Vega VEGAFLEX 61 User manual

Operating Instructions
VEGAFLEX 61
Profibus PA
Document ID:
31835
Guided Microwave

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
2.7Fulfillment of NAMUR recommendations . . . . . . . . . . 6
2.8Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.9Environmental instructions..................... 6
3Product description
3.1Structure ................................. 7
3.2Principle of operation ........................ 8
3.3Operation................................. 8
3.4Packaging,transport and storage ............... 9
4Mounting
4.1General instructions ......................... 10
4.2Mounting instructions ........................ 11
5Connecting to power supply
5.1Preparing the connection ..................... 17
5.2Connection procedure........................ 18
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 19
5.4Wiring plan,double chamber housing . . . . . . . . . . . . 20
5.5Wiring plan -version IP 66/IP 68,1bar . . . . . . . . . . . 22
6Set up with the indicating and adjustment module PLICSCOM
6.1Short description ........................... 23
6.2Insert indicating and adjustment module. . . . . . . . . . . 23
6.3Adjustment system .......................... 25
6.4Setup steps ............................... 26
6.5Menu schematic ............................ 32
6.6Saving the parameter adjustment data . . . . . . . . . . . . 34
7Set up with PACTware and other adjustment programs
7.1Connecting the PC .......................... 35
7.2Parameter adjustment with PACTware . . . . . . . . . . . . 36
7.3Parameter adjustment with PDM . . . . . . . . . . . . . . . . 36
7.4Saving the parameter adjustment data . . . . . . . . . . . . 36
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Contents
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8Maintenance and fault rectification
8.1Maintenance .............................. 37
8.2Rectify malfunctions ......................... 37
8.3Exchange or shorten cable/rod ................. 39
8.4Exchanging the electronics module . . . . . . . . . . . . . . 41
8.5Software update ............................ 42
8.6Instrument repair ........................... 42
9Dismounting
9.1Dismounting steps .......................... 44
9.2Disposal ................................. 44
10 Supplement
10.1Technical data ............................. 45
10.2Profibus PA ............................... 55
10.3Dimensions ............................... 59
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 VEGAFLEX 61,we
offer accessories and replacement parts.The corresponding doc-
umentations are:
l27720 -VEGADIS 61
l30207 -Electronics module VEGAFLEX series 60
l34296 -Protective cover
l31088 -Flanges according to DIN-EN-ASME-JIS-GOST
l30391 -Spacer
VEGAFLEX 61 •Profibus PA 3
Contents
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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.
4VEGAFLEX 61 •Profibus PA
1About this document
31835-EN-100426

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
VEGAFLEX 61 is a sensor for continuous level measurement.
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 necessary occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
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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.
2.7Fulfillment of NAMUR recommendations
With respect to compatibility,the NAMUR recommendation NE 53 is
fulfilled.This applies also to the corresponding indicating and
adjustment components.VEGA instruments are generally upward and
downward compatible.
lSensor software to DTM VEGAFLEX 61
lDTM VEGAFLEX 61 for adjustment software PACTware
lIndicating and adjustment module for sensor software
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
2.8Safety 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.
2.9Environmental 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 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"
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3Product description
3.1Structure
The scope of delivery encompasses:
lVEGAFLEX 61 level sensor
lDocumentation
-this operating instructions manual
-Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM"(optional)
-Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
The VEGAFLEX 61 consists of the components:
lProcess fitting with probe
lHousing with electronics
lHousing cover,optionally available with indicating and adjustment
module
1
2
3
Fig.1:VEGAFLEX 61 in cable version with plastic housing
1Housing cover with integrated indicating and adjustment module (optional)
2Housing with electronics
3Process fitting
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
Scope of delivery
Constituent parts
Type label
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lArticle numbers,documentation
With the serial number,you can 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
VEGAFLEX 61 is a level sensor with cable or rod probe for continuous
level measurement.
It is designed for industrial use in all areas of process technology and
can be used equally well in liquids or solids.
High frequency microwave pulses are guided along a steel rope or a
rod.Upon reaching the product surface,the microwave pulses are
reflected.The running time is evaluated by the instrument and
outputted as distance.
Power supply via the Profibus DP/PA segment coupler or VEGALOG
571 EP cards.Atwo-wire cable according to Profibus specification
serves as carrier of both power and digital data transmission for
multiple sensors.The instrument profile of VEGAFLEX 61 corresponds
to profile specification version 3.0.
