Vega VEGACAP 64 User manual

Operating Instructions
VEGACAP 64
-Relay (DPDT)
Document ID:
30012
Capacitive

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
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity ............................. 6
2.7Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.8Environmental instructions..................... 6
3Product description
3.1Configuration .............................. 7
3.2Principle of operation ........................ 8
3.3Operation................................. 9
3.4Storage and transport ........................ 9
4Mounting
4.1General instructions ......................... 11
4.2Mounting instructions ........................ 12
5Connect to power supply
5.1Prepare the connection....................... 14
5.2Connection procedure........................ 14
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 15
6Set up
6.1General information ......................... 18
6.2Adjustment elements ........................ 18
6.3Functional chart ............................ 21
7Maintenance and fault rectification
7.1Maintenance .............................. 22
7.2Remove interferences ........................ 22
7.3Exchange of the electronics module . . . . . . . . . . . . . 23
7.4Instrument repair ........................... 25
8Dismounting
8.1Dismounting steps .......................... 26
8.2Disposal ................................. 26
9Supplement
9.1Technical data ............................. 27
9.2Dimensions ............................... 31
2VEGACAP 64 • - Relay (DPDT)
Contents
30012-EN-090604

Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your VEGACAP 64,we offer
accessories and replacement parts.The associated documents are:
l30174 -Electronics module VEGACAP series 60
l34296 -Protective cover
l31088 -Flanges according to DIN-EN-ASME-JIS-GOST
VEGACAP 64 • - Relay (DPDT)3
Contents
30012-EN-090604

1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
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: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.
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.
4VEGACAP 64 • - Relay (DPDT)
1About this document
30012-EN-090604

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 plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
VEGACAP 64 is a sensor for level detection.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications 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.Arbitrary
conversions or modifications are explicitly forbidden.
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
This 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 as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use,the user is obliged to determine the
compliance of the required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
VEGACAP 64 • - Relay (DPDT)5
2For your safety
30012-EN-090604

2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,VEGA provides a confirmation
of successful testing.You can find the CE conformity declaration in the
download area of www.vega.com.
2.7Safety instructions 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.
2.8Environmental 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 management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
6VEGACAP 64 • - Relay (DPDT)
2For your safety
30012-EN-090604

3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAP 64 point level sensor
lDocumentation
-this operating instructions manual
-Safety Manual -31814 "VEGACAP series 60 -Relay (DPDT)"
(optional)
-Supplementary instructions manual "Plug connector for level
sensors"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGACAP 64 consists of the following components:
lHousing cover
lHousing with electronics
lProcess fitting with electrode
1
2
3
4
5
Fig.1:VEGACAP 64 -with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
4active screen segment
5active probe
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
Scope of delivery
Components
Type label
VEGACAP 64 • - Relay (DPDT)7
3Product description
30012-EN-090604

lArticle numbers,documentation
The serial number allows you to access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".In addition to the type label outside,you can also find the
serial number on the inside of the instrument.
3.2Principle of operation
VEGACAP 64 is a level switch with fully insulated,capacitive electrode
with active screen segment and active tip for level detection.
VEGACAP 64 is very rugged and maintenance-free and can be used
in all areas of industrial process technology.
Typical applications are overfill and dry run protection.
Fully insulated probes with screen segment like VEGACAP 64 are
preferably used in conductive,very adhesive liquids.
Due to the mechanical constructions of the active screen segment and
the active tip,buildup on the probe can be compensated.
The capacitive measuring principle places no special requirements on
installation.Hence,many different applications can be equipped with
VEGACAP 64.
The instrument can also be used problem-free in corrosive products.
Probe,measured product and 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
Application area
Functional principle
8VEGACAP 64 • - Relay (DPDT)
3Product description
30012-EN-090604

The probe and the vessel wall are the capacitor plates.The measured
product is the dielectric.Due to the higher dielectric constant (DK
value)of the product compared to air,the capacitance increases as
the probe is gradually covered.
The capacitance change is converted by the electronics module into a
switching command.
VEGACAP 64 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
PLC,a pump etc.).
The data for power supply are specified in chapter "Technical data".
3.3Operation
The probe can be adapted to the dielectric constant of the product
directly on the electronics module.
Aswitching command can be triggered when the probe is covered or
laid bare.
On the electronics module you will find the following indicating and
adjustment elements:
lSignal lamp for indication of the switching condition (green/red)
lPotentiometer for switching point adaptation
lDIL switch for measuring range selection
lDIL switch for mode adjustment
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
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly,recyclable cardboard.For special versions,PE foam or PE foil
is also used.Dispose of the packaging material via specialised
recycling companies.
Transport must be carried out under 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
concealed defects must be appropriately dealt with.
Power supply
Packaging
Transport
Transport inspection
VEGACAP 64 • - Relay (DPDT)9
3Product description
30012-EN-090604

