Vega VEGATOR 112 User manual

Operating Instructions
Double channel controller for level
detection for NAMUR sensors
VEGATOR 112
Document ID: 46106

2
Contents
VEGATOR 112 •
46106-EN-210714
Contents
1 About this document ............................................................................................................... 4
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety ......................................................................................................................... 5
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 Installation and operation in the USA and Canada ........................................................... 5
2.6 Safety instructions for Ex areas ........................................................................................ 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 7
3.3 Adjustment ....................................................................................................................... 8
3.4 Packaging, transport and storage..................................................................................... 8
4 Mounting................................................................................................................................... 9
4.1 General instructions ......................................................................................................... 9
5 Connecting to power supply................................................................................................. 10
5.1 Preparing the connection ............................................................................................... 10
5.2 Connection procedure.................................................................................................... 11
5.3 Wiring plan ..................................................................................................................... 12
6 Setup ....................................................................................................................................... 13
6.1 Adjustment system......................................................................................................... 13
6.2 Adjustment elements...................................................................................................... 13
6.3 Function table "Point level" ............................................................................................. 16
6.4 Function table, two-point control..................................................................................... 17
7 Diagnostics and servicing .................................................................................................... 20
7.1 Maintenance .................................................................................................................. 20
7.2 Rectify faults................................................................................................................... 20
7.3 Diagnosis, fault messages ............................................................................................. 20
7.4 How to proceed if a repair is necessary.......................................................................... 21
8 Dismount................................................................................................................................. 23
8.1 Dismounting steps.......................................................................................................... 23
8.2 Disposal ......................................................................................................................... 23
9 Certicatesandapprovals.................................................................................................... 24
9.1 Approvals for Ex areas ................................................................................................... 24
9.2 EU conformity................................................................................................................. 24
9.3 SIL conformity (optional) ................................................................................................ 24
9.4 Environment management system ................................................................................. 24
10 Supplement ............................................................................................................................ 25
10.1 Technical data ................................................................................................................ 25
10.2 Dimensions .................................................................................................................... 27
10.3 Industrial property rights................................................................................................. 28

3
Contents
VEGATOR 112 •
46106-EN-210714
10.4 Trademark ...................................................................................................................... 28
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
withthedelivery.Youcanndthemlistedinchapter"Product descrip-
tion".
Editing status: 2021-07-12

4
1 About this document
VEGATOR 112 •
46106-EN-210714
1 About this document
1.1 Function
This instruction provides all the information you need for mounting,
connection and setup as well as important instructions for mainte-
nance,faultrectication,theexchangeofpartsandthesafetyofthe
user. Please read this information 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 personnel.
Thecontentsofthismanualmustbemadeavailabletothequalied
personnel and implemented.
1.3 Symbols used
Document ID
This symbol on the front page of this instruction refers to the Docu-
ment ID. By entering the Document ID on www.vega.com you will
reach the document download.
Information, note, tip: This symbol indicates helpful additional infor-
mation and tips for successful work.
Note: This symbol indicates notes to prevent failures, malfunctions,
damage to devices or plants.
Caution: Non-observance of the information marked with this symbol
may result in personal injury.
Warning: Non-observance of the information marked with this symbol
may result in serious or fatal personal injury.
Danger: Non-observance of the information marked with this symbol
results in serious or fatal personal injury.
Ex applications
This symbol indicates special instructions for Ex applications.
• List
The dot set in front indicates a list with no implied sequence.
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
VEGATOR 112 •
46106-EN-210714
2 For your safety
2.1 Authorised personnel
All operations described in this documentation must be carried out
onlybytrained,qualied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
VEGATOR 112 is a universal controller for connection of level
switches.
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 this product can give rise to applica-
tion-specichazards,e.g.vesseloverllthroughincorrectmounting
or adjustment. Damage to property and persons or environmental
contamination can result. Also, the protective characteristics of the
instrument can be impaired.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and directives.The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsi-
ble for the trouble-free operation of the instrument.When measuring
aggressive or corrosive media that can cause a dangerous situation
if the instrument malfunctions, the operator has to implement suitable
measures to make sure the instrument is functioning properly.
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.Forsafety
reasons,onlytheaccessoryspeciedbythemanufacturermustbe
used.
To avoid any danger, the safety approval markings and safety tips on
the device must also be observed.
2.5 Installation and operation in the USA and
Canada
This information is only valid for USA and Canada. Hence the follow-
ing text is only available in the English language.

