Vega VEGACAP 65 User manual

Operating Instructions
VEGACAP 65
with contactless electronic switch

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
2.6Safety information for Ex areas............. 6
2.7Manufacturer declaration ................. 6
2.8Environmental 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....................... 15
5.3Wiring plans,single chamber housing ........ 16
6Set up
6.1General.............................. 19
6.2Adjustment elements .................... 19
6.3Function chart ......................... 21
7Maintenance and fault rectification
7.1Maintenance .......................... 23
7.2Fault rectification ....................... 23
7.3Exchange of the electronics module ......... 24
7.4Instrument repair ....................... 26
8Dismounting
8.1Dismounting steps ...................... 27
2VEGACAP 65 -with contactless electronic switch
Contents
30017-EN-060223

8.2Disposal ............................. 27
9Supplement
9.1Technical data......................... 28
9.2Dimensions ........................... 32
9.3Industrial property rights.................. 35
VEGACAP 65 -with contactless electronic switch 3
Contents
30017-EN-060223

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.
4VEGACAP 65 -with contactless electronic switch
About this document
30017-EN-060223

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
VEGACAP 65 is a sensor for level detection.
Detailed information on the application range of VEGACAP 65
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
VEGACAP 65 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
VEGACAP 65 is in CE conformity with 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)
-Susceptibiliy EN 61326:2004/Supplement A
lLVD:EN 61010-1:2001
VEGACAP 65 -with contactless electronic switch 5
For your safety
30017-EN-060223

2.6Safety 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.
2.7Manufacturer declaration
In conformity with DIN EN 60079-14/2004,para.5.2.3,point
c1,the capacitive probe VEGACAP 65 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 (24643)
lthe corresponding installation regulations
Max.increase of the surface temperature during operation:
40 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 +110°C
(+230°F).
Measures to maintain the explosion protection during oper-
ation:
lOperate the 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
6VEGACAP 65 -with contactless electronic switch
For your safety
30017-EN-060223

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 ingnition temperature of the concerned explosive
atmosphere
This instrument was judged by a person that fulfils the
requirements acc.to DIN EN 60079-14.
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 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"
VEGACAP 65 -with contactless electronic switch 7
For your safety
30017-EN-060223

3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAP 65 level sensor
lDocumentation
-this operating instructions manual
-Ex specific safety instructions (with Ex versions), if
necessary further certificates
VEGACAP 65 consists of the following components:
lHousing cover
lHousing with electronics
lProcess fitting with electrode
1
2
3
Fig.1:VEGACAP 65 -with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
Scope of delivery
Components
8VEGACAP 65 -with contactless electronic switch
Product description
30017-EN-060223

3.2Principle of operation
VEGACAP 65 is a level sensor with capacitive electrode for
level detection.
VEGACAP 65 is very rugged and maintenance-free and can
be used in all areas of industrial process technology.
Probes such as VEGACAP 65 can be used in solids and in
non-conductive liquids.
Typical applications are overfill and dry run protection.
The capacitive measuring principle places no special require-
ments on installation.Hence,many different applications can
be equipped with VEGACAP 65.
The instrument can also be used problem-free in adhesive
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 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 oscillator into a
switching command.
Area of application
Physical principle
VEGACAP 65 -with contactless electronic switch 9
Product description
30017-EN-060223

VEGACAP 65 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,aPLC,a pump etc.).
The exact range of the supply voltage is specified in the
"Technical data"in the "Supplement".
3.3Adjustment
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 acc.to DIN 55439.
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 %
Supply
Packaging
Storage and transport tem-
perature
10 VEGACAP 65 -with contactless electronic switch
Product description
30017-EN-060223

4Mounting
4.1General instructions
In general,VEGACAP 65 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.
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 cable (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your VEGACAP 65 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 and the process
temperature.
Switching point
Handling
Moisture
Pressure/Vacuum
VEGACAP 65 -with contactless electronic switch 11
Mounting
30017-EN-060223

4.2Mounting information
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 65,but check if you
can mount a short level switch on the side of the vessel in
horizontal position.
IfVEGACAP 65 is mounted in the filling stream,unwanted
false measurements may be generated.Mount VEGACAP 65
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.
Fig.4:Inflowing material
The probe should protrude into the vessel to avoid buildup.For
that reason,avoid using mounting bosses for flanges and
screwed fittings.This applies particularly to use with adhesive
products.
Agitators and fluidization
Inflowing material
Socket
12 VEGACAP 65 -with contactless electronic switch
Mounting
30017-EN-060223

