Vega VEGACAL 63 User manual

Operating Instructions
Capacitive rod electrode for continuous
level measurement
VEGACAL 63
For connection to a controller
Document ID: 30318

2
Contents
VEGACAL 63 • For connection to a controller
30318-EN-200317
Contents
1 About this document ............................................................................................................... 4
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety ......................................................................................................................... 5
2.1 Authorised personnel ....................................................................................................... 5
2.2 Appropriate use................................................................................................................ 5
2.3 Warning about incorrect use............................................................................................. 5
2.4 General safety instructions............................................................................................... 5
2.5 Safety label on the instrument .......................................................................................... 6
2.6 EU conformity................................................................................................................... 6
2.7 Installation and operation in the USA and Canada ........................................................... 6
2.8 Safety instructions for Ex areas ........................................................................................ 6
2.9 Environmental instructions ............................................................................................... 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Adjustment....................................................................................................................... 9
3.4 Packaging, transport and storage..................................................................................... 9
3.5 Accessories.................................................................................................................... 10
4 Mounting................................................................................................................................. 12
4.1 General instructions ....................................................................................................... 12
4.2 Mounting instructions ..................................................................................................... 14
5 Connecting to power supply................................................................................................. 16
5.1 Preparing the connection ............................................................................................... 16
5.2 Connection procedure.................................................................................................... 17
5.3 Wiring plan, single chamber housing.............................................................................. 18
5.4 Wiring plan - version IP66/IP68 (1 bar)........................................................................... 19
6 Setup with a controller .......................................................................................................... 20
6.1 General information........................................................................................................ 20
6.2 Adjustment system......................................................................................................... 20
6.3 Continuous level measurement...................................................................................... 21
7 Maintenanceandfaultrectication...................................................................................... 23
7.1 Maintenance .................................................................................................................. 23
7.2 Rectify faults................................................................................................................... 23
7.3 Exchanging the electronics module................................................................................ 24
7.4 How to proceed if a repair is necessary.......................................................................... 25
8 Dismount................................................................................................................................. 26
8.1 Dismounting steps.......................................................................................................... 26
8.2 Disposal ......................................................................................................................... 26
9 Supplement ............................................................................................................................ 27
9.1 Technical data ................................................................................................................ 27
9.2 Dimensions .................................................................................................................... 32
9.3 Industrial property rights................................................................................................. 35
9.4 Trademark ...................................................................................................................... 35

3
Contents
VEGACAL 63 • For connection to a controller
30318-EN-200317
Editing status: 2020-03-03

4
1 About this document
VEGACAL 63 • For connection to a controller
30318-EN-200317
1 About this document
1.1 Function
This instruction provides all the information you need for mounting,
connection and setup as well as important instructions for mainte-
nance,faultrectication,theexchangeofpartsandthesafetyofthe
user. Please read this information before putting the instrument into
operation and keep this manual accessible in the immediate vicinity
of the device.
1.2 Target group
This operating instructions manual is directed to trained personnel.
Thecontentsofthismanualmustbemadeavailabletothequalied
personnel and implemented.
1.3 Symbols used
Document ID
This symbol on the front page of this instruction refers to the Docu-
ment ID. By entering the Document ID on www.vega.com you will
reach the document download.
Information, note, tip: This symbol indicates helpful additional infor-
mation and tips for successful work.
Note: This symbol indicates notes to prevent failures, malfunctions,
damage to devices or plants.
Caution: Non-observance of the information marked with this symbol
may result in personal injury.
Warning: Non-observance of the information marked with this symbol
may result in serious or fatal personal injury.
Danger: Non-observance of the information marked with this symbol
results in serious or fatal personal injury.
Ex applications
This symbol indicates special instructions for Ex applications.
• List
The dot set in front indicates a list with no implied sequence.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

