Vega VEGACAL 62 User manual

Operating Instructions
VEGACAL 62
Profibus PA
Document ID:
30025
Capacitive

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
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity ............................. 6
2.7Fulfillment of NAMUR recommendations . . . . . . . . . . 6
2.8Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.9Environmental instructions..................... 6
3Product description
3.1Configuration .............................. 7
3.2Principle of operation ........................ 8
3.3Operation................................. 9
3.4Packaging,transport and storage ............... 9
4Mounting
4.1General instructions ......................... 11
4.2Mounting instructions ........................ 13
5Connect to power supply
5.1Prepare the connection....................... 15
5.2Connection procedure........................ 16
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 17
5.4Wiring plan,double chamber housing . . . . . . . . . . . . 19
5.5Wiring plan double chamber housing Ex d . . . . . . . . . 21
5.6Wiring plan -version IP 66/IP 68,1bar . . . . . . . . . . . 23
6Set up with the indicating and adjustment module PLICSCOM
6.1Short description ........................... 24
6.2Insert indicating and adjustment module. . . . . . . . . . . 24
6.3Adjustment system .......................... 26
6.4Setup procedure............................ 27
6.5Menu schematic ............................ 32
6.6Saving the parameter adjustment data . . . . . . . . . . . . 34
7Setup with PACTware and other adjustment programs
7.1Connecting the PC .......................... 35
7.2Parameter adjustment with PACTware . . . . . . . . . . . . 36
7.3Parameter adjustment with AMS™and PDM . . . . . . . 36
7.4Saving the parameter adjustment data . . . . . . . . . . . . 36
2VEGACAL 62 •Profibus PA
Contents
30025-EN-090603

8Maintenance and fault rectification
8.1Maintenance .............................. 37
8.2Remove interferences ........................ 37
8.3Exchanging the electronics module . . . . . . . . . . . . . . 39
8.4Shortening the electrode ...................... 40
8.5Instrument repair ........................... 40
9Dismounting
9.1Dismounting steps .......................... 42
9.2Disposal ................................. 42
10 Supplement
10.1Technical data ............................. 43
10.2Profibus PA ............................... 48
10.3Dimensions ............................... 52
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:
To ensure reliable setup and operation of your VEGACAL 62,we offer
accessories and replacement parts.The associated documents are:
l27720 -VEGADIS 61
l30531 -Electronics module VEGACAL series 60
l34296 -Protective cover
l31088 -Flanges according to DIN-EN-ASME-JIS
VEGACAL 62 •Profibus PA 3
Contents
30025-EN-090603

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.
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.
4VEGACAL 62 •Profibus PA
1About this document
30025-EN-090603

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
VEGACAL 62 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.
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.
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 high-tech instrument requiring the strict observance of
standard regulations and guidelines.The user must take note of the
safety instructions in this operating instructions manual,the country-
specific installation standards as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use,the user is obliged to determine the
compliance of the required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
VEGACAL 62 •Profibus PA 5
2For your safety
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2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This 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.
2.7Fulfillment of NAMUR recommendations
With respect to compatibility,the NAMUR recommendation NE 53 is
fulfilled.This applies also to the corresponding indicating and
adjustment components.VEGA instruments are generally upward and
downward compatible.
lSensor software to DTM VEGACAL 62
lDTM VEGACAL 62 for adjustment software PACTware
lIndicating and adjustment module for sensor software
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
2.8Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
2.9Environmental 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"
6VEGACAL 62 •Profibus PA
2For your safety
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3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAL 62 level sensor
lDocumentation
-this operating instructions manual
-Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM"(optional)
-Supplementary instructions manual 31708 "Heating for in-
dicating and adjustment module"(optional)
-Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGACAL 62 consists of the following components:
lProcess fitting with probe
lHousing with electronics
lHousing cover,optionally available with indicating and adjustment
module
1
2
3
Fig.1:VEGACAL 62 -rod version with plastic housing
1Housing cover with integrated indicating and adjustment module (optional)
2Housing with electronics
3Process fitting
The type label contains the most important data for identification and
use of the instrument:
lArticle number
Scope of delivery
Components
Type label
VEGACAL 62 •Profibus PA 7
3Product description
30025-EN-090603

lSerial number
lTechnical data
lArticle numbers,documentation
The serial number allows you to access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".In addition to the type label outside,you can also find the
serial number on the inside of the instrument.
3.2Principle of operation
VEGACAL 62 is a level sensor with partly insulated probe for
continuous level measurement.
The electronics functions according to the admittance principle
(phase-selective admittance processing).
It is designed for industrial use in all areas of process technology and
can be applied in all areas of industrial process measurement.
Partly insulated probes such as VEGACAL 62 are preferably used in
bulk solids.
However,the probe can also be used in non-conductive liquids such
as e.g.oil.
Probe,measured product and vessel wall form an electrical capacitor.
The capacitance is influenced by three main factors.
1
2
3
Fig.2:Functional principle -Plate capacitor
1Distance between the electrode surfaces
2Size of the electrode surfaces
3Type of dielectric between the electrodes
The probe and the vessel wall are the capacitor plates.The measured
product is the dielectric.Due to the higher dielectric constant (DK
value)of the product compared to air,the capacitance increases as
the probe is gradually covered.
Application area
Functional principle
8VEGACAL 62 •Profibus PA
3Product description
30025-EN-090603

