Vega VEGAPULS SR 68 User manual

Operating Instructions
Radar sensor for continuous level
measurement of bulk solids
VEGAPULS SR 68
Modbus and Levelmaster protocol
Document ID: 41371

2
Contents
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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................................................................................................................... 6
2.6 NAMUR recommendations .............................................................................................. 6
2.7 Radio license for Europe .................................................................................................. 6
2.8 Radio license for USA/Canada......................................................................................... 6
2.9 Environmental instructions ............................................................................................... 7
3 Product description
3.1 Conguration.................................................................................................................... 8
3.2 Principle of operation........................................................................................................ 9
3.3 Packaging, transport and storage................................................................................... 10
3.4 Accessories and replacement parts ............................................................................... 10
4 Mounting
4.1 General instructions ....................................................................................................... 12
4.2 Mounting preparations - Horn antenna........................................................................... 12
4.3 Mounting preparations - Parabolic antenna.................................................................... 13
4.4 Mounting instructions ..................................................................................................... 14
5 Connecting to power supply and bus system
5.1 Preparing the connection ............................................................................................... 27
5.2 Connection..................................................................................................................... 27
5.3 Wiring plan, double chamber housing ............................................................................ 29
5.4 Double chamber housing with DIS-ADAPT .................................................................... 30
5.5 Switch-on phase............................................................................................................. 31
6 Set up the sensor with the display and adjustment module
6.1 Adjustment volume......................................................................................................... 32
6.2 Insert display and adjustment module............................................................................ 32
6.3 Adjustment system......................................................................................................... 33
6.4 Parameter adjustment .................................................................................................... 33
6.5 Saving the parameter adjustment data........................................................................... 47
7 Setting up sensor and Modbus interface with PACTware
7.1 Connect the PC.............................................................................................................. 48
7.2 Parameter adjustment .................................................................................................... 49
7.3 Saving the parameter adjustment data........................................................................... 51
8 Diagnosis, asset management and service
8.1 Maintenance .................................................................................................................. 52
8.2 Measured value and event memory ............................................................................... 52
8.3 Asset Management function........................................................................................... 53
8.4 Rectify faults................................................................................................................... 57

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Contents
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
8.5 Exchanging the electronics module................................................................................ 59
8.6 Software update............................................................................................................. 60
8.7 How to proceed if a repair is needed.............................................................................. 60
9 Dismounting
9.1 Dismounting steps.......................................................................................................... 61
9.2 Disposal ......................................................................................................................... 61
10 Supplement
10.1 Technical data ................................................................................................................ 62
10.2 Basics Modbus............................................................................................................... 68
10.3 Modbus register ............................................................................................................. 70
10.4 Modbus RTU commands ............................................................................................... 72
10.5 Levelmaster commands ................................................................................................. 75
10.6 CongurationoftypicalModbushosts ........................................................................... 79
10.7 Dimensions .................................................................................................................... 83
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: 2014-01-28

4
1 About this document
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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 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 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 SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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 SR 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.
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.
Depending on the instrument version, the emitting frequencies are in
the C or K band range. The low emitting frequencies are far below the
internationally approved limit values. When used correctly, there is no
danger to health.

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2 For your safety
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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CECerticateofConformityinthedownloadsection
of our homepage.
Electromagnetic compatibility
Instruments with plastic housing are designed for use in an industrial
environment. Nevertheless, electromagnetic interference from electri-
cal conductors and radiated emissions must be taken into account,
as is usual with class A instruments according to EN 61326-1. If the
instrumentisusedinadierentenvironment,theelectromagnetic
compatibility to other instruments must be ensured by suitable meas-
ures.
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display/adjustment
components
•NE107–Self-monitoringanddiagnosisofelddevices
For further information see www.namur.de.
2.7 Radio license for Europe
The instrument is approved according to EN 302372-1/2 (2006-04)
for use in closed vessels.
2.8 Radio license for USA/Canada
The instrument is in conformity with part 15 of the FCC regulations.
Take note of the following two 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
Modicationsnotexpresslyapprovedbythemanufacturerwillleadto
expiry of the operating licence according to FCC/IC.
The instrument is in conformity with RSS-210 of the IC regulations.
The instrument may only be used in closed vessels made of metal,
concrete,orbre-reinforcedplastic.

