Vega VEGATOR 256C User manual

Level and Pressure
Operating Instruction
Conductive electrodes
1
2
5
100
5
10
0
on
532 Ex

2Conductive measuring system
Safety information
Safety information
The described module must only be installed
and operated as described in this operating
instruction. Please note that other action can
cause damage for which VEGA does not take
responsibility.

Conductive measuring system 3
Contents
Safety information ........................................................................ 2
1 Product description
1.1 Function and configuration .................................................. 4
1.2 Types and version ............................................................... 4
1.3 Technical data ....................................................................... 5
1.4 Dimensions ......................................................................... 14
1.5 Approvals ........................................................................... 18
2 Mounting instructions
2.1 Conductive electrodes ...................................................... 19
2.2 VEGATOR 256C ................................................................. 20
2.3 VEGATOR 532 Ex............................................................... 20
2.4 VEGATOR 631 Ex............................................................... 22
3 Electrical connection
3.1 VEGATOR 256C ................................................................. 23
3.2 VEGATOR 532 Ex............................................................... 23
3.3 VEGATOR 631 Ex............................................................... 25
4 Set-up
4.1 VEGATOR 256C ................................................................. 27
4.2 VEGATOR 532 Ex............................................................... 28
4.3 VEGATOR 631 Ex............................................................... 32
5 Diagnosis
5.1 Fault signal on VEGATOR 532 Ex ..................................... 36
5.2 Fault signal on VEGATOR 631 Ex ..................................... 37
Contents

4Conductive measuring system
Product description
1 Product description
1.1 Function and configuration
The conductive measuring principle is used
for level detection of conductive liquids.
Function
When the probe (s) is covered by the
medium, conductive electrodes detect the
product resistance.
A low alternating current flows which is
measured by the electronics of the signal
conditioning instrument on amplitude and
phase position and converted into a
switching command.
The switching signal is determined by the
length or the mounting position of the
appropriate electrode (s).
Configuration
One or two conductive electrodes and a
signal conditioning instrument VEGATOR
256C, 532 Ex or 631 Ex are required to
implement a measuring system.
1.2 Types and version
VEGATOR 256C and electrode
Application:
- level detection, pump control (Min-Max)
Series:
- module unit
Power supply:
- 200 … 250 V AC
- 24 V, 42 V, 48 V, 100 … 130 V AC
Input:
- 1 channel for probes with 1 … 3 electrodes
Output:
- 1 relay (spdt)
VEGATOR 532 Ex and electrode
Application:
- 2 level detections, pump controls
(Min-Max)
Series:
- 19"-module card, 5 TE
Power supply:
- 20 … 53 V AC
- 20 … 72 V DC
Inputs:
- 2 channels for probes with 1 … 5
electrodes
Outputs:
- 2 relays (1 spdt each)
- 2 transistors
Classification:
- [EEx ia] IIC
Approvals:
- CENELEC
- WHG
Fault monitoring:
- detection of line break
VEGATOR 631 Ex and electrode
Application:
- level detection, pump control (Min-Max)
Series:
- module unit
Power supply:
- 20 … 250 V AC
- 20 … 72 V DC
Input:
- 1 channel for probes with 1 … 3 electrodes
Output:
- 1 relay (1 spdt)
- 1 transistor
Classification:
- [EEx ia] IIC
Approvals:
- CENELEC
- WHG
Fault monitoring:
- detection of line break

