup you have to replace these protective caps with ap-
proved cable glands or close the openings with suitable blind plugs.
4.2 Mounting instructions
The vibrating element should protrude into the vessel to avoid
buildup.Forthatreason,avoidusingmountingbossesforanges
andscrewedttings.Thisappliesparticularlytousewithadhesive
products.
Mount the instrument in such a way that the vibrating rod does not
protrudedirectlyintothellingstream.
Pressure/Vacuum
Handling
Cable entries - NPT
thread
Cable glands
Mounting socket
Filling opening
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4 Mounting
VR-90 • Vibrating Rod
29266-EN-181126
20°
a. b.
Fig. 3: Horizontal installation
a Protective sheet
b Concave protective sheet for abrasive solids
If such an installation location should be necessary, mount a suitable
protective sheet above or in front of the vibrating element, see illustra-
tion "a").
In abrasive solids, mounting according to illustration "b" has proven.
A spout forms in the concave protective sheet preventing wear of the
protective sheet.
In silos for bulk solids, material cones can form and change the
switching point. Please keep this in mind when installing the sensor
in the vessel.We recommend selecting an installation location where
the vibrating rod detects an average value of the material cone.
The vibrating rod must be mounted in a way that takes the arrange-
mentofthellingandemptyingaperturesintoaccount.
To compensate measurement errors caused by the material cone in
cylindrical vessels, the sensor must be mounted at a distance of d/6
from the vessel wall.
Material cone
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4 Mounting
VR-90 • Vibrating Rod
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dd
d
6
d
6
Fig. 4: Filling and emptying centred
d
d
6
1
2
3
Fig. 5: Filling in the centre, emptying laterally
1 VR-90
2 Discharge opening
3 Filling opening
To achieve a very precise switching point, you can install VR-90
horizontally.However,iftheswitchingpointcanhaveatoleranceofa
Horizontal mounting
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4 Mounting
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few centimeters, we recommend mounting VR-90 approx. 20°
inclined to the vessel bottom to avoid buildup.
20°
Fig. 6: Horizontal mounting
IfVR-90ismountedinthefillingstream,unwantedfalse
measurement signals can be generated. For this reason, mount
VR-90atapositioninthevesselwherenodisturbances,e.g.
fromfillingopenings, agitators, etc., can occur.
In applications such as grit chambers or settling basins for coarse
sediments, the vibrating element must be protected against damage
withasuitablebae.
Thisbaemustbemanufacturedbyyou.
> 125 mm
(> 5")
> 120 mm
(> 4.7")
Fig.7:Baeforprotectionagainstmechanicaldamage
Inowingmedium
Baeprotectionagainst
falling rocks
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5 Connecting to power supply
VR-90 • Vibrating Rod
29266-EN-181126
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
Warning:
Connect only in the complete absence of line voltage.
•The electrical connection must only be carried out by trained,
qualiedpersonnelauthorisedbytheplantoperator.
•Alwaysswitchopowersupply,beforeconnectingordisconnect-
ing the instrument.
Note:
Install a disconnecting device for the instrument which is easy to
access.The disconnecting device must be marked for the instrument
(IEC/EN 61010).
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Connect the voltage supply according to the connection diagrams.
The electronics module VB60C is designed in protection class I.
To maintain this protection class, it is absolutely necessary that the
earth conductor be connected to the inner earth conductor terminal.
Keep the general installation regulations in mind.Take note of the
correspondinginstallationregulationsforhazardousareaswithEx
applications.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The instrument is connected with standard three-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas, screened cable should
be used.
Make sure that the cable used has the required temperature resist-
anceandresafetyformax.occurringambienttemperature
Use cable with round cross-section. A cable outer diameter of
5…9mm(0.2…0.35in)ensuresthesealeectofthecablegland.
Ifyouareusingcablewithadierentdiameterorcross-section,
exchange the seal or use a suitable cable gland.
Inhazardousareas,useonlyapprovedcableconnectionsforVR-90.
Take note of the corresponding installation regulations for Ex applica-
tions.
Cover all housing openings conforming to standard according to EN
60079-1.
