Vega VEGAFLEX 80 User guide

Safety Manual
VEGAFLEX 80 series
4 … 20 mA/HART - two-wire
With SIL qualication
Document ID: 42960

2
Contents
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
Contents
1 Document language
2 Scope
2.1 Instrument version............................................................................................................ 4
2.2 Area of application ........................................................................................................... 4
2.3 SIL conformity .................................................................................................................. 4
3 Planning
3.1 Safety function ................................................................................................................. 5
3.2 Safe state ......................................................................................................................... 5
3.3 Prerequisites for operation ............................................................................................... 5
4 Safety-related characteristics
4.1 Keyguresacc.toIEC61508........................................................................................... 6
4.2 FiguresaccordingtoISO13849-1.................................................................................... 6
4.3 Supplementary information .............................................................................................. 6
5 Setup
5.1 General information.......................................................................................................... 8
5.2 Instrumentparameteradjustment..................................................................................... 8
6 Diagnostics and service
6.1 Behaviour in case of failure ............................................................................................ 10
6.2 Repair ............................................................................................................................ 10
7 Proof test
7.1 General information........................................................................................................ 11
7.2 Test1-withoutcheckingthelevel .................................................................................. 11
7.3 Test2-withcheckingthelevel ....................................................................................... 11
8 Appendix A - Test report
9 AppendixB-Termdenitions
10 Supplement C - SIL conformity
Editingstatus:2014-09-24

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1Documentlanguage
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
1 Document language
DE DasvorliegendeSafety ManualfürFunktionaleSicherheitistverfügbarindenSprachen
Deutsch,Englisch,FranzösischundRussisch.
EN The current Safety ManualforFunctionalSafetyisavailableinGerman,English,Frenchand
Russianlanguage.
FR Le présent Safety Manualdesécuritéfonctionnelleestdisponibledansleslanguessuivantes:
allemand,anglais,françaisetrusse.
RU ДанноеруководствопофункциональнойбезопасностиSafety Manualимеетсяна
немецком,английском,французскомирусскомязыках.

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2 Scope
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
2 Scope
2.1 Instrument version
This safety manual applies to TDR sensors
VEGAFLEX 81, 82, 83, 86
Electronics types:
• 4…20mA/HART-two-wirewithSILqualication
• 4…20mA/HART-two-wirewithSILqualicationandsupplemen-
taryelectronics"Additionalcurrentoutput4…20mA"
Validversions:
• from HW Ver 1.0.0
• from SW Ver 1.0.0
Probetypes:
• OnlyoriginalprobesofVEGAGrieshaberKGmustbeused
2.2 Area of application
Theinstrumentcanbeusedforpointleveldetectionorlevelmeasure-
mentinliquidsandbulksolidsaswellasforinterfacemeasurementin
liquidsinasafety-instrumentedsystemaccordingtoIEC61508inthe
modeslow demand modeandhigh demand mode:
• UptoSIL2inasingle-channelarchitecture
• Up to SIL3 in a multiple-channel architecture
Thefollowinginterfaceshouldbeusedtooutputthemeasuredvalue:
• Current output: 4 … 20 mA
Thefollowinginterfacesareonlypermittedforparameteradjustment
andforinformativeuse:
• HART®
• DisplayandadjustmentmodulePLICSCOM
• VEGACONNECT
• Current output II1)
2.3 SIL conformity
TheSILconformitywasindependentlyjudgedandcertiedbythe
TÜV Rheinland accordingtoIEC61508:2010(Ed.2).2)
Thecerticateisvalidfortheentireservicelifeofallinstrumentsthat
weresoldbeforethecerticateexpired!
1) Onlywithinstrumentversionwithsupplementaryelectronics"Additionalcur-
rent output 4 … 20 mA".
2) Vericationdocumentsseeappendix

5
3Planning
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
3 Planning
3.1 Safety function
Onitscurrentoutput,thesensorgeneratesasignalbetween3.8mA
and20.5mAcorrespondingtothelevelortheinterface.Thisana-
loguesignalisfedtoaconnectedprocessingsystemtomonitorthe
followingconditions:
• Exceedingalevelorinterfacelimit
• Fallingbelowalevelorinterfacelimit
• Monitoringofalevelorinterfacerange
Fortheinterpretationofthesafetyfunction,thefollowingaspects
mustbetakenintoaccountinrespecttothetolerances:
• Duetoadangerousundetectedfailureintherangebetween
3.8mAand20.5mA,anincorrectoutputsignalcanbegenerated
whichdeviatesfromtherealmeasuredvaluebyupto2%
• Increasedmeasurementdeviationscanoccurattheboundariesof
themeasuringrange(seeTechnicalDataintheoperatinginstruc-
tions)
3.2 Safe state
Thesafestateofthecurrentoutputdependsonthesafetyfunction
andthecharacteristicssetonthesensor.
Character-
istics
Monitoring upper limit val-
ue
Monitoring lower limit value
4 … 20 mA Outputcurrent≥Switching
point
Outputcurrent≤Switching
point
20 … 4 mA Outputcurrent≤Switching
point
Outputcurrent≥Switching
point
Possiblefaultcurrents:
• ≤3.6mA("faillow")
• >21mA("failhigh")
3.3 Prerequisites for operation
• Themeasuringsystemshouldbeusedappropriatelytakingpres-
sure,temperature,densityandchemicalpropertiesofthemedium
intoaccount.Theapplication-speciclimitsmustbeobserved.
• Thespecicationsaccordingtotheoperatinginstructionsmanual,
particularlythecurrentloadontheoutputcircuits,mustbekept
withinthespeciedlimits
• Existingcommunicationinterfaces(e.g.HART,USB)arenotused
fortransmissionofthesafety-relevantmeasuredvalue
• The instructions in chapter "Safety-related characteristics", para-
graph"Supplementary information"mustbenoted
• Allpartsofthemeasuringchainmustcorrespondtotheplanned
"Safety Integrity Level (SIL)"
Safety function
Safety tolerance
Safe state
Output signals in case of
malfunction
Instructions and restric-
tions