5
2 For your safety
VEGACAL 63 • For connection to a controller
30318-EN-200317
2 For your safety
2.1 Authorised personnel
All operations described in this documentation must be carried out
onlybytrained,qualiedpersonnelauthorisedbytheplantoperator.
During work on and with the device, the required personal protective
equipment must always be worn.
2.2 Appropriate use
VEGACAL 63 is a sensor for continuous level measurement.
Youcannddetailedinformationabouttheareaofapplicationin
chapter "Product description".
Operational reliability is ensured only if the instrument is properly
usedaccordingtothespecicationsintheoperatinginstructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of this product can give rise to applica-
tion-specichazards,e.g.vesseloverllthroughincorrectmounting
or adjustment. Damage to property and persons or environmental
contamination can result. Also, the protective characteristics of the
instrument can be impaired.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and directives.The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsi-
ble for the trouble-free operation of the instrument.When measuring
aggressive or corrosive media that can cause a dangerous situation
if the instrument malfunctions, the operator has to implement suitable
measures to make sure the instrument is functioning properly.
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 regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.Forsafety
reasons,onlytheaccessoryspeciedbythemanufacturermustbe
used.

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2 For your safety
VEGACAL 63 • For connection to a controller
30318-EN-200317
To avoid any danger, the safety approval markings and safety tips on
the device must also be observed and their meaning read in this oper-
ating instructions manual.
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 EU conformity
ThedevicefullsthelegalrequirementsoftheapplicableEUdirec-
tives.ByaxingtheCEmarking,weconrmtheconformityofthe
instrument with these directives.
The EU conformity declaration can be found on our homepage.
2.7 Installation and operation in the USA and
Canada
This information is only valid for USA and Canada. Hence the follow-
ing text is only available in the English language.
Installations in the US shall comply with the relevant requirements of
the National Electrical Code (ANSI/NFPA 70).
Installations in Canada shall comply with the relevant requirements of
the Canadian Electrical Code.
2.8 Safety instructions for Ex areas
For Ex applications, only devices with corresponding Ex approval may
beused.ObservetheEx-specicsafetyinstructions.Thesearean
integral part of the operating instructions and are enclosed with every
device with Ex approval.
2.9 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 pro-
tection.Theenvironmentmanagementsystemiscertiedaccording
to DIN EN ISO 14001.
Pleasehelpusfullthisobligationbyobservingtheenvironmental
instructions in this manual:
• Chapter "Packaging, transport and storage"
• Chapter "Disposal"

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3 Product description
VEGACAL 63 • For connection to a controller
30318-EN-200317
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• Level sensor VEGACAL 63
• Documentation
– This operating instructions manual
– Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors" (optional)
– Ex-specic"Safety instructions" (with Ex versions)
– Ifnecessary,furthercerticates
The VEGACAL 63 consists of the components:
• Processttingwithprobe
• Housing with electronics
• Housing lid
1
2
3
Fig. 1: VEGACAL 63, rod version with plastic housing
1 Housing lid
2 Housing with electronics
3 Processtting
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
Scope of delivery
Constituent parts
Type label

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3 Product description
VEGACAL 63 • For connection to a controller
30318-EN-200317
2
1
11
13
12
14
15
10
9
3
6
4
5
7
8
Fig. 2: Layout of the type label (example)
1 Instrument type
2 Product code
3 Approvals
4 Process and ambient temperature, process pressure
5 Power supply and signal output, electronics
6 Protection rating
7 Probe length
8 Order number
9 Serial number of the instrument
10 Material wetted parts
11 Symbol of the device protection class
12 Reminder to observe the instrument documentation
13 ID numbers, instrument documentation
14 NotiedauthorityforCEmarking
15 Approval directives
With the serial number, you can access the delivery data of the instru-
ment via "www.vega.com", "Search".Youcanndtheserialnumber
on the inside of the instrument as well as on the type label on the
outside.
3.2 Principle of operation
The VEGACAL 63 sensor can be used universally for level measure-
ment in conductive and non-conductive liquids.
The rod probe is fully insulated and the proven mechanical construc-
tionoershighfunctionalsafety.
Probe, measured product and vessel wall form an electrical capacitor.
Thecapacitanceisinuencedbythreemainfactors.
Application area
Functional principle