The capacitance as well as the resistance change are converted by
the electronics module into a level-proportional signal.
Power supply via the Profibus DP/PA segment coupler or VEGALOG
571 EP cards.Atwo-wire cable according to Profibus specification
serves as carrier of both power and digital data transmission for
multiple sensors.The instrument profile of VEGACAL 62 corresponds
to profile specification version 3.0.
The GSD (instrument master files)and bitmap files necessary for
planning your Profibus-DP-(PA)communication network are available
from the download section on the VEGA homepage www.vega.com
under "Services -Downloads -Software -Profibus".There you can
also find the appropriate certificates.In a PDM environment,an EDD
(Electronic Device Description)is also required to enable the full range
of sensor functions (also available as a download).A CD with the
appropriate files 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 operating voltage.
The data for power supply are specified in chapter "Technical data".
The optional heating requires its own operating voltage.You can find
details in the supplementary instructions manual "Heating for indicat-
ing and adjustment module".
This function is generally not available for approved instruments.
3.3Operation
VEGACAL 62 can be adjusted with different adjustment media:
lwith indicating and adjustment module
lwith the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard,e.g.PACTware and
PC
lwith the adjustment program PDM
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 environment-
friendly,recyclable cardboard.For special versions,PE foam or PE foil
is also used.Dispose of the packaging material via specialised
recycling companies.
Power supply and bus
communication
GSD/EDD
Packaging
VEGACAL 62 •Profibus PA 9
3Product description
30025-EN-090603

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.
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 chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Transport
Transport inspection
Storage
Storage and transport
temperature
10 VEGACAL 62 •Profibus PA
3Product description
30025-EN-090603

4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,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.
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°).
Before beginning the welding work,remove the electronics module
from the sensor.By doing this,you avoid damage to the electronics
through inductive coupling.
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 hexagon for screwing in.
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.
Suitability for process
conditions
Mounting position
Welding work
Handling
Moisture
VEGACAL 62 •Profibus PA 11
4Mounting
30025-EN-090603

Fig.3:Measures against moisture penetration
The process fitting must be sealed if there is gauge or low pressure in
the vessel.Before use,check if the seal material is resistant against
the measured product and the process temperature.
The max.permissible pressure is specified in chapter "Technical data"
or on the type label of the sensor.
Insulating measures,such as e.g.covering the thread with teflon tape,
can interrupt the necessary electrical connection with metal vessels.
For this reason,ground the probe on the vessel or use a conductive
seal material.
Metal vessel
Make sure that the mechanical connection of the probe to the vessel is
electrically conductive to ensure sufficient grounding.
Use conductive seals,such as those made of copper or lead,etc.
Insulating measures,such as covering the thread with Teflon tape,can
interrupt the necessary electrical connection with metal vessels.For
this reason,ground the probe on the vessel or use a conductive seal
material.
Non-conductive vessels
In non-conductive vessels,e.g.plastic tanks,the second pole of the
capacitor must be provided separately,e.g.in the form of a concentric
tube.
If possible,the capacitive probe should be mounted vertically or
parallel to the counter electrode.This applies particularly to
applications in non-conductive products.
In cylindrical tanks,spherical tanks or other asymmetrical tank forms,
nonlinear level values are generated due to the varying distance to the
vessel wall.
Use a concentric tube in non-conductive products or linearize the
meas.signal.
Pressure/Vacuum
Vessel material
Vessel forms
12 VEGACAL 62 •Profibus PA
4Mounting
30025-EN-090603

