Vega VEGAPULS 63 User manual

Operating Instructions
VEGAPULS 63
4…20 mA/HART -four-wire
Radar

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 approval markings and safety tips . . . . . 6
2.6CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7Fulfilling of NAMUR recommendations . . . . . . . 6
2.8FCC/IC conformity (only for USA/Canada) . . . . . 7
2.9Safety instructions for Ex areas . . . . . . . . . . . . 7
2.10 Environmental instructions . . . . . . . . . . . . . . . . 8
3Product description
3.1Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2Principle of operation. . . . . . . . . . . . . . . . . . . . 10
3.3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4Packaging,transport and storage . . . . . . . . . . . 11
4Mounting
4.1General instructions. . . . . . . . . . . . . . . . . . . . . 13
4.2Mounting instructions. . . . . . . . . . . . . . . . . . . . 14
5Connecting to power supply
5.1Preparing the connection . . . . . . . . . . . . . . . . . 21
5.2Connection procedure . . . . . . . . . . . . . . . . . . . 22
5.3Wiring plan,double chamber housing . . . . . . . . 23
5.4Switch on phase . . . . . . . . . . . . . . . . . . . . . . . 25
6Set up with the indicating and adjustment module
PLICSCOM
6.1Short description . . . . . . . . . . . . . . . . . . . . . . . 27
6.2Insert indicating and adjustment module . . . . . . 27
6.3Adjustment system . . . . . . . . . . . . . . . . . . . . . 29
6.4Setup procedure . . . . . . . . . . . . . . . . . . . . . . . 30
6.5Menu schematic . . . . . . . . . . . . . . . . . . . . . . . 37
6.6Saving the parameter adjustment data . . . . . . . 39
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Contents
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7Setup with PACTware and other adjustment programs
7.1Connecting the PC . . . . . . . . . . . . . . . . . . . . . 40
7.2Parameter adjustment with PACTware . . . . . . . 41
7.3Parameter adjustment with AMS™and PDM . . 42
7.4Saving the parameter adjustment data . . . . . . . 42
8Maintenance and fault rectification
8.1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2Remove interferences . . . . . . . . . . . . . . . . . . . 43
8.3Exchanging the electronics module. . . . . . . . . . 45
8.4Instrument repair . . . . . . . . . . . . . . . . . . . . . . . 45
9Dismounting
9.1Dismounting steps . . . . . . . . . . . . . . . . . . . . . . 46
9.2Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10 Supplement
10.1Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 47
10.2Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.3Industrial property rights. . . . . . . . . . . . . . . . . . 60
10.4Trademark . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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 VEGAPULS 63,
we offer accessories and replacement parts.The associated
documents are:
l27720 -VEGADIS 61
l30176 -Electronics module VEGAPULS series 60
l31088 -Flanges according to DIN-EN-ASME-JIS
VEGAPULS 63 •4…20 mA/HART -four-wire 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
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 malfunc-
tions 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.
4VEGAPULS 63 •4…20 mA/HART -four-wire
1About 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 plant operator.
During work on and with the device the required personal
protection equipment must always be worn.
2.2Appropriate use
VEGAPULS 63 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.
Depending on the model,the emitting frequencies of all radar
sensors are either in the Cor Kband range.The low
transmitting power lies far below the internationally permitted
limit values.When the instrument used correctly,it presents no
danger to human health.It may be operated without restriction
outside of closed metallic vessels.
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2For your safety
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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.
2.5Safety approval markings and safety tips
The safety approval markings and safety tips on the device
must be observed.
2.6CE conformity
The protection goals of the EMC Directive 2004/108/EC
(EMC), the R&TTE directive 1999/5/EC and the Low Voltage
Directive 2006/95/EC (LVD)are fulfilled.1)
Conformity has been judged according to the following
standards:
EMC:EN 61326-1:2006
(electrical instruments for control technology and laboratory
use -EMC requirements)
lEmission:Class B
lSusceptibility:Industrial areas
R&TTE
I-ETS 300-440 Expert opinion No.0043052-02/SEE,Notified
Body No.0499
LVD:EN 61010-1:2001
(safety regulations for electrical measurement,control and
laboratory instruments -part 1:General requirements)
2.7Fulfilling of NAMUR recommendations
With respect to interference resistance and emitted interfer-
ence,the NAMUR recommendation NE 21 is fulfilled.
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 for DTM VEGAPULS 63 HART,PA or FF
1)R&TTE-Richtlinie 1999/5/EC:Not with version with increased sensitivity.
6VEGAPULS 63 •4…20 mA/HART -four-wire
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lDTM VEGAPULS 63 for adjustment software PACTware
lIndicating and adjustment module 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 VEGAPULS 63 can be determined as
follows:
lvia PACTware
lon the type label of the electronics
lvia the indicating and adjustment module
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.
