Vega VEGACAL 66 User manual

Operating Instructions
VEGACAL 66
4…20 mA/HART

Contents
1About this document
1.1Function ............................. 4
1.2Target group .......................... 4
1.3Symbolism used ....................... 4
2For your safety
2.1Authorised personnel .................... 5
2.2Appropriate use........................ 5
2.3Warning about misuse ................... 5
2.4General safety instructions ................ 5
2.5CE conformity ......................... 5
2.6Compatibility acc.to NAMUR NE 53......... 5
2.7Safety information for Ex areas............. 6
2.8Manufacturer declaration ................. 6
2.9Environmental instructions ................ 7
3Product description
3.1Configuration.......................... 8
3.2Principle of operation .................... 9
3.3Adjustment ........................... 10
3.4Storage and transport ................... 10
4Mounting
4.1General instructions..................... 11
4.2Mounting information .................... 12
5Connecting to power supply
5.1Preparing the connection ................. 15
5.2Connection steps....................... 16
5.3Wiring plans,single chamber housing ........ 17
5.4Wiring plans,double chamber housing ....... 19
5.5Wiring plans,double chamber housing Exd.... 21
5.6Wiring plans,version IP 66/IP 68 (1bar)...... 23
6Setup with the indicating and adjustment module
PLICSCOM
6.1Short description ....................... 24
6.2Installing the indicating and adjustment module
PLICSCOM ........................... 24
6.3Adjustment system ..................... 26
6.4Setup procedure ....................... 27
6.5Menu schematic ....................... 32
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Contents
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7Setup with PACTware™and other adjustment
programs
7.1Connecting the PC ..................... 34
7.2Parameter adjustment with PACTware™...... 35
7.3Parameter adjustment with AMS™and PDM .. 36
7.4Saving the parameter adjustment data ....... 36
8Maintenance and fault rectification
8.1Maintenance .......................... 37
8.2Fault rectification ....................... 37
8.3Exchange of the electronics module ......... 39
8.4Instrument repair ....................... 40
9Dismounting
9.1Dismounting procedure .................. 42
9.2Disposal ............................. 42
10 Supplement
10.1Technical data......................... 43
10.2Dimensions ........................... 49
10.3Industrial property rights.................. 51
VEGACAL 66 -4…20 mA/HART 3
Contents
30036-EN-060306

1About this document
1.1Function
This operating instructions manual has all the information you
need for quick setup and safe operation.Please read this
manual before you start setup.
1.2Target group
This operating instructions manual is directed to trained,
qualified personnel.The contents of this manual should be
made available to these personnel and put into practice by
them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution,warning,danger
This symbol informs you of a dangerous situation that could
occur.Ignoring this cautionary note can impair the person and/
or the instrument.
Ex applications
This symbol indicates special instructions for Ex applications.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4VEGACAL 66 -4…20 mA/HART
About this document
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2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual
must be carried out only by trained specialist personnel
authorised by the operator.For safety and warranty reasons,
any internal work on the instruments must be carried out only
by personnel authorised by the manufacturer.
2.2Appropriate use
VEGACAL 66 is a sensor for continuous level measurement.
Detailed information on the application range of VEGACAL 66
is available in chapter "Product description".
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to
system components through incorrect mounting or adjustment.
2.4General safety instructions
The VEGACAL 66 is a high-tech instrument requiring the strict
observance of standard regulations and guidelines.The user
must take note of the safety instructions in this operating
instructions manual,the country-specific installation standards
(e.g.the VDE regulations in Germany)as well as all prevailing
safety regulations and accident prevention rules.
2.5CE conformity
VEGACAL 66 is in CE conformity to EMC (89/336/EWG)and
LVD (73/23/EWG).
Conformity has been judged acc.to the following standards:
lEMC:
-Emission EN 61326:2004 (class B)
-Susceptibility EN 61326:2004 including supplement A
lLVD:EN 61010-1:2001
2.6Compatibility acc.to NAMUR NE 53
VEGACAL 66 meets NAMUR recommendation NE 53.VEGA
instruments are generally upward and downward compatible:
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lsensor software for DTM-VEGACAL 66 HART,PA or FF
lDTM VEGACAL 66 for adjustment software PACTware™
ladjustment module PLICSCOM for sensor software
The parameter adjustment of the basic sensor functions is
independent of the software version.The range of available
functions depends on the respective software version of the
individual components.
