Vega VEGACAP 66 User manual

Operating Instructions
VEGACAP 66
with relay output

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
2.5CE conformity ......................... 5
2.6Safety information for Ex areas............. 6
2.7Environmental instructions ................ 6
3Product description
3.1Configuration.......................... 7
3.2Principle of operation.................... 8
3.3Adjustment ........................... 9
3.4Storage and transport ................... 9
4Mounting
4.1General instructions..................... 10
4.2Mounting information .................... 11
5Connecting to power supply
5.1Preparing the connection ................. 14
5.2Connection procedure ................... 14
5.3Wiring plans,single chamber housing ........ 15
6Set up
6.1General.............................. 18
6.2Adjustment elements .................... 18
6.3Function chart ......................... 20
7Maintenance and fault rectification
7.1Maintenance .......................... 22
7.2Fault rectification ....................... 22
7.3Exchanging the electronics................ 23
7.4Instrument repair ....................... 25
8Dismounting
8.1Dismounting procedure .................. 26
8.2Disposal ............................. 26
2VEGACAP 66 -with relay output
Contents
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9Supplement
9.1Technical data......................... 27
9.2Dimensions ........................... 31
9.3Certificates ........................... 33
9.4Industrial property rights.................. 34
VEGACAP 66 -with relay output 3
Contents
30020-EN-050920

1About this document
1.1Function
This operating instructions manual has all the information you
need for quick setup and safe operation of VEGACAP 66.
Please read this manual before you start setup.
1.2Target group
This operating instructions manual is directed to trained
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,warning,danger
This symbol informs you of a dangerous situation that could
occur.Ignoring this cautionary note can impair the person and/
or the instrument.
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.
4VEGACAP 66 -with relay output
About this document
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2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual
must be carried out only by trained,specialised personnel
authorised by the operator.For safety and warranty reasons,
any internal work on the instruments must be carried out only
by personnel authorised by the manufacturer.
2.2Appropriate use
VEGACAP 66 is a sensor for level detection.
Detailed information on the application range of VEGACAP 66
is available in chapter Product description.
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
VEGACAP 66 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
(e.g.the VDE regulations in Germany)as well as all prevailing
safety regulations and accident prevention rules.
2.5CE conformity
VEGACAP 66 is in CE conformity with EMC (89/336/EWG)
and NSR (73/23/EWG).
Conformity has been judged acc.to the following standards:
lEMC:
-Emission EN 61326:2004 (class B)
-Susceptibility EN 61326:2004/Supplement A
lNSR:EN 61010-1:2001
VEGACAP 66 -with relay output 5
For your safety
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2.6Safety information 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.
2.7Environmental instructions
Protection of the environment is one of our most important
duties.That is why we have introduced an environment
management system with the goal of continuously improving
company environmental protection.The environment man-
agement system is certified acc.to DIN EN ISO 14001.
Please help us fulfil this obligation by observing the environ-
mental instructions in this manual:
lChapter "Storage and transport"
lChapter "Disposal"
6VEGACAP 66 -with relay output
For your safety
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3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAP 66 level sensor
lDocumentation
-this operating instructions manual
-Ex-specific safety instructions (with Ex versions)and,if
necessary,further certificates
VEGACAP 66 consists of the following components:
lHousing cover
lHousing with electronics
lProcess fitting with electrode
1
2
3
Fig.1:VEGACAP 66 -with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
Scope of delivery
Components
VEGACAP 66 -with relay output 7
Product description
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3.2Principle of operation
VEGACAP 66 is a level sensor with fully insulated capacitive
electrode for level detection.
VEGACAP 66 is very rugged and maintenance-free and can
be used in all areas of industrial process technology.
Fully insulated probes such as VEGACAP 66 are used in
solids as well as in liquids.
Typical applications are overfill and dry run protection.
The capacitive measuring principle places no special require-
ments on installation.Hence,many different applications can
be equipped with VEGACAP 66.
Problem-free use in adhesive or corrosive products.
The probe,the measured product and the 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 material gradually covers the
probe.
The capacitance change is converted by the oscillator into a
switching command.
Area of application
Physical principle
8VEGACAP 66 -with relay output
Product description
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VEGACAP 66 is a compact instrument,i.e.it can be operated
without external evaluation system.The integrated electronics
evaluates the level signal and outputs a switching signal.With
this switching signal,a connected device can be operated
directly (e.g.a warning system,aPLC,a pump etc.).
The exact range of the power supply is stated in the Technical
data in the Supplement.
3.3Adjustment
The probe can be adapted to the dielectric constant of the
product directly on the electronics module.
Aswitching command can be triggered when the probe is
covered or laid bare.