Conductive measuring system 5
Product description
1.3 Technical data
Conductive electrodes
Conductive electrode type EL 1 and EL 2
Material
- connection housing 1.4571
- thread 1.4571
- welded socket (only with type EL 2) 1.4571
- rod electrode 1.4571 or Hastelloy C4
- isolation of the rod electrode PTFE
Size of the thread G 1/2A
Length of the rod electrode
- type EL 1 40 … 4000 mm
- type EL 2 60 … 2000 mm
Protection IP 67
Temperature range -50°C … +130°C
Max. permissible vessel pressure 63 bar
Electrical connection Pg 11
Basic weight
- type EL 1 approx. 0,4 kg
- type EL 2 approx. 0,7 kg
Additional weight of the rod electrode approx. 0,04 kg per 100 mm
Conductive rod electrode type EL 1 Ex and EL 2 Ex
Temperature range -20°C … +100°C
Classification EEx ia IIC T6
Max. permissible ambient temperature
- temperature class T6 85°C
- temperature class T5 100°C
all other technical data like EL 1 and EL 2
Conductive multiple rod electrode type EL 3 (2 … 5 rod electrodes)
Material
- connection housing 1.4571
- thread 1.4571
- rod electrodes 1.4571, Hastelloy C4 or Titanium
- isolation of the rod electrodes PTFE
- distance holder PP
Size of the thread G 11/2A
Length of the rod electrodes 100 … 4000 mm
Number of rod electrodes 2 … 5
Protection IP 67
Temperature range -50°C … +130°C
Max. permissible vessel pressure 63 bar
Electrical connection Pg 16
Basic weight approx. 0,9 kg
Additional weight of the rod electrodes approx. 0,04 kg per 100 mm

6Conductive measuring system
Product description
Conductive multiple rod electrode type EL 3 Ex (2 … 5 rod electrodes)
Temperature range -20°C … +100°C
Classification EEx ia IIC T6
Max. permissible ambient temperature
- temperature class T6 85°C
- temperature class T5 100°C
all other technical data like type EL 3
Conductive multiple rod electrode type EL 4 (2 … 5 rod electrodes)
Material
- connection housing PP
- thread PP
- rod electrodes 1.4571, Hastelloy C4 or Titanium
- isolation of the rod electrodes PP
- distance holder PP
Size of the thread G 11/2A
Length of the rod electrodes 100 … 4000 mm
Number of rod electrodes 2 … 5
Protection IP 67
Temperature range -20°C … +100°C
Max. permissible vessel pressure 6 bar
Electrical connection Pg 16
Basic weight approx. 0,4 kg
Additional weight of the rod electrodes approx. 0,04 kg per 100 mm
Conductive multiple cable electrode type EL 5 (2 … 5 cable electrodes)
Material
- connection housing 1.4571
- thread 1.4571
- cable electrodes 1.4571
- isolation of the cable electrodes PTFE / FEP
- gravity weight 1.4571
Size of the thread G 11/2A
Length of the cable electrodes 300 … 20000 mm
Number of cable electrodes 2 … 5
Protection IP 67
Temperature range -50°C … +100°C
Max. permissible vessel pressure 63 bar
Electrical connection Pg 16
Basic weight approx. 1 kg
Additional weight of the cable electrodes approx. 0,01 kg per 100 mm
Conductive multiple cable electrode EL 5 Ex (2 … 5 cable electrodes)
Temperature range -20°C … +100°C
Classification EEx ia IIC T6
Max. permissible ambient temperature
- temperature class T6 85°C
- temperature class T5 100°C
all other technical data like type EL 5

Conductive measuring system 7
Product description
Conductive multiple cable electrode type EL 6 (2 … 5 cable electrodes)
Material
- connection housing PP
- thread PP
- cable electrodes 1.4571
- isolation of the cable electrodes PP / FEP
- gravity weight 1.4571
Size of the thread G 11/2A
Length of the cable electrodes 300 … 20000 mm
Number of cable electrodes 2 … 5
Protection IP 67
Temperature range -20°C … +120°C
Max. permissible vessel pressure 6 bar
Electrical connection Pg 16
Basic weight approx. 0,5 kg
Additional weight of the cable electrodes approx. 0,01 kg per 100 mm
Conductive rod electrode type EL 8
Material
- connection housing plastic
- thread 1.4305
- rod electrode 1.4571
- isolation of the rod electrode PE
Size of the thread G 1/2A
Length of the rod electrode 30 … 1000 mm
Protection IP 50
Temperature range -10°C … +60°C
Max. permissible vessel pressure 6 bar
Basic weight approx. 0,1 kg
Additional weight of the rod electrode approx. 0,04 kg per 100 mm
Conductive cable electrode type EL 9
Material
- connection housing 1.4571
- thread 1.4571
- cable electrode 1.4571
- isolation of the cable electrode FEP
- gravity weight 1.4571
Size of the thread G 1/2A
Length of the cable electrode 500 … 25000 mm
Protection IP 67
Temperature range -50°C … +100°C
Max. permissible vessel pressure 63 bar
Electrical connection Pg 11
Basic weight approx. 0,6 kg
Additional weight of the cable electrode approx. 0,01 kg per 100 mm