The software version of VEGACAL 66 can be determined as
follows:
lvia PACTware™
lon the type label of the electronics
lvia the indicating and adjustment module PLICSCOM
You can view all software histories on our website www.vega.
com.Make use of this advantage and get registered for update
information via e-mail.
2.7Safety information for Ex areas
Please note the Ex-specific safety information for installation
and operation in Ex areas.These safety instructions are part of
the operating instructions manual and come with the Ex-
approved instruments.
2.8Manufacturer declaration
In conformity with DIN EN 60079-14/2004,para.5.2.3,point
c1,the capacitive probe VEGACAL 66 is suitable for use in
zone 2.
The operator must use the instrument correctly and follow the
specifications of the following documents:
lthis operating instructions manual
lthis manufacturer declaration (24641)
lthe applicable installation regulations
Max.increase of the surface temperature during operation:
25 K(individual components in the instrument)
With an ambient temperature of +70°C(+158°F)on the
housing and a process temperature of +70°C(+158°F), the
max.ambient temperature during operation is +95°C(+203°F).
Measures to maintain the explosion protection during oper-
ation:
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lOperate you instrument in the range of the specified
electrical limit values.Permissible supply voltage:see
"Technical data"
lMount and operate the instrument in such a way that no
ignition danger is expected by electrostatic charges.The
process fitting,the plastic-coated/covered probe part or the
housing are made of electrically non-conductive plastic
(depending on the version).
lMake sure that the seal is mounted correctly between
lower part of the housing and cover.Screw the cover on
tightly.
lMake sure that there is no explosive atmosphere,if you
want to operate the instrument with open cover
lMake sure that the cable gland is tight and strain-relieved.
The outer diameter of the connection cable must be
adapted to the cable gland.Tighten the pressure screw of
the cable gland carefully.
lCover unused openings for cable glands tightly
lMount the instrument in such a position that the sensor
cannot touch the vessel wall or vessel installations.Keep
the influences of product movements in the vessel in mind.
lThe surface temperature on the housing must not exceed
the ignition temperature of the concerned explosive
atmosphere
This instrument was judged by a person that fulfils the
requirements acc.to DIN EN 60079-14.
2.9Environmental 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 protection.The environment man-
agement system is certified acc.to DIN EN ISO 14001.
Please help us fulfil this obligation by observing the environ-
mental instructions in this manual:
lChapter "Storage and transport"
lChapter "Disposal"
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3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAL 66 level sensor
ldocumentation
-this operating instructions manual
-Ex-specific safety instructions (with Ex versions), if
necessary further certificates.
VEGACAL 66 consists of the following components:
lProcess fitting with probe
lHousing with electronics
lHousing cover,optionally available with indicating and
adjustment module PLICSCOM
1
2
3
Fig.1:VEGACAL 66 -cable version with plastic housing
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics
3Process fitting
Scope of delivery
Components
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Product description
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3.2Principle of operation
VEGACAL 66 is a level sensor with fully insulated probe for
continuous level measurement.
The electronics functions acc.to the admittance principle
(phase-selective admittance processing).
It is designed for industrial use in all areas of process
technology and can be applied in all areas of industrial process
measurement.
Fully insulated probes such as VEGACAL 66 are used in
liquids and solids;preferably in conductive products.
The probe,the measured product and the vessel wall form an
electrical capacitor.The capacitance is influenced by three
main factors.
1
2
3
Fig.2:Functional principle -Plate capacitor
1Distance between the electrode surfaces
2Size of the electrode surfaces
3Type of dielectric between the electrodes
The probe and the vessel wall are the capacitor plates.The
measured product and the isolation are the dielectric.Due to
the higher dielectric constant (DK value)of the isolation and
the conductive product compared to air,the capacitance
increases as the probe is gradually covered.
The capacitance as well as the resistance change are
converted in the oscillator into a level-proportional signal.
Two-wire electronics 4…20 mA/HART for power supply and
measured value transmission on the same cable.
Area of application
Physical principle
Supply
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Product description
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The supply voltage range can differ depending on the
instrument version.The exact range is stated in the "Technical
data"in the "Supplement".
3.3Adjustment
VEGACAL 66 can be adjusted with four different adjustment
media:
lthe indicating and adjustment module PLICSCOM
lthe suitable VEGA DTM in conjunection with an adjustment
software acc.to the FDT/DTM standard,e.g.PACTware™
and PC
lthe manufacturer-specific adjustment programs AMS™or
PDM
laHART handheld
The entered parameters are generally saved in VEGACAL 66,
optionally also in PLICSCOM or in PACTware™.