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2 For your safety
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
2.9 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:
•Chapter "Packaging, transport and storage"
•Chapter "Disposal"

8
3 Product description
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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
14
15
16
17
13
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 Measuring range
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 Data-Matrix-Code for Smartphone-App
13 Symbol of the device protection class
14 ID numbers, instrument documentation
15 Reminder to observe the instrument documentation
16 NotiedauthorityforCEmarking
17 Approval directive
The type label contains the serial number of the instrument. With it
youcanndthefollowinginstrumentdataonourhomepage:
•Product code (HTML)
•Delivery date (HTML)
•Order-specicinstrumentfeatures(HTML)
•Operating instructions and quick setup guide at the time of ship-
ment (PDF)
•Order-specicsensordataforanelectronicsexchange(XML)
•Testcerticate(PDF)-optional
Go to www.vega.com, "VEGATools" and "Instrument search". Enter
the serial number.
Alternatively, you can access the data via your smartphone:
Type label
Serial number - Instru-
ment search

9
3 Product description
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
•Download the smartphone app "VEGATools" from the "Apple App
Store" or the "GooglePlayStore"
•Scan the Data Matrix code on the type label of the instrument or
•Enter the serial number manually in the app
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
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 2.1.0
•Software from 4.5.1
The scope of delivery encompasses:
•Radar sensor
•Documentation
– Quick setup guide VEGAPULS SR 68
– TestcerticateMeasurementaccuracy,dependingonthe
instrument VEGAPULS SR 68 (optional)
– Operating instructions manual "DIsplay and adjustment module
PLICSCOM" (optional)
– Supplementary instructions manual "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
3.2 Principle of operation
The VEGAPULS SR 68 is a radar sensor for continuous measurement
ofbulksolidsalsounderdicultprocessconditions.Itisparticularly
suitable for level measurement in high silos and large bunkers.
The instrument is also suitable for applications in liquids.
Electronics design
Scope of this operating
instructions manual
Scope of delivery
Application area

10
3 Product description
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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.
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
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 %
3.4 Accessories and replacement parts
The display and adjustment module PLICSCOM is used for measured
value indication, adjustment and diagnosis. It can be inserted into the
sensor or the external display and adjustment unit and removed at
any time.
You canndfurtherinformationintheoperatinginstructions"Display
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
Functional principle
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
PLICSCOM
VEGACONNECT

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3 Product description
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
parameter adjustment of these instruments, the adjustment software
PACTware with VEGA-DTM is required.
You canndfurtherinformationintheoperatinginstructions"Interface
adapterVEGACONNECT" (Document-ID 32628).
The protective cover protects the sensor housing against soiling and
intense heat from solar radiation.
You willndadditionalinformationinthesupplementaryinstructions
manual "Protective cover" (Document-ID 34296).
Screwedangesareavailableindierentversionsaccordingtothe
following standards: DIN 2501, EN 1092-1, BS 10, ANSI B 16.5,
JIS B 2210-1984, GOST 12821-80.
You canndadditionalinformationinthesupplementaryinstructions
manual "FlangesaccordingtoDIN-EN-ASME-JIS" (Document-ID
31088).
The electronics module VEGAPULS series 60 is a replacement part
forradarsensorsofVEGAPULSseries60.Thereisadierentversion
available for each type of signal output.
You canndfurtherinformationintheoperatinginstructions"Elec-
tronicsmoduleVEGAPULSseries60" (Document-ID 36801).
The supplementary electronics is a replacement part for sensors with
signal output Modbus.
You canndfurtherinformationintheoperatinginstructions"Supple-
mentary electronics Modbus" (Document-ID 41864).
The antenna impedance cone is a replacement part used for optimum
transmission of microwaves and for sealing against the process.
You ndfurtherinformationintheoperatinginstructions"Antenna
impedanceconeVEGAPULS62and68" (Document-ID 31381).
Protective cap
Flanges
Electronics module
Supplementary electron-
ics Modbus
Antenna impedance cone

12
4 Mounting
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
4 Mounting
4.1 General instructions
Oninstrumentswithprocessttingthread,thehexagonmustbetight-
enedwithasuitablescrewdriver.Wrenchsizeseechapter"Dimen-
sions".
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Protect your instrument against moisture penetration through the fol-
lowing measures:
•Use the recommended cable (see chapter "Connecting to power
supply")
•Tighten the cable gland
•Turn the housing in such a way that the cable gland points down-
ward
•Loop the connection cable downward in front of the cable gland
This applies particularly to:
•Outdoor mounting
•Installations in areas where high humidity is expected (e.g. through
cleaning processes)
•Installations on cooled or heated vessels
Make sure that all parts of the instrument exposed to the process are
suitable for the existing process conditions.
These are mainly:
•Active measuring component
•Processtting
•Process seal
Process conditions are particularly:
•Process pressure
•Process temperature
•Chemical properties of the medium
•Abrasionandmechanicalinuences
You canndthespecicationsoftheprocessconditionsinchapter
"Technicaldata" as well as on the type label.
4.2 Mounting preparations - Horn antenna
The instrument is also available in versions with an antenna whose
diameterislargerthantheprocesstting(thread,ange).Insuch
casestheantennamustbedisconnectedfromtheprocesstting
before mounting. 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)
Screwing in
Protection against mois-
ture
Suitability for the process
conditions

13
4 Mounting
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
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. 2.5 Nm (1.8 lbf ft)
Note:
The radar sensor with rinsing air connection or antenna extension
is provided with a notch on the antenna socket. This notch must be
alignedwiththemarkingontheprocesstting(themarkingspecies
the position of the polarisation of the radar signal).
3
4
1
2
Fig. 3: Dismounting of the horn antenna
1 Marking for the polarisation
2 Marking at the antenna socket
3 Hexagon screws on the antenna socket
4 Antenna
4.3 Mounting preparations - Parabolic antenna
The instrument 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SR68withtheange,e.g.inabenchvice
2. Holdtheconnectionpiece(1)withawrenchontheatsurfaces
(widthacrossats22mm)
3. Loosen counter nut (3) completely with a wrench (width across
ats36mm)inthedirectionoftheantenna
4. Loosen compression nut (2) completely with a wrench (width
acrossats41mm)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.