8Conductive measuring system
Product description
Conductive cable electrode type EL 9 Ex
Temperature range -20°C … +100°C
Classification EEx ia IIC T6
Max. permissible ambient temperature
- temperature class T6 85°C
- temperature class T5 100°C
all other technical data like type EL 9
Signal conditioning instrumentVEGATOR 256C
General
Series module unit
Mounting 2 holes for M3 or carrier rail mounting
acc. to DIN 46 277, Bl. 3
Dimensions W = 37 mm, H = 69 mm, D = 80 mm
Weight approx. 160 g
Power supply
Operating voltage
- standard 200 … 250 V AC, 50/60 Hz
- option 24 V, 42 V, 48 V, 100 … 130 V AC
+10 %, –15 %, 50/60 Hz
Power consumption 1 VA
Measuring data input
Number 1 (1 x level detection or
1 x pump control -Min-Max.)
Response resistor 1 … 200 kOhm adjustable
Meas. circuit approx. 12 V eff, approx. 1 mA
Switching hysteresis approx. 20 %
Relay output
Number 1 (1 x level detection)
Mode overfill protection (A)
Contact spdt
Contact material
Turn-on voltage min. 10 mV
max. 250 V AC or 250 V DC
Switching current min. 10 µA
max. 5 A AC or 1 A DC
Breaking capacity max. 750 VA or 54 W
Integration time
Fixed value approx. 500 ms

Conductive measuring system 9
Product description
Ambient conditions
Permissible operating temperature -20°C … +50°C
Storage and transport temperature -40°C … +70°C
Electrical protective measures
Protection IP 20
Protection class II
Electrical connection
Screw terminal max. for 1,5 mm2
CE-conformity
VEGATOR 256C signal conditioning instrument meets the protective regulations of EMVG
(89/336/EWG) and NSR (72/23/EWG). The conformity has been judged acc. to the following
standards:
EMVG Emission EN 50 081 - 1
Susceptibility EN 50 082 - 2
NSR EN 61 010 - 1
Signal conditioning instrumentVEGATOR 532 Ex
General
Series 19"-module card, multipoint connector acc. to
DIN 41 612 incl. transparent cover
Dimensions B = 25,4 mm (5 TE), H = 128,4 mm, D = 162 mm
Weight approx. 170 g
Power supply
Operating voltage 20 … 53 V AC, 50/60 Hz
20 … 72 V DC
Power consumption max. 2 W, 3 VA
Fuse
- supply range T 1 A, 250 V
- switching power min. 35 A at 250 V AC or 125 V DC
Measuring data input (channel)
Number 2 (2 x level detection or
2 x pump control -Min-Max)
Response resistor 1 … 200 kOhm adjustable
Parallel resistor
- for fault monitoring 220 kOhm
Meas. circuit max. 5 V eff, max. 1 mA
Permissible line capacitance 1 x 100 nF or
2 x 70 nF with Min-Max.-control
Switching hysteresis approx. 15 %

