Vega POINTRAC 31 User manual

Operating Instructions
POINTRAC 31
8/16 mA/HART -four-wire
Document ID:
39411
Radiation-based

Contents
1About this document
1.1Function.................................. 4
1.2Target group .............................. 4
1.3Symbolism used............................ 4
2For your safety
2.1Authorised personnel ........................ 5
2.2Appropriate use ............................ 5
2.3Warning about misuse ....................... 5
2.4General safety instructions .................... 5
2.5CE conformity ............................. 6
2.6Fulfillment of NAMUR recommendations .......... 6
2.7Environmental instructions..................... 6
3Product description
3.1Structure ................................. 7
3.2Principle of operation ........................ 8
3.3Packaging,transport and storage ............... 8
3.4Accessories and replacement parts .............. 9
3.5Corresponding source container ................ 10
4Mounting
4.1General instructions ......................... 12
4.2Mounting instructions ........................ 12
5Connecting to power supply
5.1Preparing the connection ..................... 16
5.2Connection................................ 19
6Set up with the indicating and adjustment module
6.1Insert indicating and adjustment module........... 22
6.2Adjustment system .......................... 23
6.3Parameter adjustment........................ 24
6.4Saving the parameter adjustment data ............ 33
7Setup with PACTware
7.1Connecting the PC .......................... 35
7.2Parameter adjustment with PACTware ............ 36
7.3Saving the parameter adjustment data ............ 38
8Set up with other systems
8.1DD adjustment programs ..................... 39
8.2Communicator 375,475 ...................... 39
9Diagnosis and service
9.1Maintenance .............................. 40
9.2Status messages ........................... 40
9.3Fault rectification ........................... 44
2POINTRAC 31 •8/16 mA/HART -four-wire
Contents
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9.4Exchanging the electronics module .............. 45
9.5Software update ............................ 45
9.6How to proceed in case of repair................ 46
10 Dismounting
10.1Dismounting steps .......................... 48
10.2Disposal ................................. 48
11 Supplement
11.1Technical data ............................. 49
11.2Dimensions ............................... 54
Safety 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.
Information:
Editing status:2011-04-19
POINTRAC 31 •8/16 mA/HART-four-wire 3
Contents
39411-EN-110525

1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity 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 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.
Exapplications
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.
4POINTRAC 31 •8/16 mA/HART -four-wire
1About this document
39411-EN-110525

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 plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
The POINTRAC 31 is a sensor for level detection.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
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 state-of-the-art instrument complying with all prevailing
regulations and guidelines.The instrument must only be operated in a
technically flawless 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
regulations.
The safety instructions in this operating instructions manual,the
national 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.Arbitrary
conversions or modifications are explicitly forbidden.
The safety approval markings and safety tips on the device must also
be observed.
POINTRAC 31 •8/16 mA/HART-four-wire 5
2For your safety
39411-EN-110525

2.5CEconformity
The device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,VEGA provides a confirmation
of successful testing.You can find the CE conformity declaration in the
download area of www.vega.com.
2.6Fulfillment of NAMUR recommendations
The device fulfills the requirements of the applicable NAMUR
recommendations.
2.7Environmental 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 management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
6POINTRAC 31 •8/16 mA/HART -four-wire
2For your safety
39411-EN-110525

3Product description
3.1Structure
The type label contains the most important data for identification and
use of the instrument:
2
1
9
10
4
5
3
6
7
8
9
Fig.1:Structure of the type label (example)
1Instrument type
2Product code
3Electronics
4Protection rating
5Process and ambient temperature,process pressure
6Instrument length
7Hardware and software version
8Order number
9Serial number of the instrument
10 ID numbers,instrument documentation
The serial number on the type label of the instrument allows you to call
up the order data,operating instructions manuals,sensor data for the
service DTM as well as the test certificate (depending on the
instrument). To do this,open under www.vega.com,"VEGA Tools"and
"serial number search".
This operating instructions manual applies to the following instrument
versions:
lHardware from 1.0.3
lSoftware from 1.1.0
lModification status electronics from -01
The instrument is available in different electronics versions.Each
version can be identified via the product code on the type label as well
as on the electronics:
lStandard electronics type PROTRACH.-XX
Type label
Serial number
Scope of the operating
instructions manual
Electronics versions
POINTRAC 31 •8/16 mA/HART-four-wire 7
3Product description
39411-EN-110525