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Connection cable
for Ex applications
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5 Connecting to power supply
VR-90 • Vibrating Rod
29266-EN-181126
5.2 Connection procedure
With Ex instruments, the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1. Unscrew the housing lid
2. Loosen compression nut of the cable gland and remove blind
plug
3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
Fig. 8: Connection steps 5 and 6
6. Insert the wire ends into the open terminals according to the wir-
ing plan
7. Press down the opening levers of the terminals, you will hear the
terminal spring closing
8. Check the hold of the wires in the terminals by lightly pulling on
them
9. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
10. If necessary, carry out a fresh adjustment
11. Screw the housing lid back on
Theelectricalconnectionisnished.
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-d
version.
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5 Connecting to power supply
VR-90 • Vibrating Rod
29266-EN-181126
1 2
4
3
5
5
55
Fig. 9: Material versions, single chamber housing
1 Plastic (not with Ex d)
2 Aluminium
3 Stainless steel (not with Ex d)
4 Stainless steel, electropolished (not with Ex d)
5 Filter element for pressure compensation (not with Ex d)
We recommend connecting VR-90 in such a way that the switching
circuit is open when there is a level signal, line break or failure (safe
state).
The contactless electronic switch is always shown in non-operative
condition.
Warning:
The instrument must not be operated without an intermediately
connected load, because the electronics would be destroyed if con-
nected directly to the mains. It is not suitable for connection to low
voltage PLC inputs.
Examples for typical applications:
•Loadresistanceat24VDC:88…1800Ω
•Rated power, relay 253 V AC: > 2.5 VA
•Rated power, relay 24 V AC: > 0.5 VA
For direct control of relays, contactors, magnet valves, warning lights,
horns etc.
Domestic current is temporarily lowered below 1 mA after switching
otheloadsothatcontactors,whoseholdingcurrentislowerthan
the constant domestic current of the electronics, are reliably switched
off.
WhenVR-90isusedaspartofanoverfillprotectionsystem
according to WHG, also note the regulations of the general type
approval.
Housing overview
Wiring plan
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5 Connecting to power supply
VR-90 • Vibrating Rod
29266-EN-181126
1
Fig. 10: Wiring plan
1 Shielding
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6 Setup
VR-90 • Vibrating Rod
29266-EN-181126
6 Setup
6.1 General information
Theguresinbracketsrefertothefollowingillustrations.
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
•Potentiometer for adjustment of the density range (1)
•DIL switch for mode adjustment - min./max. (2)
•Signal lamp (5)
Note:
As a rule, always set the mode with mode switch (2) before starting
the setup of VR-90. The switching output will change if you set the
mode switch (2) afterwards. This could possibly trigger other
connected instruments or devices.
6.2 Adjustment elements
3
4
5
1
2
Fig. 11: Electronics and connection compartment - contactless electronic switch
1 Potentiometer for adjustment of the density range
2 DIL switch for mode adjustment
3 Ground terminal
4 Connection terminals
5 Control lamp
With the potentiometer you can adapt the switching point to the solid.
Itisalreadypresetandmustonlybemodifiedinspecialcases.
As a default setting, the potentiometer of VR-90 is set to the complete
right position (> 0.1 g/cm³ or 0.0036 lbs/in³). In very light solids you
have to turn the potentiometer to the complete left position (0.02 …
0.1 g/cm³ or 0.0007 … 0.0036 lbs/in³). By doing this,
Function/Conguration
Electronics and connec-
tion compartment
Adjustment of the density
range (1)
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6 Setup
VR-90 • Vibrating Rod
29266-EN-181126
VR-90 will be more sensitive and light solids can be detected more
reliably.
For instruments detecting solids in water, these settings are not
applicable. The density range is preset and must not be changed.
With the mode adjustment (min./max.) you can change the switching
condition of the output.You can set the required mode according to
the "Function table"(max.-max.detectionoroverflowprotection,
min.- min. detection or dry run protection).
We recommend connecting according to the idle current principle
(contactless electronic switch is open when the switching point is
reached) because the contactless electronic switch takes on the
same (safe) state if a failure is detected.
Control lamp for indication of the switching status
•green = switch closed
•red = switch open
•red(ashing)=failure
6.3 Function table
The following table provides an overview of the switching conditions
depending on the set mode and the level.
Level Switching status Control lamp
Mode max.
Overowprotection
21
Switch closed Green
Mode max.
Overowprotection
21
Switch open Red
Mode min.
Dry run protection
21
Switch closed Green
Mode min.
Dry run protection
21
Switch open Red
Failure of the supply volt-
age
(min./max. mode)
any
21
Switch open
Mode adjustment (2)
Signal lamp (5)
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