10 Conductive measuring system
Product description
Measuring data input, Ex-technical data
Signal circuits in classification intrinsic safety EEx ia IIC
Max. values
-U
O10,6 V
-I
K8 mA
- P 20 mW
Characteristics linear
Inner effective inductance negligible
Inner effective capacitance negligible
Max. permissible outer inductance 5 mH
Max. permissible outer capacitance 570 nF
The intrinsically safe circuits are reliably galvanically separated from the not-intrinsically
safe circuits up to a peak value of the nominal voltage of 375 V.
The intrinsically safe circuits of channel 1 and channel 2 are reliably galvanically isolated.
Relay outputs
Number 2
Mode overfill protection (A) and dry run protection (B)
changeover for each output (channel) separately
Contact 1 spdt per output
Contact material AgCdO and Au plated
Turn-on voltage min. 10 mV
max. 250 V AC or 250 V DC
Switching current min. 10 µA
max. 3 A AC or 1 A DC
Breaking capacity max. 750 VA or 54 W
Transistor outputs
Number 2 (synchronously switching with relay outputs)
Galvanic isolation floating
Turn-on voltage UB= max. 36 V DC
Switching current IB= max. 60 mA
Voltage loss on the transistor UCE = approx. 1,5 V at IB= 60 mA
Blocking current IO< 10 µA
Integration time
Fixed value approx. 500 ms
Ambient conditions
Permissible ambient temperature -20°C … +60°C
Storage and transport temperature -40°C … +70°C

Conductive measuring system 11
Product description
Electrical protective measures
Protection
- not mounted IP 00
- mounted into
carrier BGT 596 Ex front side completely equipped IP 30
upper and lower side IP 20
wiring side IP 00
- mounted into
housing type 505 Ex IP 30
Protection class II
Overvoltage category II
Electrical connection
Mounted into
- carrier BGT 596 Ex 33-pole multipoint connector, series F (d, b, z)
with coding holes
- housing type 505 Ex screw terminal, max. for 1,5 mm2
CE-conformity
VEGATOR 532 Ex signal conditioning instrument meets the protective regulations of EMVG
(89/336/EWG) and NSR (72/23/EWG). The conformity has been judged acc. to the following
standards:
EMVG Emission EN 50 081 - 1
Susceptibility EN 50 082 - 2
NSR EN 61 010 - 1
Signal conditioning instrumentVEGATOR 631 Ex
General
Series module unit with plug-in socket including
transparent cover, cover of the probe
terminals,
coded pin, 2 bridges
Dimensions W = 36 mm, H = 118,5 mm, D = 134 mm
Weight approx. 170 g
Mounting carrier rail mounting acc. to DIN 46 277, Bl 3
Power supply
Operating voltage 20 … 250 V AC, 50/60 Hz
20 … 72 V DC
Power consumption max. 1,5 W, approx. 1 … 9 VA
Fuse
- supply range T 315 mA, 250 V
- switching power min. 35 A at 250 V AC or 125 V DC

12 Conductive measuring system
Measuring data input (channel)
Number 1 (1 x level detection or
1 x pump control -Min-Max)
Response resistance 1 … 200 kOhm adjustable
Parallel resistance
- for fault monitoring 220 kOhm
Meas. circuit max. 5 V eff, max. 1 mA
Permissible line capacitance 1 x 100 nF or
2 x 70 nF at Min-Max.-control
Switching hysteresis approx. 15 %
Measuring data input, Ex-technical data
Signal circuit in classification intrinsic safety EEx ia IIC
Max. values
-U
O10,6 V
-I
K8 mA
- P 20 mW
Characteristics linear
Inner effective inductance negligible
Inner effective capacitance negligible
Max. permissible outer inductance 5 mH
Max. permissible outer capacitance 570 nF
The intrinsically safe circuits are reliably galvanically isolated from the not-intrinsically safe
circuits up to a peak value of the nominal voltage of 375 V.
Relay outputs
Number 1
Mode overfill protection (A) and dry run protection (B)
changeable
Contact 1 spdt per output
Contact material AgCdO and Au plated
Turn-on voltage min. 10 mV
max. 250 V AC or 250 V DC
Switching current min. 10 µA
max. 3 A AC or 1 A DC
Breaking capacity max. 750 VA or 54 W
Transistor outputs
Number 1 (synchronuously switching with relay outputs)
Galvanic isolation floating
Turn-on voltage UB= max. 36 V DC
Switching current IB= max. 60 mA
Voltage loss on transistor UCE = approx. 1,5 V at IB= 60 mA
Blocking current IO< 10 µA
Integration time
Adjustable 0,2 … 20 s
Product description

