Vega VEGAPULS 63 User manual

Operating Instructions
VEGAPULS 63
4... 20 mA/HART
Radar

Contents
1About this document
1.1Function ............................. 5
1.2Target group .......................... 5
1.3Symbolism used ....................... 5
2For your safety
2.1Authorised personnel.................... 6
2.2Appropriate use........................ 6
2.3Warning about misuse ................... 6
2.4General safety instructions................ 6
2.5CE conformity ......................... 6
2.6Fulfilling NAMUR recommendations ......... 7
2.7SIL conformity......................... 7
2.8FCC/IC conformity (only for USA/Canada). . . .. 7
2.9Safety instructions for Ex areas ............ 8
2.10 Manufacturer declaration ................. 8
2.11 Functional range of approved instruments ..... 9
2.12 Environmental instructions ................ 9
3Product description
3.1Configuration.......................... 10
3.2Principle of operation.................... 11
3.3Operation ............................ 12
3.4Storage and transport ................... 12
4Mounting
4.1General instructions..................... 13
4.2Mounting instructions.................... 14
5Connecting to power supply
5.1Preparing the connection ................. 21
5.2Connection steps -Instrument housing ....... 22
5.3Wiring plan,single chamber housing......... 23
5.4Wiring plan,double chamber housing ........ 25
5.5Wiring plan,double chamber housing Exd..... 27
5.6Wiring plan,version IP 66/IP 68,1bar ....... 29
5.7Switch-on phase ....................... 29
6Set up with the indicating and adjustment module
PLICSCOM
6.1Short description ....................... 30
6.2Insert indicating and adjustment module ...... 30
6.3Adjustment system ..................... 32
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6.4Setup procedure ....................... 33
6.5Menu schematic ....................... 40
6.6Saving the parameter adjustment data ....... 42
7Setup with PACTware™and other adjustment
programs
7.1Connecting the PC ..................... 43
7.2Parameter adjustment with PACTware™...... 44
7.3Parameter adjustment with AMS™and PDM .. 45
7.4Saving the parameter adjustment data ....... 45
8Maintenance and fault rectification
8.1Maintenance .......................... 46
8.2Remove interferences ................... 46
8.3Exchange of the electronics module ......... 48
8.4Instrument repair ....................... 49
9Dismounting
9.1Dismounting steps ...................... 50
9.2Disposal ............................. 50
10 Supplement
10.1Technical data......................... 51
10.2Dimensions ........................... 61
10.3Industrial property rights.................. 68
10.4Trademark ........................... 68
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Contents
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Supplementary operating instructions manuals
Information:
VEGAPULS 63 is available in many versions and is therefore
supplied according to customer order.Depending on the
selected version,supplementary operating instructions man-
uals also come with the delivery.You will find the supple-
mentary operating instructions manuals in chapter "Product
description".
Operating 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:
lOperating instructions manual 30176 "External indicating
and adjustment unit VEGADIS 61"
lOperating instructions manual 27720 "Oscillator VEGA-
PULS series 60"
lSupplementary instructions manual 31088 "Flanges ac-
cording to DIN-EN-ASME-JIS"
4VEGAPULS 63 -4... 20 mA/HART
Contents
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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: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.
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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 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
VEGAPULS 63 is a sensor for continuous level measurement.
You can find detailed information on the application range of
VEGAPULS 63 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
VEGAPULS 63 is a high-tech instrument requiring the strict
observance of standard regulations and guidelines.The
emitting frequencies of all radar sensors are in the Cor K-band
range (depending on the instrument version). The low trans-
mitting power is far below the internationally permitted limit
values,and when the instrument is used correctly,no health-
endangering effects are to be expected.There are no
restrictions on using the instrument on the outside of metallic,
closed vessels.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
VEGAPULS 63 is in CE conformity with EMVG (89/336/EWG),
R&TTE directive (1999/5/EC)and LVD (73/23/EWG).1)
Conformity has been judged according to the following
standards:
1)R&TTE-Richtlinie (1999/5/EC): Not with version with increased sensitivity.
6VEGAPULS 63 -4... 20 mA/HART
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lEMC:EN 61326:2004
-Emission:Class B
-Susceptibility:Industrial areas
lR&TTE directive:I-ETS 300-440 Expert opinion No.
0043052-02/SEE,Notified Body No.0499
lLVD:EN 61010-1:2002
2.6Fulfilling NAMUR recommendations
With regard to interference resistance and interference
emission,VEGAPULS 63 fulfils NAMUR recommendation
NE 21.
VEGAPULS 63 and its indicating and adjustment components
fulfill NAMUR recommendation NE 53 in respect to compat-
ibility.VEGA instruments are generally upward and downward
compatible:
lSensor software to DTM VEGAPULS 63 HART,PA or FF
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.
2.7SIL conformity
VEGAPULS 63 fulfills the requirements for functional safety
according to IEC 61508/IEC 61511.You can find further
information in the Safety Manual "VEGAPULS series 60 -
4…20 mA/HART".
2.8FCC/IC conformity (only for USA/Canada)
VEGAPULS sensors with all antenna versions are FCC/IC
approved.
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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
lThe instrument must be insensitive to interfering emis-
sions,also to such that may cause unwanted operating
conditions.