2.8FCC/IC conformity (only for USA/Canada)
VEGAPULS sensors with all antenna versions are FCC/IC
approved.
Modifications not expressly approved by VEGA will lead to
expiry of the operating licence according to FCC/IC.
VEGAPULS 63 is in conformity with part 15 of the FCC
directives and fulfills the RSS-210 regulations.Note the
corresponding regulations for operation:
lThe instrument must not cause any interfering emissions
lThis device must accept any interference received,
including interference that may cause undesired operation.
The instrument is designed for operation with an antenna
according to chapter "Dimensions"of this operating instruc-
tions manual,with a max.amplification of 33 dB.The
instrument must not be operated with antennas not listed
therein or those having an amplification of more than 33 dB.
The required antenna impedance is 50 Ω.
2.9Safety 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.
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2.10 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 protection.The environment man-
agement system is certified according to DIN EN ISO 14001.
Please help us fulfil this obligation by observing the environ-
mental instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
8VEGAPULS 63 •4…20 mA/HART -four-wire
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3Product description
3.1Configuration
The VEGAPULS 63 radar sensor is available in two electronics
versions:
lStandard electronics type PS60KV
lElectronics with increased sensitivity type PS60KE
The respective version can be determined by means of the
type label on the electronics.
The electronics version influences the CE conformity,the
factory setting for the medium selection and vessel form,the
accuracy as well as the approvals of VEGAPULS 63.The
differences are listed in the respective sections of this
operating instructions manual.
The scope of delivery encompasses:
lVEGAPULS 63 radar sensor
lDocumentation
-this operating instructions manual
-Safety Manual 31338 "VEGAPULS series 60 -
4…20 mA/HART"
-Operating instructions manual -27835 "Indicating and
adjustment module PLICSCOM"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGAPULS 63 consists of the following components:
lProcess fitting with encapsulated antenna system
lHousing with electronics
lHousing cover,optionally available with indicating and
adjustment module PLICSCOM
The components are available in different versions.
Versions
Scope of delivery
Components
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3Product description
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1
2
3
Fig.1:VEGAPULS 63 -flange version with Alu double chamber housing
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics
3Process fitting with encapsulated antenna system
3.2Principle of operation
VEGAPULS 63 is a radar sensor in K-band technology
(emitting frequency approx.26 GHz)for continuous level
measurement.It is particularly suitable for small vessels that
contain aggressive liquids under easy process conditions.
The electronics version "Increased sensitivity"enables the
use of VEGAPULS 63 also in applications with very bad
reflective properties or products with low e
r
value.
The antenna of the radar sensor emits short radar pulses with
a duration of approx.1ns.These pulses are reflected by the
product and received by the antenna as echoes.The running
time of the radar pulses from emission to reception is
proportional to the distance and hence to the level.The
determined level is converted into an appropriate output signal
and outputted as measured value.
Four-wire electronics with separate power supply.
The supply voltage range can differ depending on the
instrument version.
Data for power supply is specified in chapter "Technical data".
Area of application
Functional principle
Voltage supply
10 VEGAPULS 63 •4…20 mA/HART -four-wire
3Product description
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Measured value transmission is carried out via the 4…20 mA/
HART output separate from power supply.
The backlight of the indicating and adjustment module is
powered by the sensor.The prerequisite for this is a supply
voltage at a certain level.The exact voltage specifications are
stated in chapter "Technical data".
3.3Operation
VEGAPULS 63 can be adjusted with different adjustment
media:
lwith indicating and adjustment module
lwith the suitable VEGA DTM in conjunction with an
adjustment software according to the FDT/DTM standard,
e.g.PACTware and PC
lwith manufacturer-specific adjustment programs AMS™or
PDM
lWith a HART handheld
The entered parameters are generally saved in VEGAPULS
63,optionally also in the indicating and adjustment module or
in PACTware.
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 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.
Transport must be carried out under consideration of the notes
on the transport packaging.Nonobservance of these instruc-
tions 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.
Packaging
Transport
Transport inspection
Storage
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3Product description
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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 "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage and transport
temperature
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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°).
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 down-
ward 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.2:Measures against moisture penetration
The reference plane for the measuring range of the sensors is
the lower edge of the flange.
Information:
If the medium reaches the antenna,buildup can form on it and
cause faulty measurements later on.
Mounting position
Moisture
Measuring range
VEGAPULS 63 •4…20 mA/HART -four-wire 13
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1 32
100%
0%
4
Fig.3:Measuring range (operating range)and max.measuring distance
1full
2empty (max.measuring distance)
3Measuring range
4Reference plane
Make sure that all parts of the instrument in contact with the
measured product,especially the sensor element,process
seal and process fitting,are suitable for the existing process
conditions such as process pressure,process temperature as
well as the chemical properties of the medium.
You can find the specifications in chapter "Technical data"in
the or on the type label.
4.2Mounting instructions
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.