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3 Product description
VEGACAL 63 • For connection to a controller
30318-EN-200317
1
2
3
Fig. 3: Functional principle - Plate capacitor
1 Distance between the electrode surfaces
2 Size of the electrode surfaces
3 Type of dielectric between the electrodes
The probe and the vessel wall are the capacitor plates.The measured
product and the insulation are the dielectric. Due to the higher dielec-
tric constant of the insulation and the conductive product compared to
air, the capacitance increases as the probe is gradually covered.
The capacitance as well as the resistance change are converted by
the electronics module into a level-proportional signal.
4 … 20 mA two-wire electronics for voltage supply and measured
value transmission on the same cable.
Thesupplyvoltagerangecandierdependingontheinstrument
version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Adjustment
VEGACAL 63 measurement signals can be evaluated with the follow-
ing:
• With a VEGAMET controller
The measuring range must be selected on the electronics module of
the probe.
The full and empty adjustment can be carried out on a VEGAMET
controller or the analogue input card of a PLC.
3.4 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
The packaging of standard instruments consists of environment-
friendly, recyclable cardboard. For special versions, PE foam or PE
foil is also used. Dispose of the packaging material via specialised
recycling companies.
Voltage supply
Packaging

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3 Product description
VEGACAL 63 • For connection to a controller
30318-EN-200317
Transport must be carried out in due consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
• Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
• Relative humidity 20 … 85 %
With instrument weights of more than 18 kg (39.68 lbs) suitable and
approved equipment must be used for lifting and carrying.
3.5 Accessories
The interface adapter VEGACONNECT enables the connection of
communication-capable instruments to the USB interface of a PC.
VEGADIS 82 is suitable for measured value indication and adjustment
of sensors with HART protocol. It is looped into the 4 … 20 mA/HART
signal cable.
The protective cover protects the sensor housing against soiling and
intense heat from solar radiation.
Screwedangesareavailableindierentversionsaccordingtothe
following standards: DIN 2501, EN 1092-1, BS 10, ASME B 16.5,
JIS B 2210-1984, GOST 12821-80.
Therearedierentreasonsfortheuseofascreeningtubeadapter.
Condensation
In case of strong condensation, the draining of condensed water
can change the measurement accuracy.The suitable version is the
Shielding against condensation.Thecondensationcandraino
outside on the shielding tube adapter.
Typical applications of the screening tube adapters are e.g. for
condensation or sockets. Apart from the standard version, there is
a second version for vacuum with a sepcial seal.When the screen-
Transport
Transport inspection
Storage
Storage and transport
temperature
Lifting and carrying
VEGACONNECT
VEGADIS 82
Protective cover
Flanges
Screening tube adapter

11
3 Product description
VEGACAL 63 • For connection to a controller
30318-EN-200317
ing tube adapter is submerged in liquid, we recommend the use of a
vacuum-tight version.
Mounting socket
In case of long sockets, the shielding tube can increase the sensitivity
oftheprobebycompensatingtheinuencesofthesocket.Thesuit-
able version is Capacitive shielding, vacuum-tight.
When the probe is mounted laterally, buildup can accumulate in the
socket. A screening tube makes the covered part of the probe inactive
andhenceinsensitivetoinuencefrombuildupandsocket.Hence,
thescreeningtubeadapterexcludeschanginginuencescausedby
the medium and ensures stable measurement conditions.The suit-
able version is Capacitive screening, vacuum-tight.