6
2 For your safety
VEGATOR 112 •
46106-EN-210714
Installations in the US shall comply with the relevant requirements of
the National Electrical Code (ANSI/NFPA 70).
Installations in Canada shall comply with the relevant requirements of
the Canadian Electrical Code.
2.6 Safety instructions for Ex areas
For applications in explosion-proof areas (Ex), only devices with cor-
respondingExapprovalmaybeused.ObservetheEx-specicsafety
instructions.These are an integral part of the operating instructions
and are enclosed with every device with Ex approval.

7
3 Product description
VEGATOR 112 •
46106-EN-210714
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• Controller VEGATOR 112
• Documentation
– This operating instructions manual
– Ex-specic"Safety instructions" (with Ex version)
– Safety Manual "Functional safety (SIL) acc. to IEC 61508" (with
SIL version)
– Ifnecessary,furthercerticates
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
• Instrument type
• Information about approvals
• Technical data
• Serial number of the instrument
• QR code for device documentation
• Manufacturer information
Move to " www.vega.com"andenterinthesearcheldtheserial
number of your instrument.
Thereyoucanndthefollowinginformationabouttheinstrument:
• Order data
• Documentation
• Software
Alternatively,youcanndallviayoursmartphone:
• Scan the QR-code on the type label of the device or
• Enter serial number manually in the VEGA Tools app (available
free of charge in the respective stores)
3.2 Principle of operation
The VEGATOR 112 is a double-channel cotroller for level detection
with two level switches with NAMUR interface. Simple monitoring and
control functions can be realised via the integrated relays.Typical
applicationsaremonitoringfunctionssuchasoverllanddryrun
protection. As an alternative to the double-channel level detection, a
two-point control can be activated.
The VEGATOR 112 controller powers connected sensors and simul-
taneously processes their measuring signals.
When the medium reaches the switching point of the sensor, the sen-
sor current changes.This is measured and evaluated by VEGATOR
112. The change causes the output relays to switch according to the
set operating mode.
Scope of delivery
Type label
Documents and software
Application area
Functional principle

8
3 Product description
VEGATOR 112 •
46106-EN-210714
3.3 Adjustment
All adjustment elements are located under a hinged front cover. The
operating mode and the line monitoring can be set via a DIL switch
block. In addition, the correct function of the measuring system can
be checked with a test key.
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

9
4 Mounting
VEGATOR 112 •
46106-EN-210714
4 Mounting
4.1 General instructions
VEGATOR 112 is designed for carrier rail mounting (top hat rail
35 x 7.5 according to DIN EN 50022/60715). Due to its protection
rating of IP20, the instrument is suitable for mounting in switching
cabinets.Itcanbemountedhorizontallyandvertically.
Note:
When several instruments are mounted together without space in
between, the ambient temperature at the installation location of the
instrument must not exceed 60 °C. Around the ventilation slots there
must be a distance of at least 2 cm to the next component.
VEGATOR 112 in Ex version is a corresponding, intrinsically safe in-
strumentandmustnotbeinstalledinhazardousareas.Asafeopera-
tion is only ensured if the operating instructions and EU type approval
certicateareobserved.VEGATOR112mustnotbeopened.
A distance of 50 mm to the intrinsically safe terminals must be en-
sured when mounting.
The instrument is suitable for standard and extended ambient condi-
tions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1.
Makesurethattheenvironmentalandambientconditionsspeciedin
chapter " Technical data" are maintained.
Mounting options
Ambient conditions