The backlight of the indicating and adjustment module is powered by
the sensor.Prerequisite is a certain level of operating voltage.
The data for power supply are specified in chapter "Technical data".
The optional heating requires its own operating voltage.You can find
details in the supplementary instructions manual "Heating for indicat-
ing and adjustment module".
This function is generally not available for approved instruments.
The GSD (instrument master files)and bitmap files necessary for
planning your Profibus-DP-(PA)communication network are available
from the download section on the VEGA homepage www.vega.com
under "Services -Downloads -Software -Profibus".There you can
also find the appropriate certificates.In a PDM environment,an EDD
(Electronic Device Description)is also required to enable the full range
of sensor functions (also available as a download).A CD with the
appropriate files can be ordered via e-mail under [e-mail] or
by phone from one of the VEGA agencies under the order number
"DRIVER.S".
3.3Operation
VEGAFLEX 61 can be adjusted with different adjustment media:
lwith indicating and adjustment module
Application area
Functional principle
Power supply and bus
communication
GSD/EDD
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lwith the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard,e.g.PACTware and
PC
lwith the adjustment program PDM
3.4Packaging,transport and storage
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.
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 %
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
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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.
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°).
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.
Suitability for the pro-
cess conditions
Mounting position
Welding work
Handling
Moisture
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Fig.2:Measures against moisture penetration
The reference plane for the measuring range of the sensors is the
sealing surface of the thread or flange.
Keep in mind that a min.distance must be maintained below the
reference plane and possibly also at the end of the probe -
measurement in these areas is not possible (dead band). Keep in mind
that the cable length cannot be used all the way to the end because
measurement in the area of the gravity weight is not possible.These
dead bands are listed in chapter "Technical data".Keep in mind for the
adjustment that the default setting for the measuring range refers to
water.
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
Mount VEGAFLEX 61 in such a way that the distance to vessel
installations or to the vessel wall is at least 300 mm (12 in).
During operation,the probe must not touch any installations or the
vessel wall.If necessary,fasten the probe end.
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 bottom.When using the cable version,
Measuring range
Pressure
Mounting position
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keep in mind that measurement down to the tip of the probe is not
possible.The exact value of the min.distance (lower dead band)is
stated in chapter "Technical data".
Fig.3:Vessel with conical bottom
Plastic vessel/Glass vessel
The guided microwave principle requires a metal surface on the
process fitting.Therefore use in plastic vessels etc.an instrument
version with flange (from DN 50)or place a metal sheet (ø>200 mm/
8in)beneath the process fitting when screwing it in.
Make sure that the plate has direct contact with the process fitting.
In bypass tubes of plastic,a metal screen must be provided on the
outside.You can glue metal foil,for example,on the outside along the
entire length of the tube.This metal screen must be connected to the
ground terminal on the instrument.
When installing rod or cable probes without metal vessel wall,e.g.in
plastic vessels,the measured value can be influenced by strong
electromagnetic fields (emitted interference according to EN 61326:
class A).
In this case,use a probe in coax version.
Vessel type
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1 2
Fig.4:Installation in plastic silo
1Flange
2Metal sheet
Concrete vessel
When installed in thick concrete ceilings,VEGAFLEX 61 should be
mounted front flush to the lower edge.In concrete silos,the distance to
the wall should be at least 500 mm (20 in).
ø >160mm
(ø >6.3")
Fig.5:Installation in concrete silo
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If possible,avoid sockets.Mount the sensor flush with the vessel top.If
this is not possible,use short sockets with small diameter.
Higher sockets or sockets with a bigger diameter can generally be
used.They simply increase the upper dead band.Check if this is
relevant for your measurement.
In such cases,always carry out a gating out of false signals after
installation.You can find further information under "Setup procedure".
h
d
d h
DN40 ... DN150 £ 150
> DN150 ... DN200 £ 100
Fig.6:Mounting socket
When welding the socket,make sure that the socket is flush to the
vessel wall.
