Vega VEGACAL 67 User manual

Operating Instructions
Capacitive high temperature probe for
level measurement of bulk solids
VEGACAL 67
For connection to a controller
Document ID: 31761

2
Contents
VEGACAL 67 • For connection to a controller
31761-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 Environmental instructions ............................................................................................... 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 9
3.3 Adjustment..................................................................................................................... 10
3.4 Packaging, transport and storage................................................................................... 10
3.5 Accessories.................................................................................................................... 11
4 Mounting................................................................................................................................. 12
4.1 General instructions ....................................................................................................... 12
4.2 Mounting instructions ..................................................................................................... 14
5 Connecting to power supply................................................................................................. 15
5.1 Preparing the connection ............................................................................................... 15
5.2 Connection procedure.................................................................................................... 16
5.3 Wiring plan, single chamber housing.............................................................................. 17
5.4 Wiring plan - version IP66/IP68, 1 bar ............................................................................ 18
6 Setup with a controller .......................................................................................................... 19
6.1 General information........................................................................................................ 19
6.2 Adjustment system......................................................................................................... 19
6.3 Continuous level measurement...................................................................................... 20
7 Maintenanceandfaultrectication...................................................................................... 22
7.1 Maintenance .................................................................................................................. 22
7.2 Rectify faults................................................................................................................... 22
7.3 Exchanging the electronics module................................................................................ 23
7.4 Shortening the electrode................................................................................................ 24
7.5 How to proceed if a repair is necessary.......................................................................... 24
8 Dismount................................................................................................................................. 25
8.1 Dismounting steps.......................................................................................................... 25
8.2 Disposal ......................................................................................................................... 25
9 Supplement ............................................................................................................................ 26
9.1 Technical data ................................................................................................................ 26
9.2 Dimensions .................................................................................................................... 30
9.3 Industrial property rights................................................................................................. 32
9.4 Trademark ...................................................................................................................... 32

3
Contents
VEGACAL 67 • For connection to a controller
31761-EN-200317
Editing status: 2020-03-03

4
1 About this document
VEGACAL 67 • For connection to a controller
31761-EN-200317
1 About this document
1.1 Function
This operating instructions provides all the information you need for
mounting, connection and setup as well as important instructions for
maintenance,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, 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.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
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 67 • For connection to a controller
31761-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 67 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.

6
2 For your safety
VEGACAL 67 • For connection to a controller
31761-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 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"

7
3 Product description
VEGACAL 67 • For connection to a controller
31761-EN-200317
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• Level sensor VEGACAL 67
• 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 67 consists of the components:
• Processttingwithprobe
• Housing with electronics
• Housing cover, optionally available with display and adjustment
module
Scope of delivery
Constituent parts

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3 Product description
VEGACAL 67 • For connection to a controller
31761-EN-200317
1
2
3
5
4
Fig. 1: VEGACAL 67 with plastic housing
1 Housing lid
2 Housing with electronics
3 Processtting
4 Supporting tube
5 Ceramic insulator
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
Type label

9
3 Product description
VEGACAL 67 • For connection to a controller
31761-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 67 is a level sensor for continuous level measurement
of bulk solids at high process temperatures.
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 67 • For connection to a controller
31761-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 is the dielectric. Due to the higher dielectric constant of the
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 67 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 67 • For connection to a controller
31761-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.
Transport
Transport inspection
Storage
Storage and transport
temperature
Lifting and carrying
VEGACONNECT
VEGADIS 82
Protective cover
Flanges

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4 Mounting
VEGACAL 67 • For connection to a controller
31761-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 67 • For connection to a controller
31761-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.
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 67 • For connection to a controller
31761-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
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.
Fig.5:Inowingmedium
Make sure that the max. permissible tensile load of the suspension
cable is not exceeded. The danger of this happening exists particu-
larly with very heavy solids and large meas. lengths.The max. permis-
sible load is stated in chapter "Technical data".
Inowingmedium
Tensile load

15
5 Connecting to power supply
VEGACAL 67 • For connection to a controller
31761-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.
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 resp. 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).
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.
Note safety instructions
Voltage supply
Connection cable
Cable screening and
grounding

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5 Connecting to power supply
VEGACAL 67 • For connection to a controller
31761-EN-200317
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.
Fig. 6: Connection steps 6 and 7

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5 Connecting to power supply
VEGACAL 67 • For connection to a controller
31761-EN-200317
5.3 Wiring plan, single chamber housing
1 2
4
3
5
5
55
Fig. 7: 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
12
1
2
Fig. 8: Electronics and connection compartment - single chamber housing
1 Ground terminal for connection of the cable screening
2 Spring-loaded terminals for voltage supply
Housing overview
Electronics and connec-
tion compartment

18
5 Connecting to power supply
VEGACAL 67 • For connection to a controller
31761-EN-200317
1
12
Fig. 9: Wiring plan - single chamber housing
1 Voltage supply/Signal output
5.4 Wiring plan - version IP66/IP68, 1 bar
1
2
Fig. 10: Wire assignment, connection cable
1 Brown (+) and blue (-) to power supply or to the processing system
2 Shielding
Wiring plan
Wire assignment, con-
nection cable

19
6 Setup with a controller
VEGACAL 67 • For connection to a controller
31761-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. 11: 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)

20
6 Setup with a controller
VEGACAL 67 • For connection to a controller
31761-EN-200317
6.3 Continuous level measurement
Continuous measurement requires a constant dielectric value, i.e. the
measured product should have constant properties.
Select the stage with the measuring range selection switch on the
electronics module of the probe according to the following table.
Look in the row that corresponds to your product and select an ap-
propriate range according to the length of your probe.
The listed lengths do not completely correspond to those of the
actually available measuring probes. If the product has a dielectric
constant that lies between the values stated in the table, the max. per-
missible probe length for each range must be calculated accordingly.
For longer lengths or if there is no information available in the chart,
select range 3. If you are not sure, always set the measuring range
selection switch to the next higher stage.
VEGACAL 67
non-conductive and dielectric con-
stant = 2
0 - 6 m = range 1/6 - 30 m = range 2
non-conductive and dielectric con-
stant = 10
0 - 1 m = range 1/1 - 5 m = range 2
conductive or dielectric constant > 50 -
Tab. 1: Range setting
Tip:
For min. adjustment the vessel should be as empty as possible, and
for max. adjustment, as full as possible. If the vessel is already full,
start with max. adjustment.
1. Set range changeover switch on the capacitive probe according
to the above table
2. When connecting to an analogue input card of a PLC, take note
of the operating instructions manual of the input card.The vessel
must be as empty as possible for empty adjustment and as full as
possible for full adjustment.
If the indication cannot be set to 100 %, proceed as follows:
• If the indication does not reach 100 %, you have to set the range
selection switch on the probe one stage lower.
• If the indication exceeds 100 % and cannot be reset, you have
to set the range selection switch of the probe to the next higher
stage. In both cases you have to repeat the adjustment.
1. Set range changeover switch on the capacitive probe according
to the above table
2. Carry out the adjustment on the controller (see operating
instructions manual of the controller: "Adjustment with medium")
When connecting to an analogue input card of a PLC, take note of the
operating instructions manual of the input card.The vessel must be as
empty as possible for empty adjustment and as full as possible for full
adjustment.
If the indication cannot be set to 100 %, proceed as follows:
General information
Analogue input card of
a PLC
VEGAMET series 300, 600
controller