10
5 Connecting to power supply
VEGATOR 112 •
46106-EN-210714
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
Warning:
Connect only in the complete absence of line voltage.
• Connect only in the complete absence of line voltage
• If overvoltage surges are expected, overvoltage arresters should
be installed
Note:
Install a disconnecting device for the instrument which is easy to
access.The disconnecting device must be marked for the instrument
(IEC/EN 61010).
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The voltage supply of VEGATOR 112 is connected with standard
cable according to the national installation standards.
The sensors are connected with standard two-wire cable without
shielding. If electromagnetic interference is expected which is above
the test values of EN 61326 for industrial areas, shielded cable should
be used.
Make sure that the cable used has the required temperature resist-
anceandresafetyformax.occurringambienttemperature
Connect the cable shielding on both ends to ground potential. In
the sensor, the shielding must be connected directly to the internal
ground terminal.The ground terminal on the outside of the sensor
housing must be connected to the potential equalisation (low imped-
ance).
If potential equalisation currents are expected, the connection on the
processing side must be made via a ceramic capacitor (e. g. 1 nF,
1500 V).The low-frequency potential equalisation currents are thus
suppressed,buttheprotectiveeectagainsthighfrequencyinterfer-
ence signals remains.
Take note of the corresponding installation regulations for Ex applica-
tions. In particular, make sure that no potential equalisation currents
owoverthecablescreen.Incaseofgroundingonbothsidesthis
can be achieved by the use of a capacitor or a separate potential
equalisation.
Safety instructions
Safety instructions
for Ex applications
Voltage supply
Connection cable
Cable screening and
grounding
Connection cable
for Ex applications

11
5 Connecting to power supply
VEGATOR 112 •
46106-EN-210714
5.2 Connection procedure
The pluggable terminals can be removed as needed to allow more
convenient connection. To make the electrical connection, proceed as
follows:
1. Mount the instrument as described in the previous chapter
2. Connect sensor cable 1 to terminal 1/2, and where applicable,
connect the shielding
3. Connect sensor cable 2 to terminal 4/5, and where applicable,
connect the shielding
4. Connectswitched-opowersupplytoterminal16/17
5. Connect relay 1 to terminal 10/11/12
6. Connect relay 2 to terminal 13/14/15
Theelectricalconnectionisnished.

12
5 Connecting to power supply
VEGATOR 112 •
46106-EN-210714
5.3 Wiring plan
1
2
5
3
4
10 11 12
13 14 15
-+
4 5
-+
1 2
-+
16 17
OPEN
1 Sensor circuit, channel 1 (1.2/2.1 mA), max. level with two-point control
2 Sensor circuit, channel 2 (1.2/2.1 mA), min. level with two-point control
3 Relay output channel 1
4 Relay output channel 2
5 Voltage supply
Information:
The connection terminals can be detached towards the front, if
necessary. This can be useful when working in tight spaces or when
exchanging an instrument.

13
6 Setup
VEGATOR 112 •
46106-EN-210714
6 Setup
6.1 Adjustment system
1
2
3
4
Fig. 1: Display and adjustment elements
1 Test key
2 DIL switch block
3 Signal lamps (LEDs)
4 Hinged front cover
6.2 Adjustment elements
Control lamps (LED) in the front plate indicate operation, switching
status and fault signal.
• Green
– Operating control lamp
– Mains voltage on, instrument is operating
• Red
– Fault indicator
– Fault on the sensor circuit due to sensor failure or line break
– The relay deenergises in case of failure
Control lamps

