Vega VEGAPULS 68 User manual

Operating Instructions
VEGAPULS 68
Foundation Fieldbus
Radar

Content
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
2.5Safety approval markings and safety tips . . . . . 6
2.6CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7Fulfilling NAMUR recommendations . . . . . . . . . 6
2.8FCC and IC conformity (only for USA/Canada) . 7
2.9Safety instructions for Ex areas . . . . . . . . . . . . 7
2.10 Manufacturer declaration . . . . . . . . . . . . . . . . . 7
2.11 Functional range of approved instruments . . . . . 8
2.12 Environmental instructions . . . . . . . . . . . . . . . . 8
3Product description
3.1Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2Principle of operation. . . . . . . . . . . . . . . . . . . . 10
3.3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4Packaging,transport and storage . . . . . . . . . . . 12
4Mounting
4.1General instructions. . . . . . . . . . . . . . . . . . . . . 13
4.2Mounting preparations -Horn antenna . . . . . . . 14
4.3Mounting preparations -Parabolic antenna . . . . 15
4.4Mounting instructions. . . . . . . . . . . . . . . . . . . . 17
5Connecting to power supply
5.1Preparing the connection . . . . . . . . . . . . . . . . . 26
5.2Connection steps -Instrument housing . . . . . . . 27
5.3Wiring plan,single chamber housing. . . . . . . . . 28
5.4Wiring plan,double chamber housing . . . . . . . . 30
5.5Wiring plan,double chamber housing Exd. . . . . 32
5.6Wiring plan -version IP 66/IP 68,1bar. . . . . . . 34
5.7Switch on phase . . . . . . . . . . . . . . . . . . . . . . . 34
6Set up with the indicating and adjustment module
PLICSCOM
6.1Short description . . . . . . . . . . . . . . . . . . . . . . . 35
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Content
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6.2Insert indicating and adjustment module . . . . . . 35
6.3Adjustment system . . . . . . . . . . . . . . . . . . . . . 37
6.4Setup procedure . . . . . . . . . . . . . . . . . . . . . . . 38
6.5Menu schematic . . . . . . . . . . . . . . . . . . . . . . . 44
6.6Saving the parameter adjustment data . . . . . . . 46
7Setup with PACTware™and other adjustment
programs
7.1Connecting the PC . . . . . . . . . . . . . . . . . . . . . 47
7.2Parameter adjustment with PACTware™. . . . . . 47
7.3Parameter adjustment with AMS™. . . . . . . . . . 48
7.4Saving the parameter adjustment data . . . . . . . 48
8Maintenance and fault rectification
8.1Maintenance,cleaning . . . . . . . . . . . . . . . . . . . 49
8.2Remove interferences . . . . . . . . . . . . . . . . . . . 49
8.3Exchange of the electronics module . . . . . . . . . 51
8.4Instrument repair . . . . . . . . . . . . . . . . . . . . . . . 52
9Dismounting
9.1Dismounting steps . . . . . . . . . . . . . . . . . . . . . . 53
9.2Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10 Supplement
10.1Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 54
10.2Foundation Fieldbus . . . . . . . . . . . . . . . . . . . . 63
10.3Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version
come with the delivery.You can find them listed in chapter
"Product description".
Instructions manuals for accessories and replacement parts
Tip:
l27835 -Indicating and adjustment module PLICSCOM
l25641 -Interface adapter VEGACONNECT 3
l32628 -Interface adapter VEGACONNECT 4
l31088 -Flanges according to DIN-EN-ASME-JIS
l30176 -Electronics module VEGAPULS series 60
l31381 -Antenna impedance cone VEGAPULS 62 and 68
VEGAPULS 68 -Foundation Fieldbus 3
Content
29264-EN-071112

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 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.
4VEGAPULS 68 -Foundation Fieldbus
About this document
29264-EN-071112

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
VEGAPULS 68 is a sensor for continuous level measurement.
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.
Due to 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.
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
VEGAPULS 68 is a high-tech instrument requiring the strict
observance of standard regulations and guidelines.Depending
on the instrument version,the emitting frequencies of all radar
sensors are in the Cor K-band range.The low emitted powers
are far below the internationally approved limit values,if used
correctly,no health problems should be expected.The
instrument can be also used outside metallic closed verssels.