On the electronics module you will find the following indicating
and adjustment elements:
lsignal lamp for indication of the switching condition (green/
red)
lPotentiometer for switching point adaptation
lDIL switch for measuring range selection
lDIL switch for mode adjustment
3.4Storage and transport
Your instrument was protected by packaging during transport.
Its capacity to handle normal loads during transport is assured
by a test acc.to DIN 55439.
The packaging of standard instruments consists of environ-
ment-friendly,recyclable cardboard.For special versions,PE
foam or PE foil is also used.Dispose of the packaging material
via specialised recycling companies.
lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 ... 85 %
Power supply
Packaging
Storage and transport tem-
perature
VEGACAP 66 -with relay output 9
Product description
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4Mounting
4.1General instructions
In general,VEGACAP 66 can be mounted in any position.The
instrument must be mounted in such a way that the probe is at
the height of the requested switching point.
With screwed versions,the housing must not be used for
screwing in!Tightening can cause damages on the locking
piston of the housing.
To screw in,use the hexagon above the thread.
Use the recommended cable (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your VEGACAP 66 additional protection against
moisture penetration by leading the connection cable down-
ward in front of the cable entry.Rain and condensation water
can thus drain off.This applies mainly to mounting outdoors,in
areas where moisture is expected (e.g.by cleaning processes)
or on cooled or heated vessels.
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.
Switching point
Handling
Moisture
Pressure/Vacuum
10 VEGACAP 66 -with relay output
Mounting
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4.2Mounting information
Due to agitators,vibrations or similar,the level switch can be
subjected to strong lateral forces.For this reason,do not use
an overly long probe for VEGACAP 66,but check if you can
mount a short level switch on the side of the vessel in
horizontal position.
IfVEGACAP 66 is mounted in the filling stream,unwanted
faulty measurements may be generated.Mount VEGACAP 66
at a location in the vessel where no disturbing influence from e.
g.filling openings,agitators,etc.can occur.
This applies to all instrument types with long probe.
Fig.4:Inflowing material
The probe should protrude into the vessel to avoid buildup.For
that reason,avoid using mounting bosses for flanges and
screwed fittings.This applies particularly to use with adhesive
products.
Material cones can form in solids silos which can change the
switching point.Please keep this in mind when installing the
sensor in the vessel.We recommend selecting an installation
location where the probe detects an average value of the
material cone.
Agitators and fluidization
Inflowing material
Socket
Material cone
VEGACAP 66 -with relay output 11
Mounting
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The measuring probe must be mounted in a way that takes the
arrangement of the filling and emptying apertures into
consideration.
To compensate measurement errors in cylindrical vessels
caused by the material cone,the sensor must be mounted at a
distance of d/6from the vessel wall.
d d
d
6
d
6
Fig.5:Filling and emptying centered
12 VEGACAP 66 -with relay output
Mounting
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d
d
6
1
2
3
Fig.6:Filling in the center,emptying laterally
1VEGACAP 66
2Emptying opening
3Filling opening
Make sure that the max.permissible tensile load of the
suspension cable is not exceeded.This danger exists
particularly with very heavy solids and large meas.lengths.
The max.permissible load is stated in the Technical data in the
Supplement.
Tensile load
VEGACAP 66 -with relay output 13
Mounting
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5Connecting to power supply
5.1Preparing the connection
Always observe the following safety instructions:
lConnect only in the complete absence of line voltage
Connect the power supply acc.to the following diagrams.
Oscillator CP60Ris designed in protection class 1.To
maintain this protection class,it is absolutely necessary that
the ground conductor is connected to the internal ground
terminal.Take note of the general installation regulations.Asa
rule,connect VEGACAP 66 to vessel ground (PA), or in case
of plastic vessels,to the next ground potential.On the side of
the housing there is a ground terminal between the cable
entries.This connection serves to drain offelectrostatic
charges.
The data for power supply are stated in the Technical data in
the Supplement.
VEGACAP 66 is connected with standard cable with round
wire cross section.An outer cable diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable entry.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
5.2Connection procedure
With Ex instruments,the housing cover may only be opened if
there is no explosive atmosphere present.
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip
approx.1cm (0.4in)insulation from the ends of the
individual wires
4Insert the cable into the sensor through the cable entry
5Lift the opening levers of the terminals with a screwdriver
(see following illustration)
6Insert the wire ends into the open terminals according to
the wiring plan
Note safety instructions
Select power supply
Selecting the connection ca-
ble
14 VEGACAP 66 -with relay output
Connecting to power supply
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7Press down the opening levers of the terminals,you will
hear the terminal spring closing
8Check the hold of the wires in the terminals by lightly
pulling on them
9Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
10 Screw the housing cover back on
The electrical connection is finished.