14
6 Setup
VEGATOR 112 •
46106-EN-210714
• Yellow
– Relay control lamp
– Lights with activated (current-carrying) relay status
The adjustment elements are located under a hinged front cover. To
open it, use a small screwdriver in conjunction with the slot on the
upper side of the front cover. To close it, push the cover at bottom and
toprmlyontothefrontcoveruntilyouhearthetworetainingclips
snap in.
The DIL switch block is located behind the front cover. The individual
switches are assigned as follows:
3
4
5
maxmin
1
2
maxmin
CH1CH2
Fig. 2: DIL switch VEGATOR 112
1 Mode (min./max. adjustment), channel 1
2 LinemonitoringO/On,channel1
3 Mode (min./max. adjustment), channel 2
4 LinemonitoringO/On,channel2
5 Two-pointcontrolOn/O
The requested operating mode is set with the min./max. switch (min.
detectioni.e.dryrunprotectionormax.detectioni.e.overllprotec-
tion)
• Dry run protection:Relayisswitchedowhenthelevelfalls
below the min. level (safe currentless state), relay is switched on
againwhenthemin.levelisexceeded(switch-onpoint>switch-o
point)
• Overowprotection:Relayisswitchedowhenthemax.levelis
exceeded (safe currentless state), relay is switched on again when
thelevelfallsbelowthemax.level(switch-onpoint<switch-o
point)
Note:
If the connected sensor has an own mode switch, then this switch
must be set to " Max.".
The following functionalities can be selected via this switch:
• Single point control (double channel level detection with one sen-
soreachandthesameswitchon/switchopoint)
• Two-pointcontrol(leveldetectionwithtwosensorsanddierent
switchon/switchopoints)
As opposed to single point control, two-point control allows the
switch-onandswitch-opointstobesetatdierentlocations(hyster-
esis). Through the installation or the distance of the two sensors, the
Front cover
DIL switch block
Mode (min./max. adjust-
ment)
Two-point control

15
6 Setup
VEGATOR 112 •
46106-EN-210714
hysteresiscanbedenedindividually.Here,themax.levelmustbe
set to sensor input 1, the min. level to sensor input 2.
Thetwo-pointcontrolisusedforexamplewhenllingandemptying
iscarriedoutviaapump.Thellingofavesselcanbeforexample
switchedonat10%andswitchedoagainat90%.Theoutputofthe
secondchannelbehavesidenticallyliketherstchannelprovidedthe
same mode is set. By changing the mode, the function of the relays
can be inverted.
When NAMUR level switches are connected, the line monitoring func-
tion can check the input continuously for line break or short-circuit. If
amechanicalswitch,e.g.aoatswitch,istobeconnected,theline
monitoring must be deactivated because only the switching condi-
tions "open" or "closed" can be delivered.
When level switches VEGAVIB/VEGAWAVE/VEGASWING in NAMUR
version are connected, a function test can be carried out.The test key
is recessed behind the front plate of the controller. Press the test key
for at least one second with a suitable object (screwdriver, pen, etc.).
Note:
Keep in mind that downstream connected devices are activated dur-
ing the function test.This allows you to check the correct function of
the complete measuring system.
Test procedure with VEGAVIB/VEGAWAVE
Pushing the test key interrupts the circuit to the sensor and triggers
a restart of the sensor. In the process, the conditions fault signal, full
alarm (< 1 mA) and empty alarm (> 2.2 mA) are simulated one after
the other. Check if a fault signal is triggered when you push the test
key (red LED lights). The red LED does not light up when line monitor-
ing is deactivated.
After the test key is released, the sensor is again supplied with
voltage.Duringthewarm-upphaseofthesensor,thecurrentbriey
increases,whichcanenergizetherelayandtheyellowLED.Thisis
not relevant for the test assessment.
Once the sensor is ready for operation, a full alarm is simulated for
approx. 3 s, the yellow LED does not light and the relay is deener-
gized.Forapositivetestassessment,thetimemustbebetween2s
and 4 s. ①
Finally, an empty alarm is simulated by the sensor for approx. 1.5 s.
TheyellowLEDlightsandtherelayisenergized.Forapositivetest
assessment, this time must be at least 1 s. ②
Thetestprocedureisnownished,LEDandrelayreturntotheactual
operating condition. ③
Line monitoring
Test key

