Vega VEGASON 63 User manual

Operating Instructions
VEGASON 63
4... 20 mA/HART
Ultrasonic

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
2.8Safety instructions for Ex areas . . . . . . . . . . . . 7
2.9Manufacturer declaration . . . . . . . . . . . . . . . . . 8
2.10 Functional range of approved instruments . . . . . 9
2.11 Environmental instructions . . . . . . . . . . . . . . . . 9
3Product description
3.1Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2Principle of operation. . . . . . . . . . . . . . . . . . . . 11
3.3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4Packaging,transport and storage . . . . . . . . . . . 12
4Mounting
4.1General instructions. . . . . . . . . . . . . . . . . . . . . 13
4.2Mounting instructions. . . . . . . . . . . . . . . . . . . . 15
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,version IP 66/IP 68,1bar . . . . . . . 27
5.6Switch-on phase . . . . . . . . . . . . . . . . . . . . . . . 27
6Set up with the indicating and adjustment module
PLICSCOM
6.1Short description . . . . . . . . . . . . . . . . . . . . . . . 28
6.2Insert indicating and adjustment module . . . . . . 28
6.3Adjustment system . . . . . . . . . . . . . . . . . . . . . 30
6.4Setup procedure . . . . . . . . . . . . . . . . . . . . . . . 31
6.5Menu schematic . . . . . . . . . . . . . . . . . . . . . . . 38
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6.6Saving the parameter adjustment data . . . . . . . 40
7Setup with PACTware™and other adjustment
programs
7.1Connect the PC via VEGACONNECT 3. . . . . . 41
7.2Connect the PC via VEGACONNECT 4. . . . . . 43
7.3Parameter adjustment with PACTware™. . . . . . 44
7.4Parameter adjustment with AMS™and PDM . . 45
7.5Saving 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 . . . . . . . . . . . . . . . . . . . . . . . 48
9Dismounting
9.1Dismounting steps . . . . . . . . . . . . . . . . . . . . . . 50
9.2Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10 Supplement
10.1Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 51
10.2Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.3Industrial property rights. . . . . . . . . . . . . . . . . . 60
10.4Trademark . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Supplementary operating instructions manuals
Information:
VEGASON 63 is available in different versions.Depending on
the selected version,supplementary operating instructions
manuals may also come with the shipment.The supplemen-
tary operating instructions manuals are listed in section
"Product description.
Operating instructions manuals for accessories and
replacement parts
Tip:
To ensure reliable setup and operation of your VEGASON 63,
we offer accessories and replacement parts.The associated
documents are:
lOperating instructions manual 27720 "External indicating
and adjustment unit VEGADIS 61"
lOperating instructions manual 30206 "Oscillator VEGA-
SON series 60"
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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.In addition,you
will find important notes on maintenance and trouble shooting.
Please read this information before putting the instrument into
operation.
Keep this manual as a product component safe and accessible
in the immediate proximity of the device.
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 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.
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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.
During work on and with the device the required personal
protection equipment must always be worn.
2.2Appropriate use
VEGASON 63 is a sensor for continuous level measurement.
You can find detailed information on the application range of
VEGASON 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
This is a are 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
(e.g.the VDE regulations in Germany)as well as all prevailing
safety regulations and accident prevention rules.
The instrument must only be opereated in technically correct
and reliable condition.The operator is responsible for the
interference-free operation of the instrument.
The user is further compelled to determine the compliance of
the necessary occupational safety measures with the current
version of the valid regulations and note new regulations
during complete duration of use.
2.5CE conformity
VEGASON 63 is in CE conformity with EMC (89/336/EWG)
and LVD (73/23/EWG).
CE conformity has been judged according to the following
standards:
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lEMC:
-Emission EN 61326:1997 (class A)
-Susceptibility EN 61326:1997/A1:1998
lLVD:EN 61010-1:2001
2.6Fulfilling NAMUR recommendations
With regard to interference resistance and interference
emission,VEGASON 63 fulfils NAMUR recommendation
NE 21.
VEGASON 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 VEGASON 63 HART,PA or FF
lDTM VEGASON 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 VEGASON 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
VEGASON 63 fulfills the requirements for functional safety
according to IEC 61508/IEC 61511.You can find further
information in the Safety Manual "VEGASON series 60 -
4…20 mA/HART".
2.8Safety 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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2.9Manufacturer declaration
In conformity with DIN EN 60079-14/2004,para.5.2.3,point
c1,VEGASON 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 (24630)
lthe applicable installation regulations
Max.increase of the surface temperature during operation:
23 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 93 °C(199 °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"
lMount and operate the instrument in such a way that no
danger of ignition by electrostatic charges is to be
expected.Transducer,process fitting and 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.
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2.10 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.
2.11 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 scope of delivery encompasses:
lVEGASON 63 ultrasonic sensor
loptionally mounting strap or compression flange
lDocumentation
-this operating instructions manual
-Supplementary instructions manual "Safety Manual
according to IEC 61508/IEC 61511 (SIL)"
-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)
-if necessary,further certificates
VEGASON 63 consists of the following components:
lProcess fitting with transducer
lHousing with electronics,optionally available with plug
connector
lHousing cover,optionally available with indicating and
adjustment module PLICSCOM
The components are available in different versions.
