Vega VEGAPULS 68 User manual

Operating Instructions
VEGAPULS 68
Probus PA
Document ID: 29263

2
Contents
VEGAPULS 68 • Probus PA
29263-EN-141215
Contents
1 About this document
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols 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 Safety label on the instrument .......................................................................................... 5
2.6 CE conformity................................................................................................................... 6
2.7 Fulllment of NAMUR recommendations ......................................................................... 6
2.8 FCC and IC conformity (only for USA/Canada) ................................................................ 6
2.9 Safety instructions for Ex areas ........................................................................................ 6
2.10 Environmental instructions ............................................................................................... 6
3 Product description
3.1 Conguration.................................................................................................................... 8
3.2 Principle of operation...................................................................................................... 10
3.3 Operation ....................................................................................................................... 10
3.4 Packaging, transport and storage................................................................................... 11
4 Mounting
4.1 General instructions ....................................................................................................... 12
4.2 Mounting preparations - Horn antenna........................................................................... 14
4.3 Mounting preparations - Parabolic antenna.................................................................... 15
4.4 Mounting instructions ..................................................................................................... 16
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 25
5.2 Connection procedure.................................................................................................... 26
5.3 Wiring plan, single chamber housing.............................................................................. 27
5.4 Wiring plan, double chamber housing ............................................................................ 28
5.5 Wiring plan, double chamber housing Ex d .................................................................... 30
5.6 Wiring plan - version IP 66/IP 68, 1 bar........................................................................... 32
5.7 Switch-on phase............................................................................................................. 33
6 Set up with the display and adjustment module PLICSCOM
6.1 Short description ............................................................................................................ 34
6.2 Insert display and adjustment module............................................................................ 34
6.3 Adjustment system......................................................................................................... 35
6.4 Setup steps .................................................................................................................... 36
6.5 Menu schematic............................................................................................................. 41
6.10 Saving the parameter adjustment data........................................................................... 43
7 Set up with PACTware and other adjustment programs
7.1 Connect the PC.............................................................................................................. 44
7.2 Parameter adjustment with PACTware............................................................................ 45
7.3 Parameter adjustment with PDM.................................................................................... 46
7.4 Saving the parameter adjustment data........................................................................... 46

3
Contents
VEGAPULS 68 • Probus PA
29263-EN-141215
8 Maintenanceandfaultrectication
8.1 Maintenance, cleaning ................................................................................................... 47
8.2 Rectify faults................................................................................................................... 47
8.3 Exchanging the electronics module................................................................................ 49
8.4 Software update ............................................................................................................. 49
8.5 How to proceed if a repair is needed .............................................................................. 50
9 Dismount
9.1 Dismounting steps.......................................................................................................... 51
9.2 Disposal ......................................................................................................................... 51
10 Supplement
10.1 Technical data ................................................................................................................ 52
10.2 Probus PA..................................................................................................................... 58
10.3 Dimensions .................................................................................................................... 62
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery. You can nd them listed in chapter "Product descrip-
tion".
Instructions manuals for accessories and replacement parts
Tip:
• 27835 - Display and adjustment module PLICSCOM
• 32628 - Interface adapter VEGACONNECT
• 43814 - Externe Anzeige VEGADIS 81
• 34296 - Protective cover
• 31088 - Flanges according to DIN-EN-ASME-JIS
• 30176 - Electronics module VEGAPULS series 60
• 31381 - Antenna impedance cone VEGAPULS 62 and 68
Editing status: 2014-12-08

4
1 About this document
VEGAPULS 68 • Probus PA
29263-EN-141215
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 specialist
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbols 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.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 Sequence of actions
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.

5
2 For your safety
VEGAPULS 68 • Probus PA
29263-EN-141215
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
VEGAPULS 68 is a sensor for continuous level measurement.
You can nd detailed information about the area of application 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.
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.
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 high-tech instrument requiring the strict observance of stand-
ard regulations and guidelines. The user must take note of the safety
instructions in this operating instructions manual, the country-specic
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 C or K band range. The low transmitting power lies far
below the internationally permitted limit values. When the instrument
is used correctly, it presents no danger to human health. It may be
operated without restriction outside of closed metallic vessels.
The instrument must only be operated in a technically awless and
reliable condition. The operator is responsible for trouble-free opera-
tion 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.
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.