Conductive measuring system 13
Ambient conditions
Permissible operating temperature -20°C … +60°C
Storage and transport temperature -40°C … +70°C
Electrical protective measures
Protection IP 20
Protection class II
Overvoltage category II
Electrical connection
Screw terminals max. for 1,5 mm2
CE-conformity
VEGATOR 631 Ex signal conditioning instrument meets the protective regulations of EMVG
(89/336/EWG) and NSR (72/23/EWG). The conformity has been judged acc. to the following
standards:
EMVG Emission EN 50 081 - 1
Susceptibility EN 50 082 - 2
NSR EN 61 010 - 1
Product description

14 Conductive measuring system
58
ø66
L2
L1
L3
20
ø6
~58
L2
54
78
ø66
22
ø4
L3
L1
~58
ø46
18
56
ø10
ø8
~43
Product description
ø46
ø34
ø10
ø11
60
~43
~114
L1 = Longest rod electrode, L2 = Shortest rod electrode
L1 = Longest rod electrode, L2 = Shortest rod electrode
L (max. 4000 mm)
SW 41
Pg 11
G 1/2A
SW 41
Pg 11
Pg 16
G 11/2A
SW 60
Pg 16
G 11/2A
SW 60
1.4 Dimensions
Conductive electrodes
Type EL 1 (Ex) Type EL 2 (Ex)
Type EL 3 (Ex) Type EL 4

Conductive measuring system 15
L2
54
78
ø66
22
ø2,5
L3
L1
~58
58
65
ø66
L2
20
ø2,5
L3
L1
80
~58
L1 = Longest cable electrode, L2 = Shortest cable electrode
G 11/2A
Pg 16
SW 60
Product description
L1 = Longest cable electrode, L2 = Shortest cable electrode
Pg 16
G 11/2A
SW 60
Type EL 5 (Ex) Type EL 6
PTFE
1.4571
FEP
PP
1.4571
FEP

16 Conductive measuring system
40 56
ø46
80
18
ø10
ø4,6
200
ø15
L
~43
30
ø6,8
ø24
9,3
27
12
ø4
Product description
Pg 11
G 1/2A
SW 41
SW 24
L (max. 1000 mm)
Type EL 8 Type EL 9 (Ex)
4
60
7,5
22
37
68
66
010
8
7
6
5
4
N
L1
3
2
1
max.
min.
R
200...250VAC 3VA
Relais: max 250V,5A,750VA
power supply
VEGATOR 256C

Conductive measuring system 17
162
100
5,5
128,4
25,4
5 TE
9
on
15
3
VEGATOR 532 Ex
Product description
Multiple plug
Transparent cover
VEGATOR 631 Ex
12 34
56 78
9 1011121314
118,5
134
54,5
36
631Ex
on
010
5
Carrier rail 35 x 7,5 or
35 x 15 acc. to EN 50 022

18 Conductive measuring system
Product description
1.5 Approvals
If measuring systems are installed according to the following approvals, the appropriate legal
documents and their regulations must be noted. The documents are supplied with the
appropriate measuring system.
WHG-approval
Signal conditioning instrument VEGATOR 532 Ex, VEGATOR 631 Ex, (VEGATOR 535 Ex)
together with conductive electrodes type EL 1 Ex, EL 2 Ex, EL 3 Ex, EL 5 Ex, EL 9 Ex as part
of an overfill protection acc. to WHG, no. Z-65.13-7.
Ex-approval
For measuring systems in hazardous areas, certificate acc. to CENELEC.
Conductive electrodes
- Type EL 1 Ex
- Type EL 3 Ex (2 … 5 rod electrodes)
- Type EL 5 Ex (2 … 5 cable electrodes)
- Type EL 9 Ex
defined in conformity certificate PTB-no. Ex-93.C.4048 X
Signal conditioning instrument VEGATOR 532 Ex
Conformity certificate PTB-no. Ex-96.D.2055 X
Signal conditioning instrument VEGATOR 631 Ex
Conformity certificate PTB-no. Ex-96.D.2064
CE-approval
- VEGATOR 256C
- VEGATOR 532 Ex
- VEGATOR 631 Ex
see the appropriate technical data