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:
lNot in the open
lDry and dust free
lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage
Storage and transport
temperature
10 VEGACAP 64 • - Relay (DPDT)
3Product description
30012-EN-090604

4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,process seal and process fitting,are
suitable for the existing process conditions.These include above all
the process pressure,process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data"or on the
type label.
In general the level switch can be mounted in any position.The
instrument must be mounted in such a way that the probe is at the
height of the requested switching point.
Before beginning the welding work,remove the electronics module
from the sensor.By doing this,you avoid damage to the electronics
through inductive coupling.
With threaded versions,the housing must not be used to screw in the
instrument!Applying tightening forces on the housing can damage its
internal parts.
Use the hexagon for screwing in.
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 entry.Rain and condensation water can thus drain off.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.
Fig.3:Measures against moisture penetration
Suitability for process
conditions
Switching point
Welding work
Handling
Moisture
VEGACAP 64 • - Relay (DPDT)11
4Mounting
30012-EN-090604

Do not hold VEGACAP 64 on the probe.Especially with heavy flange
versions or long rod versions,the sensor can be damaged simply by
the weight of the instrument.
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 and the process temperature.
The max.permissible pressure is specified in chapter "Technical data"
or on the type label of the sensor.
4.2Mounting instructions
Agitators,equipment vibration,etc., can cause the level switch to be
subjected to strong lateral forces.For this reason,do not use an overly
long probe for VEGACAP 64,but check if you can mount a short level
switch on the side of the vessel in horizontal position.
Extreme vibration caused by the system,e.g.due to agitators or
turbulence in the vessel from fluidisation,can cause the probe of
VEGACAP 64 to vibrate in resonance.If a longer rod version is
necessary,you can secure the probe by fastening a suitable brace or
guy directly above the end of the rod.
If the instrument is mounted in the filling stream,unwanted false
measurement signals can be generated.For this reason,mount the
instrument at a position in the vessel where no disturbances,e.g.from
filling openings,agitators,etc., can occur.
This applies particularly to instrument versions with a longer probe.
Transport
Pressure/Vacuum
Agitators and fluidiza-
tion
Inflowing medium
12 VEGACAP 64 • - Relay (DPDT)
4Mounting
30012-EN-090604

Fig.4:Inflowing medium
To compensate the normal voltage loss due to sealing materials,you
have to additionally use disc springs for fastening flange screws on
PTFE coated flanges.Tighten the screws moderately with the torque
stated in the technical data.
Torque with PTFE plated
flanges
VEGACAP 64 • - Relay (DPDT)13
4Mounting
30012-EN-090604

5Connect to power supply
5.1Prepare the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
Connect the operating voltage according to the following diagrams.
The electronics module with relay output is designed in protection
class 1.To maintain this protection class,it is absolutely necessary
that the ground conductor is connected to the internal ground terminal.
Take note of the general installation regulations.As a rule,connect
VEGACAP 64 to vessel ground (PA), or in case of plastic vessels,to
the next ground potential.On the side of the housing there is a ground
terminal between the cable entries.This connection serves to drain off
electrostatic charges.
The data for power supply are specified in chapter "Technical data".
The instrument is connected with standard two-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.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
5.2Connection procedure
With Ex instruments,the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)insulation from the ends of the individual wires
4Insert the cable through the cable gland into the sensor
5Lift the opening levers of the terminals with a screwdriver (see
following illustration)
6Insert the wire ends into the open terminals according to the wiring
plan
7Press down the opening levers of the terminals,you will hear the
terminal spring closing
8Check the hold of the wires in the terminals by lightly pulling on
them
Note safety instructions
Select power supply
Selecting connection
cable
14 VEGACAP 64 • - Relay (DPDT)
5Connect to power supply
30012-EN-090604

9Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
10 If necessary,carry out a fresh adjustment
11 Screw the housing cover on
The electrical connection is finished.
Fig.5:Connection steps 5and 6
5.3Wiring plan,single chamber housing
1
4
44
2 3
Fig.6:Material versions,single chamber housing
1Plastic (not with dust-Ex)
2Aluminium
3Stainless steel
4Filter element for air pressure compensation
Housing overview
VEGACAP 64 • - Relay (DPDT)15
5Connect to power supply
30012-EN-090604

4
5
6
2
1
3
Fig.7:Electronics and connection compartment
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Connection terminals
6Control lamp
We recommend connecting VEGACAP 64 in such a way that the
switching circuit is open when there is a level signal,line break or
failure (safe condition).
The relays are always shown in non-operative condition.
Electronics and connec-
tion compartment
Wiring plan
16 VEGACAP 64 • - Relay (DPDT)
5Connect to power supply
30012-EN-090604

3
2 1
Fig.8:Wiring plan
1Relay output
2Relay output
3Power supply
VEGACAP 64 • - Relay (DPDT)17
5Connect to power supply
30012-EN-090604