The scope of delivery encompasses:
lRadiation-based point level sensor
lMounting accessory
lDocumentation
-this operating instructions manual
-Safety Manual (SIL)POINTRAC 31 (optional)
-Operating instructions manual "Indicating and adjustment
module"(optional)
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
3.2Principle of operation
The instrument is suitable for applications in liquids and bulk solids in
vessels under difficult process conditions.There are application
possibilities in nearly all areas of industry.
The limit level is detected contactlessly through the vessel wall.
Neither a process fitting nor a vessel opening is required.The
instrument is thus ideal for retrofitting.
Aweak radioactive source emits gamma rays that are attenuated
when penetrating the vessel wall and medium.The PVT rod detector
on the opposite side of the tank receives the radiation.When the
intensity of the radiation drops below a defined value,e.g.due to
damping,then the POINTRAC 31 switches.The measuring principle
has proven itself well under extreme conditions because it measures
contactlessly from outside through the vessel wall.The measuring
system ensures maximum safety,reliability and plant availability
independent of the medium and its properties.
3.3Packaging,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 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 under 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
concealed defects must be appropriately dealt with.
Scope of delivery
Application area
Functional principle
Packaging
Transport
Transport inspection
8POINTRAC 31 •8/16 mA/HART -four-wire
3Product description
39411-EN-110525

Upto 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:
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 chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
3.4Accessories and replacement parts
The indicating and adjustment module PLICSCOM is used for
measured value indication,adjustment and diagnosis.It can be
inserted into the sensor and removed at any time.
You can find further information in the operating instructions "Indicating
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
parameter adjustment of these instruments,an adjustment software
such as PACTware with VEGA-DTM is required.
You can find further information in the operating instructions "Interface
adapter VEGACONNECT"(Document-ID 32628).
VEGADIS 61 is an external indicating and adjustment unit for sensors
with single chamber housing and double chamber housing Ex d.
It is suitable for measured value indication and adjustment of plics®
sensors and is connected to the sensor with a four-wire,screened
standard cable up to 50 m long.
You can find further information in the operating instructions
"VEGADIS 61"(Document-ID 27720).
The VEGADIS 62 is suitable for measured value indication of sensors.
It is looped into the 4…20 mA/HART signal cable.
You can find further information in the operating instructions
"VEGADIS 62"(Document-ID 36469).
Storage
Storage and transport
temperature
Indicating and adjust-
ment module
Interface adapter
External indicating and
adjustment unit
External indicating unit
POINTRAC 31 •8/16 mA/HART-four-wire 9
3Product description
39411-EN-110525

ThePLICSMOBILE T61 is an external GSM/GPRS radio unit for
transmission of measured values and for remote parameter adjust-
ment of plics®sensors.The adjustment is carried out via PACTware/
DTM by using the integrated USB connection.
You can find further information in the supplementary instructions
"PLICSMOBILE T61"(Document-ID 36849).
The electronics module PROTRACH series 30 is a replacement part
for radiation-based point level sensors POINTRAC 31.
You can find further information in the operating instructions
"Electronics module POINTRAC"(Document-ID 40106).
3.5Corresponding source container
For operation of a radiation-based measurement,a radiating isotope in
a suitable source container is required.
The handling of radioactive material is regulated by law.The radiation
protection rules of the country in which the system is operated are
relevant for operation.
InGermany,for example,the current radiation protection ordinance
(StrlSchV)based on the Atomic Energy Law (AtG)applies.
The following points are important for measurement with radiation-
based methods:
Ahandling permit is required for operation of a system using gamma
rays.This permit is issued by the respective government office or the
responsible authority (in Germany,for example,offices for environ-
mental protection,trade supervisory boards,etc.)
You can find further instructions in the operating instructions manual of
the source container.
External radio unit
Electronics module
Handling permit
10 POINTRAC 31 •8/16 mA/HART -four-wire
3Product description
39411-EN-110525