1
2
3
Fig.1:VEGASON 63 with plastic housing
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics,optionally available with plug connection
3Process fitting with transducer
Scope of delivery
Components
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Product description
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3.2Principle of operation
VEGASON 63 is an ultrasonic sensor for continuous level
measurement.It is suitable for liquids and solids in practically
all industries.
The transducer of the ultrasonic sensor transmits short
ultrasonic pulses to the measured product.These pulses are
reflected by product surface and received again by the
rtansducer as echoes.The running time of the ultrasonic
pulases from emission to reception is proportional to the
distance and hence 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".
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 FM or CSA only at a later
date.
The optional heating requires its own power supply.You can
find further details in the supplementary instructions manual
"Heating for indicating and adjustment module".
This function is generally not available for approved instru-
ments.
3.3Operation
VEGASON 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
Area of application
Functional principle
Supply
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Product description
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PDM
lwith a HART handheld
The entered parameters are generally saved in VEGASON 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 packaging must be closed and
stored according to the orientation and storage markings on
the outside.
Unless otherwise indicated,the packaging 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 %
Packaging
Transport
Transport inspection
Storage
Storage and transport tem-
perature
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4Mounting
4.1General instructions
Make sure that the wetted parts of VEGASON 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".
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 VEGASON 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 is the lower edge
of the transducer.
Wetted materials
Installation position
Moisture
Measuring range
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Make sure that a min.distance -the so called dead zone -
below the reference plane is maintained in which a measure-
ment is not possible.The exact value of the dead zone is
stated in chapter "Technical data"in the "Supplement".
1
2
Fig.3:Min.distance to the max.level
1Dead zone
2Reference plane
Information:
If the medium reaches the transducer,buildup can form on it
and cause faulty measurements later on.
1 32
100%
0%
Fig.4:Measuring range (operating range)and max.measuring distance
1full
2empty (max.measuring distance)
3Measuring range
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Gauge pressure in the vessel does not influence VEGASON
63.Low pressure or vacuum does,however,damp the
ultrasonic pulses.This influences the measuring result,
particularly if the level is very low.With pressures under -
0.2bar (-20 kPa)you should use a different measuring
principle,e.g.radar or guided microwave.
4.2Mounting instructions
When mounting VEGASON 63,keep a distance of at least
200 mm to the vessel wall.If the sensor is installed in the
center of dished or spherical vessel tops,multiple echoes can
arise.These can,however,be faded out by an appropriate
adjustment (see "Setup").
If you cannot keep this distance you should carry out a false
echo memory before setup.This applies mainly if buildup is
expected on the vessel wall.In this case,we recommend to
repeat a false echo memory later with existing buildup.
12
> 200 mm
Fig.5: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.
Pressure/Vacuum
Installation position
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Fig.6:Vessel with conical bottom
Preferably the transducer should be mounted flush to the
vessel top.
If the reflective properties of the medium are good,you can
mount VEGASON 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
45˚
hmax.
d
100 mm/4"
150 mm/6"
200 mm/8"
250 mm/10"
300 mm
400 mm
500 mm
600 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
To optimally align the sensor to solid products,a swivelling
holder (mounting strap)can be implemented.
Fig.9:Orientation in solids
To reduce the min.distance to the medium,you can also
mount VEGASON 63 with a beam deflector.By doing this,it is
possible to fill the vessel nearly to maximum.Such an
arrangement is suitable primarily for open vessels such as e.g.
overflow basins.
Sensor orientation
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~200
~400x400
45˚
Fig.10:Beam deflector
The ultrasonic sensor should be installed at a location where
no installations cross the ultrasonic beam.
Vessel installations such as for example,ladders,limit
switches,heating spirals,struts etc.can cause false echoes
superimposed on the useful echo.Make sure when planning
your measuring site that the ultrasonic signals have "free
access"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 or plastic baffles above
the installations scatter the ultrasonic signals and avoid direct
false echoes.
α
α
α
α
α
α
Fig.11: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.
Vessel installations
Agitators
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Fig.12:Agitators
Do not mount the instruments in or above the filling stream.
Make sure that you detect the product surface and not the
inflowing product.
Fig.13:Inflowing liquid
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 are causing measurement errors,the sensor should
be used in a standpipe or,alternatively,the more suitable
guided radar sensors (TDR)should be used.
Guided radar is not influenced by foam generation and is
particularly suitable for such applications.
Inflowing medium
Foam
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If there are strong air currents in the vessel,e.g.due to strong
winds in outdoor installations,or because of air turbulence,e.
g.by cyclone exhaustion you should mount VEGASON 63 in a
standpipe or use a different measuring principle,e.g.radar or
guided radar (TDR).
By using a standpipe (surge or bypass tube), the influence of
vessel installations,foam generation and turbulence is
excluded.
Standpipes must extend all the way down to the requested
min.level,as measurement is only possible within the tube.
max.
min.
1
Fig.14:Standpipe in tank
1Vent hole ø5…10 mm
VEGASON 63 can be used from tube diameters of 100 mm.
Avoid large gaps and thick welding joints when connecting the
tubes.Generally carry out a false echo storage.
Measurement in a standpipe is not recommended for adhesive
products.
Air turbulences
Standpipe measurement
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