12
4 Mounting
VEGACAL 63 • For connection to a controller
30318-EN-200317
4 Mounting
4.1 General instructions
Make sure that all parts of the instrument coming in direct contact
with the process, especially the sensor element, process seal and
processtting,aresuitablefortheexistingprocessconditions,such
as process pressure, process temperature as well as the chemical
properties of the medium.
Youcanndthespecicationsinchapter"Technical data" and on the
nameplate.
The instrument is suitable for standard and extended ambient condi-
tions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1.
Select such a mounting location that the instrument is within easy
reach for mounting and connecting. For this purpose the housing can
be rotated by 330° without any tools being required.
Before beginning the welding work, remove the electronics module
from the sensor. By doing this, you avoid damage to the electronics
through inductive coupling.
Ground the probe before welding directly on the rod or cable.
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gland.Rainandcondensationwatercanthusdraino.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.
To maintain the housing protection, make sure that the housing lid is
closed during operation and locked, if necessary.
Makesurethatthedegreeofcontaminationspeciedinchapter
"Technical data" meets the existing ambient conditions.
Suitability for the process
conditions
Suitability for the ambient
conditions
Installation position
Welding work
Handling
Moisture

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4 Mounting
VEGACAL 63 • For connection to a controller
30318-EN-200317
Fig. 4: Measures against moisture ingress
Theprocesstting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speciedinchapter"Technical
data" or on the type label of the sensor.
Insulatingmeasures,suchase.g.coveringthethreadwithteon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sucientgrounding.
Use conductive seals, such as those made of copper or lead, etc.
Insulatingmeasures,suchascoveringthethreadwithTeon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 par-
allel 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.
Metric threads
In the case of instrument housings with metric thread, the cable
glands are screwed in at the factory.They are sealed with plastic
plugs as transport protection.
You have to remove these plugs before electrical connection.
Pressure/Vacuum
Vessel material
Vessel forms
Cable entries - NPT
thread
Cable glands

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4 Mounting
VEGACAL 63 • For connection to a controller
30318-EN-200317
NPT thread
In the case of instrument housings with self-sealing NPT threads, it is
not possible to have the cable entries screwed in at the factory. The
free openings for the cable glands are therefore covered with red dust
protection caps as transport protection.
Prior to setup you have to replace these protective caps with ap-
proved cable glands or close the openings with suitable blind plugs.
4.2 Mounting 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. 5: Fasten the probe
1 Measuring probe
2 Plastic socket
In vessels with conical bottom it can be advantageous to mount the
sensor in the centre of the vessel, as measurement is then possible
down to the bottom.
Iftheinstrumentismountedinthelling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
llingopenings,agitators,etc.,canoccur.
This applies particularly to instrument versions with a longer probe.
Installation position
Inowingmedium

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4 Mounting
VEGACAL 63 • For connection to a controller
30318-EN-200317
Fig.6:Inowingmedium
Tocompensatethematerial-specicpreloadlossduetosealingma-
terials,youhavetoadditionallyusediscspringsforfasteningange
screwsonPTFEcoatedanges.Tightenthescrewsmoderatelywith
the torque stated in the technical data. Depending on the process and
ambient conditions, this value can vary. In individual cases you should
occasionally check the tightness on site.
Torque with PTFE plated
anges

16
5 Connecting to power supply
VEGACAL 63 • For connection to a controller
30318-EN-200317
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
• Connect only in the complete absence of line voltage
• If overvoltage surges are expected, overvoltage arresters should
be installed
Tip:
We recommend using VEGA overvoltage arresters B63-48 and
ÜSB 62-36G.X.
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Power supply and current signal are carried on the same two-wire
cable.Thevoltagesupplyrangecandierdependingontheinstru-
ment version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
Provide a reliable separation between the supply circuit and the
mains circuits according to DIN VDE 0106 part 101.The VEGA power
supply units VEGATRENN 149AEx, VEGASTAB 690, VEGADIS 371
as well as all VEGAMETs meet this requirement.
Keepinmindthefollowingadditionalfactorsthatinuencetheoperat-
ing voltage:
• Output voltage of the power supply unit can be lower under nomi-
nal load (with a sensor current of 20.5 mA or 22 mA in case of fault
message)
• Inuenceofadditionalinstrumentsinthecircuit(seeloadvaluesin
chapter "Technical data")
The instrument is connected with standard two-wire cable without
shielding. If electromagnetic interference is expected which is above
the test values of EN 61326 for industrial areas, shielded cable should
be used.
Make sure that the cable used has the required temperature resist-
anceandresafetyformax.occurringambienttemperature
Use cable with round cross-section. A cable outer diameter of
5…9mm(0.2…0.35in)ensuresthesealeectofthecablegland.
Ifyouareusingcablewithadierentdiameterorcross-section,
exchange the seal or use a suitable cable gland.
If shielded cable is required, 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 equalisa-
tion (low impedance).
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Cable screening and
grounding