14
4 Mounting
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
Note:
A damaged O-ring seal must be replaced: FKM (SHS FPM 70C3
GLT),FFKM(Kalrez6375)
8. Remount the parabolic antenna (4)
9. Fastencompressionnut(2)withawrench(widthacrossats41),
torque max. 50 Nm
10. Fastencounternut(3)withawrench(widthacrossats36),
torque max. 40 Nm
Note:
On the version with rinsing air connection, make sure that the holes
intheantennaandintheprocessttingcoincide.Thisensuresasuf-
cientairow(theairisledthroughtheholestothefeedsystem.A
rinsing of the whole parabolic antenna is not intended).
1
2
3
4
Fig. 4: Dismounting, parabolic antenna
1 Connection piece
2 Compression nut
3 Locknut
4 Parabolic antenna
4.4 Mounting instructions
The emitted radar impulses of the radar sensor are electromagnetic
waves. The polarisation is the direction of the electrical wave compo-
nent.Byturningtheinstrumentintheconnectionangeormounting
boss,thepolarisationcanbeusedtoreducetheeectsoffalse
echoes.
Thepositionofthepolarisationismarkedontheprocessttingofthe
instrument.
Polarisation

15
4 Mounting
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
12
Fig. 5: Position of the polarisation
1 Marking with screwed version
2 Markingwithangeversion
Mount the sensor at least 200 mm (7.874 in) away from the vessel
wall.
200 mm
(7.87
")
Fig. 6: Mounting of the radar sensor on the vessel top
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 a case, it is recommended to repeat
the false signal storage at a later date with existing buildup.
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.
Installation position
Inowingmedium

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VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
Fig.7:Mountingoftheradarsensorwithinowingmedium
Withbulksolidssiloswithlateralpneumaticlling,mountingshould
notbeinthellingstreamasthemicrowavesignalwillbeinterferred.
Theoptimummountingpositionisnexttothelling.Toavoidstrong
pollution,thedistancetothelterordustextractionmustbeasbigas
possible.

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4 Mounting
VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
Fig.8:Mountingoftheradarsensorwithinowingmedium
The socket piece should be dimensioned in such a way that the
antenna end protrudes slightly out of the socket.
Socket

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VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
ca. 10 mm
Fig. 9: Recommended socket mounting with horn antenna
> 10 mm
(0.39")
Fig. 10: Recommended socket mounting with parabolic antenna
When using a swivelling holder, keep in mind that the distance
between antenna and socket gets smaller as the inclination of the
sensorincreases.Additionalfalsereectionsmaybegeneratedwhich
caninuencethemeasuringresultatcloserange.
Fig. 11: Distance between antenna and socket with horn antenna

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VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
Fig. 12: Distance between antenna and socket with parabolic antenna
Ifthemediumhasgoodreectiveproperties,VEGAPULSSR68
with horn antenna can also be mounted on a longer socket piece.
Recommendedvaluesforsocketheightsarespeciedinthefollowing
illustration. You must carry out a false echo storage afterwards.
d
hmax.
Fig. 13: Deviating socket dimensions
Socket diameter d Socket length h Recommended anten-
na diameter
40 mm ≤100mm 40 mm
50 mm ≤150mm 48 mm
80 mm ≤250mm 75 mm
100 mm ≤500mm 95 mm
150 mm ≤800mm 95 mm
Socket diameter d Socket length h Recommended anten-
na diameter
1½" ≤3.9in 1½"
2" ≤5.9in 2"
3" ≤9.8in 3"
4" ≤19.7in 4"
6" ≤31.5in 4"
Tip:
The instrument is also optionally available with an antenna extension.
The antenna length can be selected (either ex works or later) to allow
the antenna to protrude slightly out of the end of the mounting socket.
Duetotheantennaextensionhowever,disturbingreectionsare
generated in the close-up range. This can lead to an increase in the

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VEGAPULS SR 68 • Modbus and Levelmaster protocol
41371-EN-140209
requiredminimumdistance,especiallywithpoorlyreectingmedia
such as plastic powder. In practice, a cleanly constructed mounting
socket, if necessary with rounded edges, introduces fewer disturbing
inuencesthananantennaextension.
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 mounting is
carried out on a socket. It should be positioned on one third up to the
half of the vessel radius.
rrr...
/
13
/
12
Fig. 14: 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