6
2 For your safety
VEGAPULS 68 • Probus PA
29263-EN-141215
2.6 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 CE Certicate of Conformity in the download section
of our homepage.
2.7 Fulllmentof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 display/adjustment
components
For further information see www.namur.de.
2.8 FCCandICconformity(onlyforUSA/Canada)
VEGAPULS sensors with all antenna versions are FCC and IC ap-
proved:
• FCC ID: O6QPULS68
• IC: 3892A-PS68
Modications not expressly approved by VEGA will lead to expiry of
the operating licence according to FCC.
VEGAPULS 68 is in conformity with part 15 of the FCC regulations.
Take note of the respective operating regulations:
• The instrument must not cause any interfering emissions
• The device must be insensitive to interfering immissions, including
those that may cause undesirable operating conditions
2.9 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.
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 pro-
tection. The environment management system is certied according
to DIN EN ISO 14001.
Please help us fulll this obligation by observing the environmental
instructions in this manual:

7
2 For your safety
VEGAPULS 68 • Probus PA
29263-EN-141215
• Chapter "Packaging, transport and storage"
• Chapter "Disposal"

8
3 Product description
VEGAPULS 68 • Probus PA
29263-EN-141215
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• VEGAPULS 68 radar sensor
• Documentation
– this operating instructions manual
– Operating instructions manual - 27835 "Display and adjustment
module PLICSCOM" (optional)
– Supplementary instructions manual 31708 "Heating for display
and adjustment module" (optional)
– Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors" (optional)
– Ex-specic "Safety instructions" (with Ex versions)
– if necessary, further certicates
The VEGAPULS 68 consists of the components:
• Horn or parabolic antenna
• process tting (depending on the version ange or thread)
• Optionally available with swivelling holder (only with ange), rins-
ing air connection, reux valve
• Housing with electronics, optionally available with plug connector,
optionally available with connection cable
• Housing cover, optionally available with display and adjustment
module PLICSCOM
The components are available in dierent versions.
Scope of delivery
Constituent parts

9
3 Product description
VEGAPULS 68 • Probus PA
29263-EN-141215
1
2
3
4
Fig. 1: VEGAPULS 68 - horn antenna and swivelling holder
1 Housing cover with integrated PLICSCOM (optional)
2 Housing with electronics
3 Swivellingholderwithange
4 Horn antenna
The type label contains the most important data for identication and
use of the instrument:
• Instrument type
• Article and serial number device
• Article numbers, documentation
• Technical data: Approvals, antenna type, process tting, process
seal/temperature, signal output, voltage supply, protection, protec-
tion class
With the serial number, you can access the delivery data of the instru-
ment via www.vega.com, "VEGA Tools" and "serial number search".
You can nd the serial number on the inside of the instrument as well
as on the type label on the outside.
This operating instructions manual applies to the following instrument
versions:
• Hardware version < 2.0.0
• Software version ≤ 3.8
Type label
Scope of this operating
instructions manual

10
3 Product description
VEGAPULS 68 • Probus PA
29263-EN-141215
3.2 Principle of operation
VEGAPULS 68 is a radar sensor in K-band technology for continuous
level measurement of solids.
A version of VEGAPULS 68 is available for each area of application.
• The version with horn antenna is particularly suitable for measure-
ment of virtually all bulk solids in small silos and vessels.
• The version with parabolic antenna is particularly suitable for large
silos and vessels with up to 70 m (76 yd) measuring distance and
for measurement of solids with low dielectric gure.
VEGAPULS 68 is also suitable for applications in liquids.
The antenna of the radar sensor emits short radar pulses with a
duration of approx. 1 ns. These pulses are reected by the product
and received by the antenna as echoes. The transit 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 appropri-
ate output signal and outputted as measured value.
Power supply via the Probus DP/PA segment coupler or VEGALOG
571 EP cards. A two-wire cable according to Probus specication
serves as carrier of both power and digital data transmission for mul-
tiple sensors. The instrument prole of VEGAPULS 68 corresponds to
prole specication version 3.0.
The GSD (instrument master les) and bitmap les necessary for
planning your Probus-DP-(PA) communication network are available
from the download section on the VEGA homepage www.vega.com
under "Services-Downloads-Software-Probus". There you can
also nd the appropriate certicates. 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 les can be ordered via e-mail under [e-mail].
com or by phone from one of the VEGA agencies under the order
number "DRIVER.S".
The backlight of the display and adjustment module is powered by the
sensor. Prerequisite is a certain level of operating voltage.
The data for power supply are specied in chapter "Technical data".
The optional heating requires its own operating voltage. You can nd
detailed information in the supplementary instructions manual "Heat-
ing for display and adjustment module". This function is generally not
available for approved instruments.
3.3 Operation
The instrument can be adjusted with the following adjustment media:
• With the display and adjustment module
• with the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard, e.g. PACTware and
PC
• with the adjustment program PDM
Area of application
Functional principle
Power supply and bus
communication
GSD/EDD