When handling radioactive sources,unnecessary radiation exposure
must be avoided.An unavoidable radiation exposure must be kept as
low as possible.Take note of the following three important measures:
1 2 3
Fig.2:Measures for protection against radioactive radiation
1Shielding
2Time
3Distance
Shielding -Provide good shielding between the radioactive source
and yourself as well as all other persons.Special source containers (e.
g.VEGASOURCE)as well as all materials with high density (e.g.lead,
iron,concrete,etc.) provide effective shielding.
Time -Stay as short a time as possible in radiation exposed areas.
Source -Your distance to the source should be as large as possible.
The local dose rate of the radiation decreases in proportion to the
square of the distance to the radiation source.
The plant operator must appoint a radiation safety officer with the
necessary expert knowledge.He is responsible that the radiation
protection ordinance is maintained and that all radiation protection
measures are implemented.
Control areas are areas in which the local dose rate exceeds a certain
value.Only persons who undergo official dose monitoring are allowed
into these control areas.You can find the respectively valid limit values
for control areas in the guideline of the respective authority (in
Germany,for example,the radiation protection ordinance).
We are at your disposal for further information concerning radiation
protection and regulations in other countries.
General instructions for
radiation protection
Radiation safety officer
Control area
POINTRAC 31 •8/16 mA/HART-four-wire 11
3Product description
39411-EN-110525

4Mounting
4.1General instructions
The source container is part of the measuring system.In case the
source container is already equipped with an active isotope,the
source container must be locked before mounting.
Danger:
Before mounting make sure that the source is reliably switched off.
Protect the switched offcondition of the source container with a
padlock against unintended switching on again.
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 off.This
applies 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.
Make sure that all parts of the instrument exposed to the process,in
particular the active measuring component,process seal and process
fitting,are suitable for the existing process conditions.These include
above all the process pressure,process temperature as well as the
chemical properties of the medium.
You can find the specifications in chapter "Technical data"or on the
type label.
In the case of instrument housings with self-sealing NPT threads,it is
not possible to have the cable glands screwed in at the factory.The
openings of the cable glands are therefore closed with red protection
caps as transport protection.
Prior to setup you have to replace these protective caps with approved
cable glands or close the openings with suitable blind plugs.
The suitable cable glands and blind plugs come with the instrument.
4.2Mounting instructions
Note:
Along with the planning,your specialists will analyse the conditions of
the measurement loop to dimension the source (isotope)respectively.
Switch offsource
Moisture
Suitability for the pro-
cess conditions
Protective caps
Mounting position
12 POINTRAC 31 •8/16 mA/HART -four-wire
4Mounting
39411-EN-110525

You will get a "Source Sizing"document with the required isotope
strength and all relevant mounting information for your measurement
loop.
In addition to the following mounting information,you have to follow the
instructions of this "Source Sizing"document.
The following mounting information is applicable as long as there is
nothing else specified in the "Source Sizing"document.
2
1
Fig.3:Mounting position -level detection
1Vertical mounting
2Mounting horizontally,across the level
You can find information on protective fences and the mounting of the
corresponding source container in the operating instructions manual of
the source container,for example,VEGASOURCE.
For level detection,the sensor is generally mounted horizontally at the
height of the requested limit level.Make sure that there are no struts or
reinforcements at this position in the vessel.
Direct the exit beam of the source container exactly towards the
measuring range of POINTRAC 31.
Fasten the sensors in such a way that they cannot fall out of the holder.
If necessary,provide the sensor with a support to the bottom.
Mount the source container and POINTRAC 31 as close as possible to
the vessel.If there are gaps,secure the area with a safety fence and
protective grating so that no one can reach into the dangerous area.
POINTRAC 31 •8/16 mA/HART-four-wire 13
4Mounting
39411-EN-110525