The user must take note of the safety instructions in this
operating instructions manual,the country-specific installation
standards as well as all prevailing safety regulations and
accident prevention rules.
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2.5Safety approval markings and safety tips
The safety approval markings and safety tips on the device
must be observed.
2.6CE conformity
VEGAPULS 68 is in CE conformity with EMC (89/336/EWG)
and LVD (73/23/EWG).
Conformity has been judged according to the following
standards:
lEMC:
-Emission EN 61326:1997 (class B)
-Susceptibility EN 61326:1997/A1:1998
lR&TTE directive:I-ETS 300-440 Expert Opinion No.
05-111723,Notified Body No.0700
lLVD:EN 61010-1:2001
2.7Fulfilling NAMUR recommendations
With regard to interference resistance and interference
emission,VEGAPULS 68 fulfils NAMUR recommendation
NE 21.
VEGAPULS 68 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 VEGAPULS 68 HART,PA or FF
lDTM VEGAPULS 68 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 VEGAPULS 68 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.
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2.8FCC and IC conformity (only for USA/Canada)
VEGAPULS sensors with all antenna versions are FCC and IC
approved:
lFCC ID:O6QPULS68
lIC:3892A-PS68
Modifications not expressly approved by VEGA will lead to
expiry of the operating licence according to FCC.
VEGAPULS 68 is in conformity with part 15 of the FCC
regulations.Take note of the respective operating regulations:
lThe instrument must not cause any interfering emissions
lThe instrument must be insensitive to interfering emis-
sions,also to such that may cause unwanted operating
conditions.
2.9Safety 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.
2.10 Manufacturer declaration
In conformity with DIN EN 60079-14/2004,para.5.2.3,point
c1,VEGAPULS 68 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 (24636)
lthe valid installation regulations
Max.increase of the surface temperature during operation:
15 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 85 °C(185 °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"
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lMount and operate the instrument in such a way that no
danger of ignition from electrostatic charges is to be
expected.The antenna,the process fitting or the 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.
2.11 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.
2.12 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:
lVEGAPULS 68 radar sensor
lDocumentation
-this operating instructions manual
-Operating instructions manual -27835 "Indicating and
adjustment module PLICSCOM"(optional)
-Supplementary instructions manual -31708 "Heating
for indicating and adjustment module"(optional)
-Supplementary instructions manual "Plug connector for
continuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGAPULS 68 consists of the following components:
lHorn or parabolic antenna
lprocess fitting (depending on the version flange or thread)
lOptionally available with swivelling holder (only with
flange), rinsing air connection,reflux valve
lHousing with electronics,optionally available with plug
connector,optionally available with connection cable
lHousing cover,optionally available with indicating and
adjustment module PLICSCOM
The components are available in different versions.
Scope of delivery
Components
VEGAPULS 68 -Foundation Fieldbus 9
Product description
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1
2
3
4
Fig.1:VEGAPULS 68 with horn antenna and swivelling holder
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics
3Swivelling holder with flange
4Horn antenna
3.2Principle of operation
VEGAPULS 68 is a radar sensor in K-band technology for
continuous level measurement in solids.
Aversion of VEGAPULS 68 is available for each area of
application:
lThe version with horn antenna is particularly suitable for
measurement of virtually all bulk solids in small silos and
vessels.
lThe version with parabolic antenna is particularly suitable
for large silos and vessels with up to 70 m(76 yd)
measuring distance and for measurement of solids with low
dielectric constant.
VEGAPULS 68 is also suitable for applications in liquids.
The antenna of the radar sensor emits short radar pulses with
a duration of approx.1ns.These pulses are reflected by the
product and received by the antenna as echoes.The running
time of the radar pulses from emission to reception is
Area of application
Functional principle
10 VEGAPULS 68 -Foundation Fieldbus
Product description
29264-EN-071112

proportional to the distance and hence to the level.The
determined level is converted into an appropriate output signal
and outputted as measured value.