11
3 Product description
VEGAPULS 68 • Probus PA
29263-EN-141215
3.4 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
based on ISO 4180.
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 in due 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 %
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature

12
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
4 Mounting
4.1 General instructions
Select an installation position you can easily reach for mounting and
connecting as well as later retrotting of a display and adjustment
module. The housing can be rotated by 330° without the use of any
tools. You can also install the display and adjustment module in four
dierent positions (each displaced by 90°).
Warning:
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 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 o. This ap-
plies 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 ingress
The reference plane for the measuring range of the sensors is the
lower edge of the ange or the seal surface of the thread.
Installation position
Screwing in
Moisture
Measuring range

13
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
1 32
100%
0%
4
Fig. 3: Measuring range (operating range), max. measuring distance and refer-
ence plane
1 full
2 empty (max. measuring distance)
3 Measuring range
4 Reference plane
Information:
If the medium reaches the antenna, buildup can form on it and cause
faulty measurements later on.
The emitted radar pulses of VEGAPULS 68 are electromagnetic
waves. They thus have electrical and magnetical components that are
perpendicular to each other. The polariation is dened by the direction
of the electrical component. With radar sensors, the polarisation can
be used to considerably reduce the eect of false echoes by turning
the instrument in the connection ange or mounting boss. The posi-
tion of the polarisation is marked on the instrument.
1
Fig. 4: Position of the polarisation of VEGAPULS 68
1 Marking hole
Polarisation

14
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
Make sure that all parts of the instrument coming in direct contact
with the process, especially the sensor element, process seal and
process tting, are suitable for the existing process conditions, such
as process pressure, process temperature as well as the chemical
properties of the medium.
You can nd the specications in chapter "Technical data" and on the
nameplate.
4.2 Mounting preparations - Horn antenna
Information:
This information applies only to special versions!
VEGAPULS 68 is also available in versions where the antenna has a
bigger diameter than the process tting (thread, ange). The antenna
must therefore be disconnected from the process tting before mount-
ing. Proceed as follows:
1. Loosen the hexagon socket screws (3) on the antenna socket
with an Allen wrench (size 3)
2. Remove the antenna (4)
Note:
The plastic cone may not be pulled out of the antenna socket.
3. Insert the antenna from below into the vessel socket and secure it
against falling o
4. Retighten the antenna with hexagon screws to the antenna
socket; torque max. 10 Nm (7.5 lbf ft)
Note:
The VEGAPULS 68 with rinsing air connection or antenna exten-
sion is provided with a notch on the antenna socket. This notch must
correspond to the marking on the hexagon of the process tting (the
marking species the position of the polarisation of the radar signal).
Suitability for the process
conditions

15
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
4
3
5
1
2
Fig. 5: Dismounting of the horn antenna
1 Marking
2 Notch
3 Hexagon screws on the antenna socket
4 Antenna
4.3 Mounting preparations - Parabolic antenna
Information:
This information applies only to special versions!
VEGAPULS 68 is also available in versions where the antenna has
a diameter larger than the process tting (thread, ange). With such
versions the antenna must be disconnected from the process tting
before mounting. Proceed as follows:
1. Clamp VEGAPULS 68 with the ange, e.g. in a bench vice
2. Hold the connection piece (3) with a wrench (spanner size 22) on
the attenings
3. Loosen counter nut (2) with spanner size 36 completely in the
direction antenna
4. Loosen compression nut (1) with a wrench SW 41 completely in
the direction of the antenna
5. Remove the parabolic antenna (4) axially
6. Mount sensor ange on the adapter ange and fasten it tightly
7. Check if the O-ring seal is present on the connection piece and
make sure it is not damaged.
Note:
A damaged O-ring seal must be replaced: FKM article no. 2.28248,
FFKM (Kalrez 6375) article no. 2.27351
8. Remount the parabolic antenna (4)
9. Tighten compression nut (1) with SW 41, torque max. 50 Nm
10. Tighten locknut (2) with SW 36, torque max. 40 Nm.