Level detection -max.detection
The POINTRAC 31 is suitable for level detection in liquids or bulk
solids.It is mounted at the height of the requested switching point.
Fig.4:POINTRAC 31 as max.level detection (uncovered)
Level detection -min.detection
Fig.5:POINTRAC 31 as min.level detection (covered)
Sensor orientation
Bulk solids with low
density
14 POINTRAC 31 •8/16 mA/HART -four-wire
4Mounting
39411-EN-110525

Fig.6:POINTRAC 31 as level detection (top view)
POINTRAC 31 lends itself well for level detection of bulk solids with
low density.Mount the instrument horizontally at the height of the
requested switching point.
Mount the source container VEGASOURCE displaced by 90°in order
to get the widest possible radiation angle.
When the sensor is covered by the medium,the radiation damping is
considerably stronger -hence,the switching point is all the more
reliable.
If the max.ambient temperature is exceeded,you have to take suitable
measures to protect the instrument against overheating.
You can protect the instrument by a respective insulation against the
heat or mount the instrument further away from the heat source.
Make sure that these measures are also taken into account for the
planning.If you want to carry out such measures later on,you have to
contact our specialists so that the accuracy of the application is not
impaired.
In case theses measures are not sufficient to keep the max.ambient
temperature,we offer a water cooling for the POINTRAC 31.
The water cooling must also be included in the calculation of the
measurement loop.Contact our specialists regarding the dimensioning
of the water cooling.
Protection against heat
POINTRAC 31 •8/16 mA/HART-four-wire 15
4Mounting
39411-EN-110525

5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,install overvoltage arresters
Supply voltage and current output are carried on separate two-wire
connection cables if reliable separation is required.The supply voltage
range can differ depending on the instrument version.
The data for power supply are specified in chapter "Technical data".
This instrument is designed in protection class I.To maintain this
protection class,it is absolutely necessary that the ground conductor
be connected to the internal ground terminal.Take note of the general
installation regulations.
Always connect the instrument to vessel ground (potential equal-
isation)or in case of plastic vessels to the next ground potential.For
this purpose there is a ground terminal on the side of the instrument
housing.
For power supply,an approved installation cable with PE conductor is
necessary.
The 8/16 mAcurrent output is connected with standard two-wire cable
without screen.If electromagnetic interference is expected which is
above the test values of EN 61326 for industrial areas,screened cable
should be used.
Use cable with round cross-section.Acable outer diameter of
6…12 mm (0.24 …0.47 in)ensures the seal effect of the cable gland.
If you are using cable with a different diameter or cross-section,
exchange the seal or use a suitable cable gland.
With plastic housing,the NPT cable gland or the Conduit steel tube
must be screwed without grease into the threaded insert.
Max.torque for all housings see chapter "Technical data"
In the case of instrument housings with self-sealing NPT threads,it is
generally not possible to have the cable glands screwed in at the
factory.The openings for the cable glands are therefore covered with
red protective caps as transport protection.
You have to replace these protective caps before setup by approved
cable glands or cover them with suitable blind covers.
The suitable cable glands and blind covers are attached to the
instrument.
Safety instructions
Voltage supply
Select connection cable
Cable gland ½NPT
16 POINTRAC 31 •8/16 mA/HART -four-wire
5Connecting to power supply
39411-EN-110525

