Vega VEGAFLEX 81 User manual

Operating Instructions
TDR sensor for continuous level and
interface measurement of liquids
VEGAFLEX 81
Modbus and Levelmaster protocol
Document ID: 41828

2
Contents
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
Contents
1 About this document
1.1 Function ............................................................................. 4
1.2 Target group ....................................................................... 4
1.3 Symbolism used................................................................. 4
2 For your safety
2.1 Authorised personnel ......................................................... 5
2.2 Appropriate use.................................................................. 5
2.3 Warning about incorrect use............................................... 5
2.4 General safety instructions................................................. 5
2.5 CE conformity..................................................................... 5
2.6 NAMUR recommendations ................................................ 6
2.7 Environmental instructions ................................................. 6
3 Product description
3.1 Conguration...................................................................... 7
3.2 Principle of operation.......................................................... 8
3.3 Packaging, transport and storage..................................... 10
3.4 Accessories and replacement parts ................................. 10
4 Mounting
4.1 General instructions ......................................................... 13
4.2 Instructions for installation................................................ 13
5 Connecting to power supply and bus system
5.1 Preparing the connection ................................................. 19
5.2 Connecting....................................................................... 19
5.3 Wiring plan ....................................................................... 21
5.4 Switch-on phase............................................................... 22
6 Set up with the indicating and adjustment module
6.1 Adjustment volume........................................................... 23
6.2 Insert indicating and adjustment module .......................... 23
6.3 Adjustment system........................................................... 24
6.4 Parameter adjustment ...................................................... 24
6.5 Saving the parameter adjustment data............................. 41
7 Setting up sensor and Modbus interface with PACTware
7.1 Connect the PC ................................................................ 42
7.2 Parameter adjustment with PACTware.............................. 43
7.3 Set up with the quick setup............................................... 44
7.4 Saving the parameter adjustment data............................. 49
8 Set up with other systems
8.1 DD adjustment programs ................................................. 50
8.2 Communicator 375, 475................................................... 50
9 Diagnostics and service
9.1 Maintenance .................................................................... 51
9.2 Diagnosis memory ........................................................... 51
9.3 Status messages.............................................................. 52
9.4 Rectify faults..................................................................... 56
9.5 Exchanging the electronics module.................................. 59

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Contents
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
9.6 Software update ............................................................... 59
9.7 How to proceed in case of repair...................................... 60
10 Dismounting
10.1 Dismounting steps............................................................ 61
10.2 Disposal ........................................................................... 61
11 Supplement
11.1 Technical data .................................................................. 62
11.2 Basics Modbus................................................................. 70
11.3 Modbus register ............................................................... 72
11.4 Modbus RTU commands ................................................. 74
11.5 Levelmaster commands ................................................... 77
11.6 Conguration of typical Modbus hosts.............................. 81
11.7 Dimensions ...................................................................... 85
Safety instructions for Ex areas
Please note the Ex-specic safety information for installation and op-
eration in Ex areas. These safety instructions are part of the operating
instructions manual and come with the Ex-approved instruments.
Editing status: 2012-11-06

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1 About this document
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tions for maintenance and fault rectication. Please read this informa-
tion before putting the instrument into operation and keep this manual
accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained qualied
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbolism 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.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

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2 For your safety
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
2 For your safety
2.1 Authorised 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.
2.2 Appropriate use
VEGAFLEX 81 is a sensor for continuous level measurement.
You can nd detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly
used according to the specications in the operating instructions
manual as well as possible supplementary instructions.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to
application-specic hazards, e.g. vessel overll or damage to system
components through incorrect mounting or adjustment.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines. The instrument must only be operated in a
technically awless and reliable condition. The operator is responsible
for the 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 regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
trary conversions or modications are explicitly forbidden.
The safety approval markings and safety tips on the device must also
be observed.
2.5 CE conformity
The device fullls the legal requirements of the applicable EC guide-
lines. By axing the CE marking, we conrm successful testing of the
product.
You can nd the conformity certicate in the download section of our
homepage.

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2 For your safety
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
The instrument is designed for use in an industrial environment.
Nevertheless, electromagnetic interference from electrical conductors
and radiated emissions must be taken into account, as is usual with a
class A instrument according to EN 61326-1. If the instrument is used
in a dierent environment, its electromagnetic compatibility with other
devices must be ensured by suitable measures.
2.6 NAMUR recommendations
NAMUR is the automation technology user association in the process
industry in Germany. The published NAMUR recommendations are
accepted as the standard in eld instrumentation.
The device fullls the requirements of the following NAMUR recom-
mendations:
• NE 21 – Electromagnetic compatibility of equipment
• NE 43 – Signal level for malfunction information from measuring
transducers
• NE 53 – Compatibility of eld devices and indicating/adjustment
components
• NE 107 - Self-monitoring and diagnosis of eld devices
For further information see www.namur.de.
2.7 Environmental instructions
Protection of the environment is one of our most important duties.
That is why we have introduced an environment management system
with the goal of continuously improving company environmental pro-
tection. The environment management system is certied according
to DIN EN ISO 14001.
Please help us full this obligation by observing the environmental
instructions in this manual:
• Chapter "Packaging, transport and storage"
• Chapter "Disposal"