16
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
Note:
Take note for VEGAPULS 68 with rinsing air connection that the holes
in the antenna and in the process tting correspond. This ensures a
sucient air ow (the air is led through the holes to the feed system. A
rinsing of the parabolic antenna in total is not intended).
1
2
3
4
Fig. 6: Dismounting, parabolic antenna
1 Compression nut
2 Locknut
3 Connection piece
4 Parabolic antenna
4.4 Mounting instructions
The illustrations with the following mounting instructions show a
VEGAPULS 68 with horn antenna. The mounting instructions apply
analogously also to the version with parabolic antenna.
Mount the sensor at least 200 mm (7.874 in) away from the vessel
wall.
> 200 mm
(7.87
")
Fig. 7: Installation position
1 Reference plane
If you cannot maintain this distance, you should carry out a false
signal storage during setup. This applies particularly if buildup on the
vessel wall is expected. In such cases, we recommend repeating the
false signal storage at a later date with existing buildup.
Horn and parabolic
antenna
Installation position

17
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
To measure as much of the vessel volume as possible, the sensor
should be aligned so that the measuring beam reaches the lowest
level in the vessel. In a cylindrical silo with conical outlet, the easiest
way is to mount the instrument in the center of the silo.
r
rr...
/
13
/
12
Fig. 8: Orientation
If mounting in the centre of the silo is not possible, the sensor can be
directed to the vessel center by using the optional swivelling holder.
The following description shows a simple way to determine the
required angle of inclination.
Orientation

18
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
d
a
α
Fig. 9: Proposal for installation after orientation VEGAPULS 68
The angle of inclination depends on the vessel dimensions. It can be
easily checked with a suitable level or water leve on the sensor.
Tip:
VEGA recommends the adjusting aid from VEGA line of accessory.
This is a round, direction-independent water level which is simply
place to the sensor housing.
The following chart species the distance "a" between installation
position and vessel centre dependent on the measuring distance for
inclination angles of 2° … 10°.
Distance d
(m)
2° 4° 6° 8° 10°
2 0.1 0.1 0.2 0.3 0.4
4 0.1 0.3 0.4 0.6 0.7
6 0.2 0.4 0.6 0.8 1.1
8 0.3 0.6 0.8 1.1 1.4
10 0.3 0.7 1.1 1.4 1.8
15 0.5 1.0 1.6 2.1 2.6
20 0.7 1.4 2.1 2.8 3.5
25 0.9 1.7 2.6 3.5 4.4
30 1.0 2.1 3.2 4.2 5.3
35 1.2 2.4 3.7 4.9 6.2

19
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
Distance d
(m)
2° 4° 6° 8° 10°
40 1.4 2.8 4.2 5.6 7.1
45 1.6 3.1 4.7 6.3 7.9
50 1.7 3.5 5.3 7 8.8
55 1.9 3.8 5.8 7.7 9.7
60 2.1 4.2 6.3 8.4 10.6
65 2.3 4.5 6.8 9.1 11.5
70 2.4 4.9 7.4 9.8 12.3
Example:
In a vessel 20 m high, the installation position of the sensor is 1.4 m
from the vessel centre.
The necessary angle of inclination of 4° can be read out from this
chart.
Proceed as follows to adjust the angle of inclination with the swivelling
holder:
1. Loosen terminal screw of the swivelling holder with a fork spanner
SW 13
2. Align the sensor, check angle of inclination
Information:
The max. angle of inclination of the swivelling holder is approx. 15°
3. Tighten the terminal screw, torque max. 20 Nm.
Information:
The hexagon screws must not be loosened.
Mounting should not be too close to the inowing material as the
microwave signal will be interferred. The optimum mounting position is
on the opposite of the lling. To avoid strong pollution, the distance to
the lter or dust extraction must be as big as possible.
Inowingmedium

20
4 Mounting
VEGAPULS 68 • Probus PA
29263-EN-141215
Fig.10:Inowingmedium
The socket piece should be dimensioned in such a way that the an-
tenna end protrudes at least 10 mm (0.4 in) out of the socket.
10 mm (0.39
")
>
Fig. 11: Recommended socket mounting
If the reective properties of the medium are good, you can mount
VEGAPULS 68 on sockets which are higher than the length of the
antenna. You will nd recommended values for socket heights in the
following illustration. The socket end should be smooth and burr-free,
if possible also rounded. After installation you must carry out a false
echo storage.
Socket