If condensate forms on the vessel top,the run-offliquid can cause
bridging and hence measurement errors.
For this reason,use a screening tube or a longer insulation.The length
depends on the amount of condensate and the drain-offbehaviour of
the product.
4.2Mounting instructions
During operation,the probe must not touch any installations or the
vessel wall.The measured value can also change if the distance to the
vessel wall changes considerably.If necessary,secure the end of the
probe (insulated).
1
2
1
2
Fig.4:Fasten the probe
1Probe
2Plastic socket
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel,as measurement is then possible
down to the lowest point of the vessel bottom.
If the instrument is mounted in the filling stream,unwanted false
measurement signals can be generated.For this reason,mount the
instrument at a position in the vessel where no disturbances,e.g.from
filling openings,agitators,etc., can occur.
This applies particularly to instrument versions with a longer probe.
Condensation
Mounting position
Inflowing medium
VEGACAL 62 •Profibus PA 13
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Fig.5:Inflowing medium
14 VEGACAL 62 •Profibus PA
4Mounting
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5Connect to power supply
5.1Prepare the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,overvoltage arresters should
be installed according to Profibus specifications
Tip:
We recommend VEGA overvoltage arrester B63-32.
In hazardous areas you should take note of the appropriate regulations,
conformity and type approval certificates of the sensors and power
supply units.
Power is supplied via a Profibus DP/PA segment coupler or a
VEGALOG 571 EP input card.The power supply range can differ
depending on the instrument version.
The data for power supply are specified in chapter "Technical data".
Connection is made with screened cable according to the Profibus
specification.Power supply and digital bus signal are carried over the
same two-wire connection cable.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 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.
Please make sure that your installation is carried out according to the
Profibus specification.In particular,make sure that the termination of
the bus is done with appropriate terminating resistors.
On the instrument with cable entry ½NPT and plastic housing there is
a metallic ½" threaded insert moulded into the plastic housing.
Caution:
No grease should be used when screwing the NPT cable gland or
steel tube into the threaded insert.Standard grease can contain
additives that corrode the connection between threaded insert and
housing.This would influence the stability of the connection and the
tightness of the housing.
Safety instructions
Power supply
Connection cable
Cable gland ½NPT
VEGACAL 62 •Profibus PA 15
5Connect to power supply
30025-EN-090603

In systems with potential equalisation,connect the cable screen
directly to ground potential at the power supply unit,in the connection
box and at the sensor.The screen in the sensor must be connected
directly to the internal ground terminal.The ground terminal outside on
the housing must be connected to the potential equalisation (low
impedance).
In systems without potential equalisation,connect the cable screen
directly to ground potential at the power supply unit and at the sensor.
In the connection box or T-distributor,the screen of the short stub to
the sensor must not be connected to ground potential or to another
cable screen.The cable screens to the power supply unit and to the
next distributor must be connected to each other and also connected
to ground potential 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 interference signals remains.
The total capacitance of the cable and of all capacitors must not exceed
10 nFin Ex applications.
Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equalisation
currents flow 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.
5.2Connection procedure
Proceed as follows:
1Unscrew the housing cover
2If an indicating and adjustment module is installed,remove it by
turning it slightly to the left.
3Loosen compression nut of the cable entry
4Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)insulation from the ends of the individual wires
5Insert the cable through the cable gland into the sensor
6Lift the opening levers of the terminals with a screwdriver (see
following illustration)
Cable screening and
grounding
16 VEGACAL 62 •Profibus PA
5Connect to power supply
30025-EN-090603

7Insert the wire ends into the open terminals according to the wiring
plan
Fig.6:Connection steps 6and 7
8Press down the opening levers of the terminals,you will hear the
terminal spring closing
9Check the hold of the wires in the terminals by lightly pulling on
them
10 Connect the screen to the internal ground terminal,connect the
outer ground terminal with potential equalisation
11 Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
12 Screw the housing cover on
The electrical connection is finished.
5.3Wiring plan,single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
VEGACAL 62 •Profibus PA 17
5Connect to power supply
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5
5
55
1 2
4
3
Fig.7:Material versions,single chamber housing
1Plastic
2Aluminium
3Stainless steel,investment casting
4Stainless steel,electro-polished
5Filter element for air pressure compensation of all material versions.Blind
stopper with version IP 66/IP 68,1bar for Aluminium and stainless steel
I²C
Display
1 2 5 6 7 8
3
4
1
2
Fig.8:Electronics and connection compartment,single chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Spring-loaded terminals for connection of the external indication VEGADIS
61
3Ground terminal for connection of the cable screen
4Spring-loaded terminals for voltage supply
Housing overview
Electronics and connec-
tion compartment
18 VEGACAL 62 •Profibus PA
5Connect to power supply
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I2C
Display
1
1 2 5 6 7 8
Fig.9:Wiring plan,single chamber housing
1Voltage supply/Signal output
5.4Wiring plan,double chamber housing
The following illustration apply to non-Ex as well as Ex ia versions.The
Exd version is described in the next subchapter.
1 2 3
45
Fig.10:Double chamber housing
1Housing cover,connection compartment
2Blind stopper or plug M12 x1for VEGADIS 61 (optional)
3Housing cover,electronics compartment
4Filter element for air pressure compensation
5Cable gland
Wiring plan
Housing overview
VEGACAL 62 •Profibus PA 19
5Connect to power supply
30025-EN-090603

1
32
Display
1 2 5 6 7 8
I²C
Fig.11:Electronics compartment,double chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Internal connection cable to the connection compartment
3Terminals for VEGADIS 61
3
1
2
Display
1 2 I²C
Fig.12:Connection compartment double chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Ground terminal for connection of the cable screen
3Spring-loaded terminals for voltage supply
Electronics compart-
ment
Connection compart-
ment
20 VEGACAL 62 •Profibus PA
5Connect to power supply
30025-EN-090603