Power is supplied via the H1Fieldbus.Atwo-wire cable
according to Fieldbus specification serves as carrier of both
power and digital data transmission for multiple sensors.This
cable can be operated in two versions:
lvia an H1interface card in the control system and
additional power supply
lvia a linking device with HSE (High speed Ethernet)and
additional voltage supply according to IEC 61158-2
The DD (Device Descriptions)and CFF (capability files)
necessary for planning and configuration of your FF (Founda-
tion Fieldbus)communication network are available in the
download area of the VEGA homepage www.vega.com under
"Services -Downloads -Software -Foundation Fieldbus".The
appropriate certificates are also available there.A CD with the
appropriate files and certificates can be ordered via e-mail
under [e-mail] or by phone from one of the VEGA
agencies under the order number "DRIVER.S".
The backlight of the indicating and adjustment module is
powered by the sensor.Prerequisite is a certain level of supply
voltage.
The data for voltage supply are specified in chapter "Technical
data".
This function is available for instruments with national
approvals such as e.g.according to CSA only at a later date.
The optional heating requires its own power supply.You can
find detailed information in the supplementary instructions
manual "Heating for indicating and adjustment module".This
function is generally not available for approved instruments.
3.3Operation
VEGAPULS 68 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
Power supply and bus com-
munication
DD/CFF
VEGAPULS 68 -Foundation Fieldbus 11
Product description
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la configuration tool
The entered parameters are generally saved in VEGAPULS
68,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 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 "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Transport
Transport inspection
Storage
Storage and transport tem-
perature
12 VEGAPULS 68 -Foundation Fieldbus
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4Mounting
4.1General instructions
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°).
Warning:
With threaded versions,the housing must not be used to screw
in the instrument!Applying tightening forces on the housing
can damage its internal parts.
Use the recommended cables (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your VEGAPULS 68 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 outdoor mounting,
areas where high humidity is expected (e.g.from cleaning
processes)or cooled or heated vessels.
Fig.2:Measures against moisture penetration
The reference plane for the measuring range of the sensors is
the lower edge of the flange or the seal surface of the thread.
Installation position
Screwing in
Moisture
Measuring range
VEGAPULS 68 -Foundation Fieldbus 13
Mounting
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1 32
100%
0%
4
Fig.3:Measuring range (operating range), max.measuring distance and
reference plane
1full
2empty (max.measuring distance)
3Measuring range
4Reference plane
Information:
If the medium reaches the antenna,buildup can form on it and
cause faulty measurements later on.
Make sure that the wetted parts of the instrument,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".
4.2Mounting preparations -Horn antenna
Information:
This information applies only to special versions!
VEGAPULS 68 is also available in versions where the antenna
has a bigger diameter than the process fitting (thread,flange).
The antenna must therefore be disconnected from the process
fitting before mounting.Proceed as follows:
1Loosen the hexagon screws (3)on the antenna socket with
an Allan key (size 3)
2Remove the antenna (4)
Materials,wetted parts
14 VEGAPULS 68 -Foundation Fieldbus
Mounting
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Note:
The plastic conemust not be pulled out of the antenna socket.
3Insert the antenna from below into the vessel socket and
secure it against falling off
4Retighten the antenna with hexagon screws to the antenna
socket;torque max.10 Nm(7.5lbf ft)
Note:
VEGAPULS 68 with rinsing air connection or antenna
extension is provided with a notch on the antenna socket.This
notch must correspond to the marking on the hexagon of the
process fitting (the marking specifies the position of the
polarisation level of the radar signal).
3
4
1
2
Fig.4:Dismounting horn antenna
1Marking
2Notch
3Hexagon screws on the antenna socket
4Antenna
4.3Mounting preparations -Parabolic antenna
Information:
This information applies only to special versions!
Der VEGAPULS 68 is also available in versions where the
antenna has a bigger diameter than the process fitting (thread,
flange). The antenna must therefore be disconnected from the
flange before mounting.Proceed as follows:
VEGAPULS 68 -Foundation Fieldbus 15
Mounting
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1Clamp VEGAPULS 68 with flange,e.g.in a bench vice
2Hold the connection piece (3)with a wrench SW 22 on the
flattenings
3Unscrew the locknut (2)with SW 36 against the antenna
4Loosen compression nut (1)with a screwdriver SW 41
completely in the direction of the antenna
5Remove the parabolic antenna (4)axially
6Mount sensor flange to the adapter flange and clamp it
7Check,if the O-ring seal is available on the adapter and if it
is not damaged.