When mounting VEGAPULS 63,keep a distance of at least
200 mm (7.874 in)to the vessel wall.If the sensor is installed in
the center of dished or round vessel tops,multiple echoes can
arise.These can,however,be suppressed by an appropriate
adjustment (see chapter "Setup").
If you cannot keep this distance you should carry out a false
echo storage before setup.This applies mainly if buildup on
the vessel wall is expected.In this case,we recommend
repeating a false echo storage later with existing buildup.
Suitability for process
conditions
Torque with PTFE plated
flanges
Mounting position
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12
> 200 mm
Fig.4:Mounting on round vessel tops
1Reference plane
2Vessel center or symmetry axis
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.
Fig.5:Vessel with conical bottom
Do not mount the instruments in or above the filling stream.
Make sure that you detect the product surface,not the
inflowing product.
Inflowing medium
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Fig.6:Inflowing liquid
Flush mounting
The best way to mount the sensor,also with respect to
cleanability,is flush on a block flange (flange without socket
piece)or with hygienic fittings,e.g.Neumo Biocontrol.
Mounting on socket
If the reflective properties of the medium are good,you can
mount VEGAPULS 63 on a socket piece.You will find
recommended values for socket heights in the following
illustration.The socket end should be smooth and burr-free,if
possible also rounded.Then carry out a false echo storage.
d
hmax.
d
50 mm/2"
80 mm/3"
100 mm/4"
150 mm/6"
100 mm
150 mm
250 mm
400 mm
hmax.
Fig.7:Deviating socket dimensions
Socket
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Align the sensor in liquids as vertical as possible to the product
surface to achieve optimum measurement.
Fig.8:Alignment in liquids
The mounting location of the radar sensor should be a place
where no other equipment or fixtures cross the path of the
microwave signals.
Vessel installations such as,for example,ladders,limit
switches,heating spirals,struts,etc.can cause false echoes
that get superimposed on the useful echo.Make sure when
planning your measuring site that the radar sensor has a "clear
view"to the measured product.
In case of existing vessel installations,a false echo storage
should be carried out during setup.
If large vessel installations such as struts or supports cause
false echoes,these can be attenuated through supplementary
measures.Small,inclined sheet metal baffles above the
installations scatter the radar signals and prevent direct
interfering reflections.
Fig.9:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false echo storage should
be carried out with the agitators in motion.This ensures that
the interfering reflections from the agitators are saved with the
blades in different positions.
Sensor orientation
Vessel installations
Agitators
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Fig.10:Agitators
Through the action of filling,stirring and other processes in the
vessel,dense foams which considerably damp the emitted
signals may form on the product surface.
If foams lead to measurement errors,you should use the
biggest possible radar antennas and low frequency radar
sensors (C-band).
As an alternative,sensors with guided microwave can be
used.These are unaffected by foam generation and are best
suited for such applications.
By using a standpipe,the influence of vessel installations and
turbulence can be excluded.Under these prerequisites,the
measurement of products with low dielectric values (from DK
value 1.6)is possible.
Surge or bypass tubes must extend all the way down to the
requested min.level,as measurement is only possible within
the tube.
Surge pipe
Make sure you provide the necessary upper vent hole in the
surge pipe.The hole must be aligned so that it and the
polarisation marking on the sensor are in the same plane (see
illustration:"Pipe antenna system in a tank").
Foam generation
Measurement in the
standpipe (surge or by-
pass tube)
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max.
min.
2
1
Fig.11:Pipe antenna system in a tank.The vent hole in the surge pipe must be
in one plane with the polarisation marking on the sensor.
1Marking of the polarisation direction
2Vent holde max.ø5mm (0.2in)
If possible,the antenna diameter of the sensor should
correspond to the inner diameter of the tube.With VEGAPULS
63 this is approx.40 mm (1.575 in). The sensor can be used
with tube diameters between 40 …80 mm (1.575 …3.15 in).
Bypass tube
As an alternative to the surge pipe in the vessel,a pipe system
can be mounted outside of the vessel as a bypass tube.For
setup,select the function "Bypass tube".
Align the sensor in such a way that the polarisation marking on
the process fitting is in the same plane as the tube holes or the
tube connection openings (see illustration:"VEGAPULS in a
bypass tube").
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100%
0%
1
> 300 mm
Fig.12:VEGAPULS 63 in a bypass tube.The polarisation marking on the
process fitting must be in one plane with the tube holes or the tube connection
openings.
1Marking of the polarisation direction
When the sensor is mounted on a bypass tube,the distance
from VEGAPULS 63 to the upper tube connection should be
approx.300 mm (11.81 in)or more.In case of extremely rough
tube inner walls,you should use an inserted tube (tube in tube)
or a radar sensor with tube antenna.
Information:
With VEGAPULS 63 in flange version,the polarisation plane is
always in the center between two flange holes.
20 VEGAPULS 63 •4…20 mA/HART -four-wire
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