Ifscreened cable is necessary,connect the cable screen on both ends
to ground potential.In the sensor,the screen must be connected
directly to the internal ground terminal.The ground terminal on the
outside of the housing must be connected to the potential equalisation
(low impedance).
If potential equalisation currents are expected,the connection on the
processing side must be made via a ceramic capacitor (e.g.1nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed,but the protective effect against high frequency interfer-
ence signals remains.
Warning:
Within galvanic plants as well as vessels with cathodic corrosion
protection there are considerable potential differences.Considerable
equalisation currents can be caused via the cable screen when the
screen is earthed on both ends.
To avoid this,the cable screen must only be connected to ground
potential on one side of the switching cabinet in such applications.The
cable screen must not be connected to the internal ground terminal in
the sensor and the outer ground terminal on the housing not to the
potential equalisation!
Information:
The metal parts of the instrument are conductive connected with the
inner and outer ground terminal on the housing.This connection exists
either directly metallic or with instruments with external electronics via
the screen of the special connection cable.
You can find specifications to the potential connections within the
instrument in chapter "Technical data".
The connection of the voltage supply and the signal output is carried
out via the spring-loaded terminals in the housing.
The connection to the indicating and adjustment module or to the
interface adapter is carried out via contact pins in the housing.
Proceed as follows:
The procedure applies to instruments without explosion protection.
1Unscrew the big housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)of insulation from the ends of the individual wires
Cable screening and
grounding
Connection technology
Connection procedure
POINTRAC 31 •8/16 mA/HART-four-wire 17
5Connecting to power supply
39411-EN-110525

4Insert the cable into the sensor through the cable entry
1
Fig.7:Connection steps 4and 5
1Locking of the terminal blocks
5Insert a small slotted screwdriver firmly into the rectangular locking
openings of the respective connection terminal
6Insert the wire ends into the round openings of the terminals
according to the wiring plan
Information:
Solid cores as well as flexible cores with cable end sleeves are
inserted directly into the terminal openings.In case of flexible cores
without end sleeves,press the rectangular locking opening with a
small screwdriver;the terminal opening is freed.When the screwdriver
is released,the terminal opening closes again.
7Check the hold of the wires in the terminals by lightly pulling on
them
To loosen a line,insert a small slotted screwdriver firmly into the
rectangular locking opening according to the illustration
8Connect the screen to the internal ground terminal,connect the
outer ground terminal to potential equalisation
9Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
10 Screw the housing cover on
18 POINTRAC 31 •8/16 mA/HART -four-wire
5Connecting to power supply
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The electrical connection is finished.
Information:
The terminal block are pluggable and can be detached from the
electronics.For this purpose loosen the two lateral locking levers of
the terminal block with a small screwdriver.When loosening the
locking,the terminal block is automatically squeezed out.It must snap
in when inserting it again.
5.2Connection
Non-Ex instruments and instruments with pressure-tight encap-
sulation (Ex-d approval)
1
1
2 4
/L
/N
PE
5 6 9 10 11
22
11
12
2122 1920 18 17 14 1316 15 12
2
7
3
1
45
6
8
9
10
Fig.8:Electronics and connection compartment with non-Ex instruments and
instruments with Ex-d approval
1Voltage supply
2Relay output
3Signal output 8/16 mA/HART active
4Signal output 8/16 mA/HART Multidrop passive
5Signal input 4…20 mA
6Switching input for NPN transistor
7Switching input floating
8Transistor output
9Interface for sensor-sensor communication
10 Adjustment of bus address for sensor-sensor communication (MGC)1)
1)MGC =Multi Gauge Connection
Electronics and
connection
compartment -
Non-Ex instru-
ments,Ex-d ap-
proval
POINTRAC 31 •8/16 mA/HART-four-wire 19
5Connecting to power supply
39411-EN-110525

1
2
5 6 7 8
Fig.9:Adjustment and connection compartment with non-Ex instruments and
instruments with Ex-d approval
1Terminals for the external indicating and adjustment unit
2Contact pins for the indicating and adjustment module or interface adapter
Instruments with intrinsically safe current output (Ex-ia appro-
val)
You can find detailed information of the explosion-protected versions
(Ex-ia,Ex-d)in the Ex specific safety instructions.These safety
instructions are part of the scope of delivery and come with the Ex-
approved instruments.
Adjustment and connec-
tion compartment -Non-
Ex instruments,Ex-d
approval
20 POINTRAC 31 •8/16 mA/HART -four-wire
5Connecting to power supply
39411-EN-110525