3.4Storage and transport
Your instrument was protected by packaging during transport.
Its capacity to handle normal loads during transport is assured
by a test acc.to DIN EN 24180.
The packaging of standard instruments consists of environ-
ment-friendly,recyclable cardboard.For special versions,PE
foam or PE foil is also used.Dispose of the packaging material
via specialised recycling companies.
lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Storage and transport tem-
perature
10 VEGACAL 66 -4…20 mA/HART
Product description
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4Mounting
4.1General instructions
Select an installation position you can easily reach for
mounting and connecting as well as later retrofitting of an
indicating and adjustment module.The housing can be rotated
by 330°without the use of any tools.You can also install the
indicating and adjustment module in four different positions
(each displaced by 90°).
With screwed versions,the housing must not be used for
screwing in!Tightening can cause damages on the locking
piston of the housing.
To screw in,use the hexagon above the thread.
Use the recommended cables (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your VEGACAL 66 additional protection against
moisture penetration by leading the connection cable down-
ward in front of the cable entry.Rain and condensation water
can thus drain off.This applies mainly to mounting outdoors,in
areas where moisture is expected (e.g.by cleaning processes)
or on cooled or heated vessels.
Fig.3:Measures against moisture penetration
The process fitting 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.
Installaton position
Handling
Moisture
Pressure/Vacuum
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Mounting
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Insulating measures,such as e.g.covering the thread with
teflon tape,can interrupt the necessary electrical connection
with metal vessels.For this reason,ground the probe on the
vessel or use a conductive seal material.
Metal vessel
Make sure that the mechanical connection of the probe to the
vessel is electrically conductive to ensure sufficient grounding.
Use conductive seals such as e.g.copper or lead etc.
Insulating measures,such as covering the thread with Teflon
tape,can interrupt the necessary electrical connection with
metal vessels.For this reason,ground the probe on the vessel
or use a conductive seal material.
Non-conductive vessel
In non-conductive vessels,e.g.plastic tanks,the second pole
of the capacitor must be provided separately,e.g.in the form
of a concentric tube.
If possible,the capacitive probe should be mounted vertically
or parallel to the counter electrode.This applies particularly to
applications in non-conductive products.
In cylindrical tanks,spherical tanks or other asymmetrical tank
forms,nonlinear level values are generated due to the varying
distance to the vessel wall.
Use a concentric tube in non-conductive products or linearize
the meas.signal.
4.2Mounting information
During operation,the probe must not touch any installations or
the vessel wall.The measured value can also change if the
distance to the vessel wall changes considerably.If necessary,
secure the end of the probe (insulated).
In the gravity weight there is a thread (M12), e.g.for a ring bolt
(article no.2.27424). The thread is already insulated in the
gravity weight.
Make sure that the probe cable is not completely taut.Avoid
tensile loads on the rope.
Vessel material
Vessel forms
Installaton position
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Mounting
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1
3
2
Fig.4:Fasten the probe
1Gravity weight
2Lug M12 (article no.2.27423)
In vessels with conical bottom it can be advantageous to
mount the sensor in the center of the vessel,as measurement
is then possible down to the lowest point of the vessel bottom.
Caution:
It is not possible to measure on the gravity weight.The
measuring range of the probe ends at the upper edge of the
gravity weight.
IfVEGACAL 66 is mounted in the filling stream,unwanted
switching signals may be generated.Mount VEGACAL 66 at a
location in the vessel where no disturbing influence from e.g.
filling openings,agitators,etc.can occur.
This applies particularly to instrument versions with a longer
probe.
Inflowing material
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Mounting
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Fig.5:Inflowing material
14 VEGACAL 66 -4…20 mA/HART
Mounting
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5Connecting to power supply
5.1Preparing the connection
Always observe the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltages are expected,overvoltage arresters should
be installed
Tip:
We recommend using VEGA overvoltage arresters ÜS-F-LB-I
and ÜSB 62-36G.X.
In hazardous areas you should take note of the appropriate
regulations,conformity and type approval certificates of the
sensors and power supply units.
Power supply and current signal are transmitted via the same
two-wire connection cable.The supply voltage range can differ
depending on the instrument version.The exact range is
stated in the "Technical data"in the "Supplement".
Provide a reliable separation between the supply circuit and
the mains circuits acc.to DIN VDE 0106 part 101.The VEGA
power supply units VEGATRENN 149AEx,VEGASTAB 690,
VEGADIS 371 as well as all VEGAMETs meet this require-
ment.