The instrument is designed for operation with an antenna
according to the "Dimensions"in the "Supplement"of this
operating instructions 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 Ohm.
2.9Safety instructions for Exareas
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.
2.10 Manufacturer declaration
In conformity with DIN EN 60079-14/2004,para.5.2.3,point
c1,VEGAPULS 63 is suitable for use in zone 2.
The operator must use the instrument as it was intended to be
used and follow the specifications of the following documents:
lthis operating instructions manual
lthis manufacturer declaration (24626)
lthe applicable installation regulations
Max.increase of the surface temperature during operation:
27 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 97 °C(207 °F).
Measures to maintain explosion protection during operation:
lOperate the instrument in the range of the specified
electrical limit values.Permissible supply voltage:see
"Technical data"
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lMount and operate the instrument in such a way that no
danger of ignition from electrostatic charges is to be
expected.The antenna,the process fitting or the housing
(as the case may be depending on instrument version)are
made of electrically non-conductive plastic.
lMake sure that the seal is mounted correctly between
lower part of the housing and cover.Screw the cover on
tightly.
lMake sure there is no explosive atmosphere present if you
intend to operate the instrument with opened 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
lMount the instrument in such a way that the sensor cannot
touch the vessel wall or vessel installations.Keep in mind
the influence of product movement in the vessel.
lThe surface temperature of the housing must not exceed
the ignition temperature of the surrounding explosive
atmosphere
This instrument was assessed by a person who fulfils the DIN
EN 60079-14 requirements.
2.11 Functional range of approved instruments
Instruments with specific approvals are partly supplied with an
earlier hardware or software version.For approval-technical
reasons,some functions for these instruments will be available
only at a later date.
You will find corresponding instructions in the description of
the individual functions in this operating instructions manual.
2.12 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"
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3Product description
3.1Configuration
The VEGAPULS 63 radar sensor is available in two electronics
versions:
lStandard electronics type PS60KH
lElectronics with increased sensitivity type PS60KD
The respective version can be determined by means of the
type label on the electronics.
The electronics version influences the CE conformity,the
functional safety (SIL), the factory setting for product selection
and vessel form,the accuracy,the voltage supply as well as
the approvals of VEGAPULS 63.The differences are specified
in this operating instructions manual in the respective para-
graphs.
The scope of delivery encompasses:
lVEGAPULS 63 radar sensor
lDocumentation
-this operating instructions manual
-Supplementary instructions manual "Safety Manual
according to IEC 61508/IEC 61511 (SIL)"2)
-Operating instructions manual "Indicating and adjust-
ment module"(optional)
-Supplementary instructions manual "Heating for indi-
cating and adjustment module"(optional)
-Supplementary instructions manual "Plug connector for
continuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGAPULS 63 consists of the following components:
lProcess fitting with flange
lHousing with electronics,optionally available with plug
connector,optionally available with connection cable
lHousing cover,optionally available with indicating and
adjustment module PLICSCOM
The components are available in different versions.
2)Not with electronics version with increased sensitivity,not with version for
temperatures <-40 °C(-40 °F)
Versions
Scope of delivery
Components
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Product description
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3
2
1
Fig.1:VEGAPULS 63,flange version with plastic 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.
Two-wire electronics 4…20 mA/HART for power supply and
measured value transmission over the same cable.
The supply voltage range can differ depending on the
instrument version.
The data for power supply are stated in chapter "Technical
data"in the "Supplement".
Area of application
Functional principle
Supply
VEGAPULS 63 -4... 20 mA/HART 11
Product description
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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"in the "Supplement".
This function is available for instruments with national
approvals such as e.g.according to CSA only at a later date.
The optional heating requires its own power supply.You can
find detailed information in the supplementary instructions
manual "Heating for indicating and adjustment module".This
function is generally not available for approved instruments.
3.3Operation
VEGAPULS 63 can be adjusted with different adjustment
media:
lwith the 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™.
3.4Storage 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 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 %
Packaging
Storage and transport tem-
perature
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Product description
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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 VEGAPULS 63 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.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.
Installation position
Moisture
Measuring range
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132
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 the wetted parts of VEGAPULS 63,especially
the seal and process fitting,are suitable for the existing
process conditions such as pressure,temperature etc.as well
as the chemical properties of the medium.
You can find the specifications in chapter "Technical data"in
the "Supplement".
4.2Mounting instructions
The flange screws of VEGAPULS 63 must be always screwed
with the torque stated in the technical data so that the PTFE
washer of the encapsulated antenna system seals.
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 "Setup").
If this distance cannot be maintained,a false echo storage
should be carried out during setup.This applies particularly if
buildup on the vessel wall is expected.In such case,we
recommend repeating the false echo storage later on with
existing buildup.
Wetted materials
Torque of the flange screws
Installation 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 and not the
inflowing product.
Inflowing medium
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Fig.6:Inflowing liquid
Flush mounting
The optimum installation location of the sensor,also in respect
to the 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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Direct the sensor in liquids as perpendicular as possible to the
product surface to achieve optimum measurement results.
Fig.8:Orientation 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,e.g.VEGAPULS 65,66 (C-band).
VEGAFLEX sensors with guided microwaves are not influ-
enced by foam generation and are particularly suitable 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 stand-
pipe (surge or bypass 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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