17
5 Connecting to power supply
VEGACAL 63 • For connection to a controller
30318-EN-200317
If potential equalisation currents are expected, the connection on the
processing side must be made via a ceramic capacitor (e. g. 1 nF,
1500 V).The low-frequency potential equalisation currents are thus
suppressed,buttheprotectiveeectagainsthighfrequencyinterfer-
ence signals remains.
Take note of the corresponding installation regulations for Ex applica-
tions. In particular, make sure that no potential equalisation currents
owoverthecablescreen.Incaseofgroundingonbothsidesthis
can be achieved by the use of a capacitor or a separate potential
equalisation.
5.2 Connection procedure
Proceed as follows:
1. Unscrew the housing lid
2. Loosen compression nut of the cable gland and remove blind
plug
3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
6. Insert the wire ends into the open terminals according to the wir-
ing plan
7. Press down the opening levers of the terminals, you will hear the
terminal spring closing
8. Check the hold of the wires in the terminals by lightly pulling on
them
9. Connect the screen to the internal ground terminal, connect the
external ground terminal to potential equalisation
10. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
11. Screw the housing lid back on
Theelectricalconnectionisnished.
Connection cable
for Ex applications

18
5 Connecting to power supply
VEGACAL 63 • For connection to a controller
30318-EN-200317
Fig. 7: Connection steps 6 and 7
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
1 2
4
3
5
5
55
Fig. 8: Material versions, single chamber housing
1 Plastic
2 Aluminium
3 Stainless steel (precision casting)
4 Stainless steel (electro-polished)
5 Filter element for air pressure compensation of all material versions. Blind
plug with version IP66/IP68, 1 bar for Aluminium and stainless steel
Housing overview

19
5 Connecting to power supply
VEGACAL 63 • For connection to a controller
30318-EN-200317
12
1
2
Fig. 9: Electronics and connection compartment - single chamber housing
1 Ground terminal for connection of the cable screening
2 Spring-loaded terminals for voltage supply
1
12
Fig. 10: Wiring plan - single chamber housing
1 Voltage supply/Signal output
5.4 Wiring plan - version IP66/IP68 (1 bar)
1
2
Fig. 11: Wire assignment, connection cable
1 Brown (+) and blue (-) to power supply or to the processing system
2 Shielding
Electronics and connec-
tion compartment
Wiring plan
Wire assignment, con-
nection cable

20
6 Setup with a controller
VEGACAL 63 • For connection to a controller
30318-EN-200317
6 Setup with a controller
6.1 General information
During setup, the probe must be calibrated with the medium that will
later be measured.To adjust the probe, open the housing cover.You
can select the sensitivity range on the electronics module by means
of the measuring range selection switch.
• range 1: 0 … 120 pF
• Range 2: 0 … 600 pF
• Range 3: 0 … 3000 pF
The adjustment is described in the operating instructions manual of
the respective controller.
6.2 Adjustment system
1
2
3
Fig. 12: Display and adjustment elements - Oscillator
1 DIL switch for measuring range selection
2 Ground terminal
3 Connection terminals
With the measuring range selection switch (1) you can adapt the
sensitivity of the probe to the electrical properties of the measured
medium and the conditions in the vessel.This is necessary to ensure
that the output current range is a big as possible.The resolution of the
probe is thus also correspondingly increased.
Due to this, the probe can for example also detect products with very
low or very high dielectric constant reliably.
• range 1 (sensitive): 0 … 120 pF
• range 2 (standard): 0 … 600 pF
• range 3 (less sensitive): 0 … 3000 pF
Function/Conguration
Measuring range selec-
tion switch (1)