Note:
Adamaged O-ring seal must be replaced:FKM (Viton)article
no.2.28248,Kalrez 6375 article no.2.27351
8Remount the parabolic antenna (4)
9Tighten compression nut (3)with SW 41,torque max.
50 Nm
10 Tighten locknut (2)with SW 36,torque max.40 Nm.
Note:
Take note for VEGAPULS 68 with rinsing air connection that
the holes in the antenna and in the process fitting correspond.
This ensures a sufficient air flow (the air is led through the
holes to the feed system.Arinsing of the parabolic antenna in
total is not intended).
1
2
3
4
Fig.5:Dismounting,parabolic antenna
1Compression nut
2Locknut
3Connection piece
4Parabolic antenna
16 VEGAPULS 68 -Foundation Fieldbus
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4.4Mounting instructions
The illustrations to the following mounting instructions show
VEGAPULS 68 with horn antenna.The mounting instructions
apply analogously also to VEGAPULS 68 with parabolic
antenna.
Mount the sensor at least 200 mm (7.874 in)away from the
vessel wall.
12
Fig.6:Installation position
1Reference plane
If you cannot keep this distance you should carry out a false
echo storage before setup.This applies mainly if buildup on
the vessel wall is expected.In this case,we recommend
repeating a false echo storage later with existing buildup.
To measure as much of the vessel volume as possible,the
sensor should be aligned so that the measuring beam reaches
the lowest level in the vessel.In a cylindrical silo with conical
outlet,the easiest way is to mount the instrument in the center
of the silo.
Horn and parabolic antenna
Installation position
Orientation
VEGAPULS 68 -Foundation Fieldbus 17
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Fig.7:Orientation
If mounting in the center of the silo is not possible,the sensor
can be directed to the vessel center by means of an optional
swivelling holder.The following description gives an overview
on the determination of the necessary angle of inclination.
18 VEGAPULS 68 -Foundation Fieldbus
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d
a
α
Fig.8:Proposal for installation after orientation VEGAPULS 68
The angle of inclination depends on the vessel dimensions.It
can be checked easily on the sensor with a suitable level or
air-lever.The following chart states the distance "a"between
installation position and vessel center depending on the
measuring distance for an angle of inclination of 2°…10°.
Distance
d(m)
2°4°6°8°10°
2 0.1 0.1 0.2 0.3 0.4
4 0.1 0.3 0.4 0.6 0.7
6 0.2 0.4 0.6 0.8 1.1
8 0.3 0.6 0.8 1.1 1.4
10 0.3 0.7 1.1 1.4 1.8
15 0.5 1.0 1.6 2.1 2.6
20 0.7 1.4 2.1 2.8 3.5
25 0.9 1.7 2.6 3.5 4.4
30 1.0 2.1 3.2 4.2 5.3
35 1.2 2.4 3.7 4.9 6.2
40 1.4 2.8 4.2 5.6 7.1
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Distance
d(m)
2°4°6°8°10°
45 1.6 3.1 4.7 6.3 7.9
50 1.7 3.5 5.3 7 8.8
55 1.9 3.8 5.8 7.7 9.7
60 2.1 4.2 6.3 8.4 10.6
65 2.3 4.5 6.8 9.1 11.5
70 2.4 4.9 7.4 9.8 12.3
Example:
In a vessel with 20 m height,the installation position of the
sensor is 1.4m from the vessel center.
The necessary angle of inclination of 4°can be read out from
this chart.
Proceed as follows to adjust the angle of inclination with the
swivelling holder:
1Loosen terminal screw of the swivelling holder with a fork
spanner SW 13
2Direct the sensor,check angle of inclination
Information:
The max.angle of inclination of the swivelling holder is approx.
15°
3Tighten the terminal screw,torque max.20 Nm.
Information:
The hexagon screws must not be loosened.
Mounting should not be too close to the inflowing material as
the microwave signal will be interferred.The optimum
mounting position is on the opposite of the filling.To avoid
strong pollution,the distance to the filter or dust extraction
must be as big as possible.
Inflowing medium
20 VEGAPULS 68 -Foundation Fieldbus
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