Conductive measuring system 19
Mounting instructions
2 Mounting instructions
2.1 Conductiveelectrodes
General
When mounting the electrodes it should be
noted that the rod or cable electrodes do not
touch the vessel wall.
Lateral load
Note that the electrode is not subjected to
strong lateral forces.
Mount the electrode on a position in the
vessel where no interferences such as e.g.
by stirrers, vessel openings etc. occur. This
is mainly valid for very long rod and cable
electrodes.
Pressure
In case of gauge or low pressure in the
vessel, the mounting boss must be sealed on
the thread. Use the attached seal ring. Check
if the seal ring is resistant against the
medium.
Note for electrodes with earth rod (e.g. EL 1,
EL 2, EL 8) that the thread of the electrode is
electrically conductive connected with the
vessel to ensure a sufficient ground.
Use conductive seals such as e.g. copper,
lead etc. Isolating measures such as e.g.
covering the thread with Teflon tape or a
paper seal can interrupt the necessary
electrical connection.
In this case connect the earth connection
terminal on the electrode housing via an
external earth cable to the vessel.
Ex-measuring systems
Important instruction for multiple rod or multi-
ple cable electrodes type … Ex, VEGATOR
532 Ex and VEGATOR 631 Ex. To implement
a line monitoring, a resistor of 220 kOhm is
mounted between terminal 1 and terminal 2 in
the connection housing. Please note that in
case you want to adap the rod or cable
electrode by yourself, i.e. shortening so that
L1 or terminal 1 corresponds to the longest
and L2 or terminal 2 to the shortest rod or
cable electrode (see also paragraph "Fault
signal").
Probe with 3 rod or cable
electrodes
If a modification of the installation place
should not be possible for you, it would be
necessary that the rod or cable electrodes
must be stabilized by an isolated holder.
3
2
1

20 Conductive measuring system
Probe with 4 rod or cable
electrodes
Mounting instructions
2.3 VEGATOR 532 Ex
VEGATOR 532 Ex can be either mounted in a
single housing type 505 Ex or into a carrier
BGT 596 or BGT 596 Ex by means of a
module.
- Module consisting of:
Multipoint connector DIN 41 612, series F,
33-pole (d, b, z) with coded pin and
mounting material for mounting in carrier
BGT 596
- Ex-module consisting of:
Multipoint connector DIN 41 612, series F,
33-pole (d, b, z) with coded pins, Ex-
separating chamber and mounting material
for mounting in carrier BGT 596 Ex
- Single housing
Plastic housing type 505 Ex for single
mounting of signal conditioning instrument
with instrument width 5 TE (25,4 mm)
Mounting carrier
Mount the appropriate module (standard or
Ex-version) on your carrier BGT 596 or BGT
596 Ex. Wire the connection of the multipoint
connector acc. to section "3 Electrical
connection".
The multipoint connector is available as
follows:
- Wire-Wrap standard connection
1,0 x 1,0 mm
- Plug connection 2,8 x 0,8 mm
- Termi-Point standard connection
1,6 x 0,8 mm
- Soldering connection
- Screw terminals 2 x 0,5 mm2
For further information concerning mounting
see the operating instruction of the carrier.
When mounting VEGATOR 532 with Ex-
approval into a carrier, you have to use a
VEGA-Ex-module. Keep a distance of at least
10 mm (2 TE) to instruments of other
manufacturers. When you want to mount
VEGATOR completely to the left in the carrier,
you have to mount a blind cover of at least
20 mm (4 TE) in front of the module of the
instrument.
4
3
2
1
15
4
3
2
Probe with 5 rod or cable
electrodes
2.2 VEGATOR 256C
The signal conditioning instrument VEGATOR
256C can be either mounted directly to the
wall via two screws or plugged to a carrier
rail 35 x 7,5 acc. to DIN EN 50 022.
Carrier rail mounting
Place VEGATOR 256C from the bottom to the
carrier rail and push the instrument to the rail
until snap-in.
Wall mounting
Fasten the instrument directly to the wall by
means of two screws (ø max. 3 mm).
4
60
7,5
22