Fig.7:Connection steps 5and 6
5.3Wiring plans,single chamber housing
1
4
44
2 3
Fig.8:Material versions,single chamber housing
1Plastic (not with dust-Ex)
2Aluminium
3Stainless steel
4Filter element for pressure compensation
Housing overview
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Connecting to power supply
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4
5
6
2
1
3
Fig.9:Electronics and connection compartment
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Terminals
6Control lamp
We recommend connecting VEGACAP 66 in such a way that
the switching circuit is open when there is a level signal,line
break or failure (safe condition).
The relays are always shown in non-operative condition.
Electronics and connection
compartment
Wiring plan
16 VEGACAP 66 -with relay output
Connecting to power supply
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32 1
Fig.10:Wiring plan
1Relay output
2Relay output
3Supply voltage
VEGACAP 66 -with relay output 17
Connecting to power supply
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6Set up
6.1General
The numbers in brackets refer to the following illustrations.
On the electronics module you will find the following indicating
and adjustment elements:
lPotentiometer for switching point adaptation
lDIL switch for measuring range selection
lDIL switch for mode adjustment -min/max
lControl lamp
Note:
As a rule,always set the mode with the mode switch (3)before
starting to set up VEGACAP 66.The switching output will
change if you set the mode switch (3)afterwards.This could
possibly trigger other connected instruments or devices.
6.2Adjustment elements
4
5
6
2
1
3
Fig.11:Oscillator -Relay output
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Terminals
6Control lamp
Function/Configuration
18 VEGACAP 66 -with relay output
Set up
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The switching status of the electronics can be checked with
closed housing (only plastic housing), see "Function chart“.
Note:
Screw the housing cover tightly to the point where the
inspection glass is above the control lamp (LED).
To adjust VEGACAP 66,first of all remove the housing cover.
You can adapt the switching point to the solid with the
potentiometer.
As a default setting,the potentiometer of VEGACAP 66 is set
to mid position.To make the instrument less sensitive,turn the
potentiometer clockwise.VEGACAP 66 can then detect
products with high dielectric value (e.g.water)more reliably.
To make the instrument more sensitive,turn the potentiometer
anticlockwise.VEGACAP 66 can then detect products with low
dielectric value (e.g.oil)more reliably.
With the potentiometer (1)and the meas.range selection
switch (2)you can change the switching point of the probe or
adapt the sensitivity of the probe to the electrical properties of
the product and the conditions in the vessel.This is necessary
so that the level switch can also reliably detect products,e.g.
with very low or very high dielectric value.
Range 1–0... 20 pF
Range 2–0... 85 pF
Range 3–0... 450 pF
With the mode switch (3)you can change the switching
condition of the relay.You can set the required mode.max.–
max.detection or overfill protection,min.–min.detection or
dry run protection.
We recommend connecting acc.to the quiescent current
principle (replay contact deenergizes when reaching the
switching point), because the relay takes on the same (safe)
condition if a failure is detected.
Signal lamp for indication of the switching condition.
lgreen =relay energized
lred =relay deenergized
lred (flashing)=failure
Switching point adaptation (1)
Measuring range selection
switch (2)
Mode adjustment (3)
Signal lamp (6)
VEGACAP 66 -with relay output 19
Set up
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The adjustment of the switching point is only possible in
installed condition
The numbers in brackets refer to the following illustrations.
Vertically mounted probes
1Set mode switch (3)to mode max.
2Set meas.range selection switch (2)to range 1.
3Fill the vessel up to the requested level.
4Turn the potentiometer (1)to 10;the control lamp (6)lights
green.
5Turn the potentiometer (1)very slowly anticlockwise until
the control lamp (6)lights red.If the control lamp does not
light red,then you have to set the meas.range selection
switch (2)to the next higher stage and repeat the setting
with the potentiometer (1)until the control lamp lights red.
The measuring system is now ready for operation.
1Set mode switch (3)to mode min.
2Set meas.range selection switch (2)to position 1.
3Lower the level to the requested min.level.
4Turn the potentiometer (1)to 0;the control lamp (6)lights
green.
5Turn the potentiometer (1)very slowly clockwise until the
control lamp (6)lights red.If the control lamp does not light
red,set the meas.range selection switch (2)the the next
higher stage and repeat the setting with the potentiometer
(1)until the control lamp lights red.
The measuring system is now ready for operation.
6.3Function chart
The following chart provides an overview of the switching
conditions depending on the adjusted mode and level.
Level Switching sta-
tus
Control lamp
max.mode
Overfill protection
53 4
(8)(6) (7)
Relay energized Green
Switching point adjustment
Mode max.(max.de-
tection)
Mode min.(min.detection)
20 VEGACAP 66 -with relay output
Set up
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