In silos with bulk solids,material cones can form which change
the switching point.Please keep this in mind when installing
the sensor in the vessel.We recommend selecting an
installation location where the probe detects the average value
of the material cone.
The measuring probe must be mounted in a way that takes the
arrangement of the filling 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/6from the vessel wall.
d d
d
6
d
6
Fig.5:Filling and emptying centered
Material cone
VEGACAP 65 -with contactless electronic switch 13
Mounting
30017-EN-060223

d
d
6
1
2
3
Fig.6:Filling in the center,emptying laterally
1VEGACAP 65
2Emptying opening
3Filling opening
Make sure that the max.permissible tensile load of the
suspension cable is not exceeded.The danger of this
happening exists particularly with very heavy solids and large
meas.lengths.The max.permissible load is stated under
"Technical data"in the "Supplement".
Tensile load
14 VEGACAP 65 -with contactless electronic switch
Mounting
30017-EN-060223

5Connecting to power supply
5.1Preparing the connection
Always observe the following safety instructions:
lConnect only in the complete absence of line voltage
Connect the power supply acc.to the following diagrams.
Oscillator CP60Cis 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.Asa
rule,connect VEGACAP 65 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 offelectrostatic
charges.
The data for power supply are stated in the "Technical data"in
the "Supplement".
VEGACAP 65 is connected with standard cable with round
wire cross section.An outer cable diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable entry.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
5.2Connection steps
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 into the sensor through the cable entry
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
Note safety instructions
Select power supply
Select connection cable
VEGACAP 65 -with contactless electronic switch 15
Connecting to power supply
30017-EN-060223

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
9Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
10 Screw the housing cover back on
The electrical connection is hence finished.
Fig.7:Connection steps 5and 6
5.3Wiring plans,single chamber housing
1
4
44
2 3
Fig.8:Material versions,single chamber housing
1Plastic (not with dust-Ex)
2Aluminium
3Stainless steel
4Filter element for pressure compensation
Housing overview
16 VEGACAP 65 -with contactless electronic switch
Connecting to power supply
30017-EN-060223

4
5
6
3
2
1
Fig.9:Electronics and connection compartment
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Terminals
6Control lamp
We recommend connecting VEGACAP 65 in such a way that
the switching circuit is open when there is a level signal,line
break or failure (safe condition).
The contactless electronic switch is always shown in non-
operative condition.
The instrument is used for direct control of relays,contactors,
magnet valves,warning lights,horns etc.It must not be
operated without an intermediately connected load,because
the electronics would be destroyed if connected directly to the
mains.It is not suitable for connection to low voltage PLC
inputs.
The domestic current briefly below 1mAafter switching offthe
load so that contactors the holding current of which is lower
than the permanently flowing domestic current of the elec-
tronics are nevertheless switched offreliably.
When VEGACAP 65 is used as part of an overfill protection
system acc.to WHG,also note the regulations of the general
type approval.
Electronics and connection
compartment
Wiring plan
VEGACAP 65 -with contactless electronic switch 17
Connecting to power supply
30017-EN-060223

1
Fig.10:Wiring plan
1Voltage supply
18 VEGACAP 65 -with contactless electronic switch
Connecting to power supply
30017-EN-060223

6Set up
6.1General
The numbers 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 65.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
3
2
1
Fig.11:Oscillator -Contactless electronic switch
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Terminals
6Control lamp
Function/Configuration
VEGACAP 65 -with contactless electronic switch 19
Set up
30017-EN-060223

The switching status of the electronics can be checked with
closed housing (only plastic housing), see "Function chart".
Note:
Screw the housing cover tightly to the point where the
inspection glass is above the control lamp (LED).
To adjust VEGACAP 65,first of all remove the housing cover.
You can adapt the switching point to the solid with the
potentiometer.
As a default setting,the potentiometer of VEGACAP 65 is set
to mid position.To make the instrument less sensitive,turn the
potentiometer clockwise.VEGACAP 65 can then detect
products with high dielectric value (e.g.water)more reliably.
To make the instrument more sensitive,turn the potentiometer
anticlockwise.VEGACAP 65 can then detect products with low
dielectric value (e.g.oil)more reliably.
With the potentiometer (1)and the meas.range selection
switch (2)you can change the switching point of the probe or
adapt 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 status
of the output.The required mode can be set acc.to the
function chart.
max.-max.detection or overfill protection
min.-min.detection or dry run protection.
We recommend connecting acc.to the quiescent current
principle (contactless electronic switch is open when the
switching point is reached)because the contactless electronic
switch takes on the same (safe)condition if a failure is
detected.
Switching point adaptation (1)
Measuring range selection
switch (2)
Mode adjustment (3)
20 VEGACAP 65 -with contactless electronic switch
Set up
30017-EN-060223