Bear in mind the following factors regarding supply voltage:
lthe reduction of the output voltage of the power supply unit
under nominal load (with a sensor current of 20.5mAor
22 mAin case of fault signal)
lThe influence of additional instruments in the circuit (see
load values in "Technical data").
VEGACAL 66 is connected with standard two-wire cable
without screen.Aouter cable diameter of 5…9mm ensures
the seal effect of the cable gland.If electromagnetic
interference is expected which is above the test values of
EN 61326 for industrial areas,screened cable should be used.
For HART multidrop operation we recommend as standard
practice the use of screened cable.
OnVEGACAL 66 with cable gland ½NPT and plastic housing,
a metal ½" threaded insert is moulded in the plastic housing.
Note safety instructions
Take note of safety
instructions for Ex
applications
Select power supply
Select connection cable
Cable gland ½NPT
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Connecting to power supply
30036-EN-060306

Caution:
No grease should be used when screwing the NPT cable
gland or steel tube into the threaded insert.Standard grease
can contain additives affecting the connection between
threaded insert and housing.This will influence the stability of
the connection and the tightness of the housing.
If screened cable is necessary,connect the cable screen on
both ends to ground potential.In the sensor,the screen must
be connected directly to the internal ground terminal.The
ground terminal on the outside of the housing must be
connected to the potential equalisation (low impedance).
If potential equalisation currents are expected,the connection
on the evaluation side must be made via the ceramic capacitor
(e.g.1nF,1500 V). The low frequency potential equalisation
currents are thus suppressed,but the protective effect against
high frequency interference signals remains.
Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equal-
isation currents flow over the cable screen.In case of
grounding on both sides this can be achieved by the use of a
capacitor or a separate potential equalisation.
5.2Connection steps
Proceed as follows:
1Unscrew the housing cover
2If an indicating and adjustment module is installed,remove
it by turning it slightly to the left.
3Loosen compression nut of the cable entry
4Remove approx.10 cm (4in)of the cable mantle,strip
approx.1cm (0.4in)insulation from the ends of the
individual wires
5Insert the cable into the sensor through the cable entry
6Lift the opening levers of the terminals with a screwdriver
(see following illustration)
7Insert the wire ends into the open terminals according to
the wiring plan
Cable screening and ground-
ing
Select connection
cable for Ex applica-
tions
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Fig.6:Connection steps 6and 7
8Press the opening lever of the terminals downward,you will
hear the terminal spring closing
9Check the hold of the wires in the terminals by lightly
pulling on them
10 Connect the screen to the internal ground terminal and the
external ground terminal to potential equalisation
11 Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
12 Screw the housing cover back on
The electrical connection is finished.
5.3Wiring plans,single chamber housing
The following illustrations apply to the non-Ex as well as to the
Ex ia version.
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1
4
44
2 3
Fig.7:Material versions,single chamber housing
1Plastic
2Aluminium
3Stainless steel
4Filter element for pressure compensation or blind stopper with version IP 66/
IP 68,1bar
I2C
Display
12 5678
3
4
1
2
Fig.8:Electronics and connection compartment,single chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Spring-loaded terminals for connection of the external indication VEGADIS
61
3Ground terminal for connection of the cable screen
4Spring-loaded terminals for power supply
Housing overview
Electronics and connection
compartment
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I2C
Display
1
12 5678
Fig.9:Wiring plan,single chamber housing
1Power supply/Signal output
5.4Wiring plans,double chamber housing
The following illustration apply to non-Ex as well as Exia
versions.The Exd version is described in the next subchapter.
1 2 3
45
Fig.10:Double chamber housing
1Housing cover,connection compartment
2Blind stopper or plug M12x1for VEGADIS 61 (option)
3Housing cover,electronics compartment
4Filter element for pressure compensation or blind stopper with version IP 66/
IP 68,1bar1)
5Cable entry or plug
1)Version IP 66/IP 68,1bar not with four-wire instruments.
Wiring plan
Housing overview
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1
32
Display
12 5678
I2C
Fig.11:Electronics compartment,double chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Internal connection cable to the connection compartment
3Terminals for VEGADIS 61
3
1
2
Display
12
I2C
Fig.12:Connection compartment,double chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Ground terminal for connection of the cable screen
3Spring-loaded terminals for power supply
Electronics compartment
Connection compartment
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