1 2
Fig.7:Socket must be installed flush
1Unfavourable installation
2Socket flush -optimum installation
Socket
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Standpipes or bypass tubes are normally metal tubes with a diameter
of 30 …200 mm (1.18 …7.87 in). In measurement technology such a
tube corresponds to a coax probe.It does not matter if the standpipe is
perforated or slotted for better mixing.Lateral inlets with bypass tubes
also do not influence the measurement.
Measuring probes can be mounted in bypass tubes up to DN 200.
IfVEGAFLEX 61 is used in standpipes or bypass tubes,contact with
the tube wall should be avoided.We offer spacers as accessories for
fastening the probe in the middle of the tube.
Depending on the tube diameter or tube length,one or several spacers
can be mounted.With cable probes,the cable can also be strained to
avoid contact with the tube.
Keep in mind that buildup can form on the spacers.Strong buildup can
influence the measurement.
Microwaves can penetrate plastics.For process technical reasons,
plastic standpipes are problematic.If durability is no problem,then we
recommend the use of metal standpipes.
1
Fig.8:Position of the spacer
1Spacer
Note:
Measurement in a standpipe is not recommended for very adhesive
products.
Standpipes or bypass
tubes
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Make sure that the probe is not subjected to strong lateral forces.
Mount VEGAFLEX 61 at a position in the vessel where no
disturbances,e.g.from filling openings,agitators,etc., can occur.
Fig.9:Lateral load
If there is a danger of the probe touching the vessel wall during
operation due to product movements or agitators etc., the measuring
probe should be securely fixed.
In the gravity weight there is a thread (M12), e.g.for a ring bolt
(optional) - (article no.2.27424).
Make sure that the probe cable is not completely taut.Avoid tensile
loads on the cable.
Avoid undefined cable-vessel connections,i.e.the connection must be
either grounded reliably or isolated reliably.Any deviation from this
requirement can lead to measurement errors.
Inflowing medium
Fixing
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5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,overvoltage arresters should
be installed according to Profibus specifications
Tip:
We recommend VEGA overvoltage arrester B63-32.
In hazardous areas you should take note of the appropriate regulations,
conformity and type approval certificates of the sensors and power
supply units.
Power is supplied via a Profibus DP/PA segment coupler or a
VEGALOG 571 EP input card.The power supply range can differ
depending on the instrument version.
The data for power supply are specified in chapter "Technical data".
Connection is made with screened cable according to the Profibus
specification.Power supply and digital bus signal are carried over the
same two-wire connection cable.
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.
Please make sure that your installation is carried out according to the
Profibus specification.In particular,make sure that the termination of
the bus is done with appropriate terminating resistors.
On the instrument with cable entry ½NPT and plastic housing there is
a metallic ½" threaded insert moulded into the plastic housing.
Caution:
No grease should be used when screwing the NPT cable gland or
steel tube into the threaded insert.Standard grease can contain
additives that corrode the connection between threaded insert and
housing.This would influence the stability of the connection and the
tightness of the housing.
Safety instructions
Voltage supply
Connection cable
Cable gland ½NPT
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In systems with potential equalisation,connect the cable screen
directly to ground potential at the power supply unit,in the connection
box and at the sensor.The screen in the sensor must be connected
directly to the internal ground terminal.The ground terminal outside on
the housing must be connected to the potential equalisation (low
impedance).
In systems without potential equalisation,connect the cable screen
directly to ground potential at the power supply unit and at the sensor.
In the connection box or T-distributor,the screen of the short stub to
the sensor must not be connected to ground potential or to another
cable screen.The cable screens to the power supply unit and to the
next distributor must be connected to each other and also connected
to ground potential via a 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.
The total capacitance of the cable and of all capacitors must not exceed
10 nFin Ex applications.
Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equalisation
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 procedure
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)of 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)
Cable screening and
grounding
18 VEGAFLEX 61 •Profibus PA
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7Insert the wire ends into the open terminals according to the wiring
plan
Fig.10:Connection steps 6and 7
8Press down the opening levers of the terminals,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,connect the
outer 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 on
The electrical connection is finished.
5.3Wiring plan,single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
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I²C
Display
1 2 5 6 7 8
3
4
1
2
Fig.11:Electronics and connection compartment with 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 voltage supply
I2C
Display
1
1 2 5 6 7 8
Fig.12:Wiring plan,single chamber housing
1Voltage supply/Signal output
5.4Wiring plan,double chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
Electronics and connec-
tion compartment
Wiring plan
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