16
6 Setup
VEGATOR 112 •
46106-EN-210714
> 2,2
I/mA
< 1
3 ±1 t/s
1 2 3
1,5 ±0,5
Fig. 3: Flow chart function test
1 Simulation full alarm
2 Simulation empty alarm
3 Current measurement status
Test process with VEGASWING
Pressing the test button interrupts the circuit to the sensor and
thereby initiates a restart of the sensor. This only simulates a fault
signal. Check whether the fault signal occurs when the test button is
pressed (red LED lights up). If the line monitoring is deactivated, the
red LED does not light up.
After releasing the test button, the sensor is supplied with voltage
again. After that, if the function is correct, the red fault LED must no
longer light up and the relays are energised or de-energised depend-
ing on the state of the sensor.
Information:
This test is accepted as proof test acc. to WHG.
6.3 Function table "Point level"
The following table provides an overview of the switching conditions
depending on the set mode and the level.
Note:
The switching conditions in the tables are only valid if the mode
switch on the sensor is set to " Max.".
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
> 2.1 mA ON
Overllprotection,point
level

17
6 Setup
VEGATOR 112 •
46106-EN-210714
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
< 1.2 mA OFF
any < 0.35 mA
> 6.8 mA OFF
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
< 1.2 mA ON
> 2.1 mA OFF
any < 0.35 mA
> 6.8 mA OFF
6.4 Function table, two-point control
The following charts provide an overview of the switching conditions
depending on the set mode and the level.
Note:
The switching conditions in the tables are only valid if the mode
switch on the sensor is set to " Max.".
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
> 2.1 mA
> 2.1 mA
ON
Dry run protection, point
level
Overllprotection,two-
point control

18
6 Setup
VEGATOR 112 •
46106-EN-210714
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
> 2.1 mA
< 1.2 mA
ON
< 1.2 mA
< 1.2 mA
OFF
> 2.1 mA
< 1.2 mA
OFF
> 2.1 mA
> 2.1 mA
ON
any < 0.35 mA
> 6.8 mA OFF
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
> 2.1 mA
> 2.1 mA
OFF
> 2.1 mA
< 1.2 mA
OFF
< 1.2 mA
< 1.2 mA
ON
> 2.1 mA
< 1.2 mA
ON
> 2.1 mA
> 2.1 mA
OFF
Dru run protection, two-
point control

19
6 Setup
VEGATOR 112 •
46106-EN-210714
Sensor Controller
Level Sensor cur-
rent
LED yellow
(output)
LED red
(fault)
Relay
any < 0.35 mA
> 6.8 mA OFF

20
7 Diagnostics and servicing
VEGATOR 112 •
46106-EN-210714
7 Diagnostics and servicing
7.1 Maintenance
If the device is used properly, no special maintenance is required in
normal operation.
The cleaning helps that the type label and markings on the instrument
are visible.
Take note of the following:
• Use only cleaning agents which do not corrode the housings, type
label and seals
• Use only cleaning methods corresponding to the housing protec-
tion rating
7.2 Rectify faults
The operator of the system is responsible for taking suitable meas-
ures to rectify faults.
Thedeviceoersmaximumreliability.Nevertheless,faultscanoccur
during operation.These may be caused by the following, e.g.:
• Measured value from sensor not correct
• Voltage supply
• Interference in the cables
Therstmeasuretobetakenistochecktheinputandoutputsignals.
The procedure is described as follows. In many cases the causes can
bedeterminedthiswayandfaultscanbeeasilyrectied.
Depending on the reason for the fault and the measures taken, the
steps described in chapter " Setup" must be carried out again or must
be checked for plausibility and completeness.
Should these measures not be successful, please call in urgent cases
the VEGA service hotline under the phone no. [phone].
The hotline is also available outside normal working hours, seven
days a week around the clock.
Sinceweoerthisserviceworldwide,thesupportisprovidedin
English.The service itself is free of charge, the only costs involved are
the normal call charges.
7.3 Diagnosis, fault messages
The controller and the connected sensors are permanently monitored
during operation. If irregularities occur, a fault signal is triggered. In
the event of a failure, the fault indication lights up and the relays are
de-energized(safestate).
Maintenance
Cleaning
Reaction when malfunc-
tion occurs
Causes of malfunction
Faultrectication
Reaction after fault recti-
cation
24 hour service hotline
Fault signal