6Set up
6.1General information
The figures in brackets refer to the following illustrations.
On the electronics module you will find the following indicating and
adjustment elements:
lPotentiometer for switching point adaptation
lDIL switch for measuring range selection
lDIL switch for mode adjustment -min./max.
lControl lamp
Note:
As a rule,always set the mode with the mode switch (3)before starting
setup VEGACAP 64.The switching output will change if you set the
mode switch (3)afterwards.This could possibly trigger other
connected instruments or devices.
6.2Adjustment elements
4
5
6
2
1
3
Fig.9:Oscillator with relay output
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection (with compensation button)
3DIL switch for mode adjustment
4Ground terminal
5Connection terminals
6Control lamp
The switching status of the electronics can be checked with closed
housing (only plastic housing), see "Function chart".
Function/Configuration
18 VEGACAP 64 • - Relay (DPDT)
6Set up
30012-EN-090604

Note:
Screw the housing cover tightly up to the thread stop so that the
inspection glass is above the control lamp (LED).
To adjust VEGACAP 64,first of all remove the housing cover.
You can adapt the switching point to the solid with the potentiometer.
With the potentiometer (1)and the measuring range selection switch
(2)you can change the sensitivity of the probe to the electrical
properties of the product and the conditions in the vessel.This is
necessary so that the level switch can also reliably detect products e.
g.with very low or very high dielectric value.
range 1:0…20 pF
Range 2:0…85 pF
Range 3:0…450 pF
With the mode switch (3)you can change the switching condition of
the relay.You can set the required mode (max. - max.detection or
overfill protection,min. - min.detection or dry run protection).
We recommend connecting according to the quiescent current
principle (relay contact deenergizes when the switching point is
reached), because the relay always takes on the same (safe)condition
if a failure is detected.
Control lamp for indication of the switching status
lgreen =relay energized
lred =relay deenergized
lred (flashing)=failure
The adjustment of the switching point is only possible in installed
condition.
The specifications in parenthesis refer to the preceding illustration.
Horizontally mounted probes,angled probes
1Set mode switch (3)to mode max [min.].
2Set meas.range selection switch (2)to range 1.
3Make sure the probe is not covered by the medium.
4Turn the potentiometer (1)to 0,the control lamp (6)lights red
[lights green].
5To determine the empty switch point,turn the potentiometer (1)
very slowly clockwise until the control lamp lights green [lights
red]. If the control lamp still lights red [lights green], then you have
to set the meas.range selection switch (2)to the next higher stage
and repeat the setting with the potentiometer (1)until the control
lamp lights green [lights red].
6Note the position of the potentiometer (1).
Switching point adapta-
tion (1)
Measuring range selec-
tion switch (2)
Mode adjustment (3)
Signal lamp (6)
Switching point adjust-
ment
Mode max.
[mode min.]
VEGACAP 64 • - Relay (DPDT)19
6Set up
30012-EN-090604

In some cases the lowest range (range 1=highest sensitivity)is
not sufficient to adjust the full switch point.This would make
another filling procedure necessary.
For this reason we recommend setting and noting the empty
switching point in all three meas.ranges.Set the meas.range
selection switch (2)to the next higher range and repeat the setting.
Also note the values for the next ranges.
7Reset meas.range selection switch (2)to the next lower range in
which the control lamp lights green [lights red].
8Fill the vessel until the probe is completely covered.
9Turn the potentiometer (1)very slowly clockwise until the control
lamp lights green [lights red].
10 Note the position of the potentiometer (1). We recommend
documenting the value of the empty switch point and the full switch
point as well as the range.
11 If the control lamp does not light green [light red], then you have to
set the meas.range switch (2)to the next higher stage and repeat
the setting with the potentiometer until the control lamp lights
green [lights red].
12 Set the potentiometer (1)to the average value of the two noted
values.
The measuring system is now ready for operation.
Empty adjustment Full adjustment
range 1
range 2
range 3
Tab.1:Note the position of the potentiometer.
Note:
If you do not find the full switch point in one of the ranges,we
recommend setting the meas.range selection switch (2)to the lowest
range in which you have found the empty switch point.Set the
potentiometer (1)to the average value between empty switch point
and 10.
Vertically mounted probes
1Set mode switch (3)to mode max.
2Set meas.range selection switch (2)to range 1.
3Fill the vessel up to the requested level.
4Turn potentiometer (1)to position 10.
When the control lamp (6)lights red:set the measuring range
selection switch (2)to the next higher measuring range.
When the control lamp (6)lights green:continue with the next item.
5Turn the potentiometer (1)very slowly anticlockwise until the
control lamp (6)lights red.
Mode max.
(max.detection)
20 VEGACAP 64 • - Relay (DPDT)
6Set up
30012-EN-090604