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3 Product description
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
3 Product description
3.1 Conguration
The type label contains the most important data for identication and
use of the instrument:
2
1
13
14
15
16
12
11
5
3
6
4
7
8
9
10
Fig. 1: Layout of the type label (example)
1 Instrument type
2 Product code
3 Approvals
4 Power supply and signal output, electronics
5 Protection rating
6 Probe length
7 Process and ambient temperature, process pressure
8 Material, wetted parts
9 Hardware and software version
10 Order number
11 Serial number of the instrument
12 Symbol of the device protection class
13 ID numbers, instrument documentation
14 Note to observe the instrument documentation
15 NotiedauthorityforCEmarking
16 Approval directive
With the serial number of the instrument on the type label you have
access to the following data on our homepage:
• Article number of the instrument (HTML)
• Delivery date (HTML)
• Order-specic instrument features (HTML)
• Operating instructions at the time of shipment (PDF)
• Order-specic sensor data for an electronics exchange (XML)
• Test certicate "Measuring Accuracy" (PDF)
For this purpose, move to www.vega.com and "VEGATools".
The instrument contains two dierent electronics in its housing cham-
bers:
• The Modbus electronics for power supply and communication with
the Modbus-RTU
• The sensor electronics for the actual measuring tasks
Type label
Serial number
Electronics design

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3 Product description
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
2
1
Fig. 2: Position of Modbus and sensor electronics
1 Modbus electronics
2 Sensor electronics
This operating instructions manual applies to the following instrument
versions:
• Hardware from 1.0.0
• Software from 1.0.0
The instrument can be supplied in two dierent electronics versions.
Each electronics version can be identied via the product code on the
type label as well as on the electronics.
• Standard electronics with supply voltage 90 … 253 V AC;
50/60 Hz: Type FX80B.-
• Standard electronics with supply voltage 9.6 … 48 V DC;
20 … 42 V AC: Type FX80I.-
The scope of delivery encompasses:
• Sensor
• Documentation
– this operating instructions manual
– Test certicate measuring accuracy (optional)
– Operating instructions manual "Indicating and adjustment
module" (optional)
– Supplementary instructions "GSM/GPRSradiomodule"
(optional)
– Supplementary instructions manual "Heating for indicating and
adjustment module" (optional)
– Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors" (optional)
– Ex-specic "Safety instructions" (with Ex versions)
– CE declarations of conformity
– if necessary, further certicates
3.2 Principle of operation
The VEGAFLEX 81 is a level sensor with cable or rod probe for
continuous level or interface measurement, suitable for applications
in liquids.
High frequency microwave pulses are guided along a steel rope or
a rod. Upon reaching the product surface, the microwave pulses are
Scope of this operating
instructions manual
Versions
Scope of delivery
Application area
Functional principle -
level measurement

9
3 Product description
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
reected. The running time is evaluated by the instrument and output-
ted as level.
High frequency microwave impulses are guided along a steel cable
or rod. When reaching the product surface, a part of the microwave
impulses is reected. The other part passes the upper product and is
reected a second time by the interface. The running times to the two
product layers are processed by the instrument.
TS
d1
h1
h2
d2
1
L2
L1
Fig. 3: Interface measurement
1 Sensorreferenceplane(sealsurfaceoftheprocesstting)
d1 Distancetotheinterface(HARTvalue1)
d2 Distancetothelevel(HARTvalue3)
TS Thicknessoftheuppermedium(d1-d2)
h1 Height - Interface
h2 Height - Level
L1 Lower medium
L2 Upper medium
Upper medium (L2)
• The upper medium must not be conductive
• The dielectric constant of the upper medium must be known (input
required). Min. dielectric constant: rod version 1.6. You can nd a
list with the dielectric constants on our home page: www.vega.com
• The composition of the upper medium must be stable, no varying
products or mixtures
• The upper medium must be homogeneous, no stratications
within the medium
• Min. thickness of the upper medium 50 mm (1.97 in)
• Clear separation from the lower medium, no emulsion phase, no
mull layer
• If possible, no foam on the surface
Lower medium (L1)
• The dielectric gure must be 10 higher than the dielectric constant
of the upper medium, preferably electrically conductive. Example:
upper medium dielectric constant 2, lower medium at least dielec-
tric constant 12.
Functional principle - in-
terface measurement
Prerequisites for inter-
face measurement

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3 Product description
VEGAFLEX 81 • Modbus and Levelmaster protocol
41828-EN-121112
The instrument is always preset to the application "Level measure-
ment".
For the interface measurement, you can select the requested output
signal with the setup.
3.3 Packaging, 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 con-
cealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
• Storage and transport temperature see chapter "Supplement -
Technicaldata-Ambientconditions"
• Relative humidity 20 … 85 %
3.4 Accessories and replacement parts
The indicating and adjustment module PLICSCOM is used for meas-
ured value indication, adjustment and diagnosis. It can be inserted
into the sensor and removed at any time.
You can nd further information in the operating instructions "Indicat-
ingandadjustmentmodulePLICSCOM" (Document-ID 27835).
The interface adapter VEGACONNECT enables the connection of
communication-capable instruments to the USB interface of a PC. For
parameter adjustment of these instruments, an adjustment software
such as PACTware with VEGA-DTM is required.
You can nd further information in the operating instructions "Interface
adapterVEGACONNECT" (Document-ID 32628).
Output signal
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
Indicating and adjust-
ment module
Interface adapter