6
4Safety-relatedcharacteristics
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
4 Safety-related characteristics
4.1 Keyguresacc.toIEC61508
Parameter Value
SafetyIntegrityLevel SIL2insingle-channelarchitecture
SIL3 in multiple channel architecture3)
Hardwareerrortolerance HFT = 0
Instrument type Type B
Mode Lowdemandmode,Highdemandmode
SFF >90%
MTTR 8 h
MTBF=MTTF+MTTR4) 0.3x106h(35years)
Diagnosistestinterval5) < 30 min
Failure rates
λSλDD λDU λHλLλAD λAU
0 FIT 2154 FIT 158 FIT 9 FIT 56 FIT 32 FIT 19 FIT
PFDAVG 0.133x10-2 (T1=1year)
PFDAVG 0.196x10-2 (T1=2years)
PFDAVG 0.382x10-2 (T1=5years)
PFH 0.158x10-6 1/h
4.2 Figures according to ISO 13849-1
Derivedfromthesafety-relatedcharacteristics,thefollowinggures
resultaccordingtoISO13849-1(machinesafety):6)
Parameter Value
MTTFd 47 years
DC 93%
Performance Level 1.58x10-71/h(correspondsto"d")
4.3 Supplementary information
ThefailureratesoftheinstrumentweredeterminedbyanFMEDA
accordingtoIEC61508.Basisforthecalculationsarethecomponent
failureratesaccordingtoSN 29500.
Allguresrefertoanaverageambienttemperatureof40°C(104°F)
duringtheoperatingtime.Forhighertemperatures,thevaluesshould
becorrected:
• Continuousapplicationtemperature>50°C(122°F)byfactor1.3
Determination of the
failure rates
3) Homogeneousredundancypossible
4) Includingerrorsoutsidethesafetyfunction.
5) Timeduringwhichallinternaldiagnosesarecarriedoutatleastonce.
6) ISO13849-1wasnotpartofthecerticationoftheinstrument.

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4Safety-relatedcharacteristics
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
• Continuousapplicationtemperature>60°C(140°F)byfactor2.5
Similarfactorsapplyiffrequenttemperatureuctationsareexpected.
• The failure rates are constant. Take note of the useful service life of
thecomponentsaccordingtoIEC61508-2.
• Multipleerrorsarenottakenintoaccount
• Wear on mechanical parts is not taken into account
• Failureratesofexternalpowersuppliesarenottakenintoaccount
• Theenvironmentalconditionscorrespondtoanaverageindustrial
environment
The values for PFDAVGspeciedabovewerecalculatedasfollowsfora
1oo1 architecture:
PFDAVG= +λDD x MTTR +
PTC × λ
DU
× T1
2
(1 – PTC) ×
λ
DU
× LT
2
• T1(ProofTestInterval)
• MTTR=8h
• PTC=90%
• LT = 10 years
Aconnectedcontrolandprocessingunitmusthavethefollowing
properties:
• Theoutputcircuitofthetransmitterisjudgedaccordingtotheidle
current principle
• "fail low"and"fail high"signalsareinterpretedasafailure,which
triggersafaultmessage
Ifthisisnotthecase,therespectivepercentagesofthefailurerates
mustbeassignedtothedangerousfailuresandthevaluesstatedin
chapter Safety-related characteristics“redetermined!
InmultiplechannelsystemsforSIL3applications,thismeasuringsys-
temcanalsobeusedinahomogeneouslyredundantconguration.
Thesafety-relatedcharacteristicsmustbecalculatedespeciallyfor
theselectedstructureofthemeasuringchainusingthestatedfailure
rates.Indoingthis,asuitableCommonCauseFactormustbeconsid-
ered(seeIEC61508-6,appendixD).
Assumptions of the
FMEDA
Calculation of PFDAVG
Boundary conditions re-
latingtotheconguration
of the processing unit
Multiple channel archi-
tecture

8
5 Setup
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
5 Setup
5.1 General information
Takenoteofthemountingandinstallationinstructionsintheoperating
instructions manual.
Whenlockingtheadjustment,theinstrumentchecksthedataofthe
measurementloopanddecidesonthebasisoftheevaluationresults
if it is necessary to check the level.
Hencethefollowingactionsmustbecarriedoutatthetimeofevery
startup:
• Unlockadjustment
• ifnecessary,changeparameters
• Lockadjustmentandverifymodiedparameters,ifnecessary
5.2 Instrument parameter adjustment
Thefollowingadjustmentunitsarepermittedforparameterizationof
the safety function:
• Displayandadjustmentmodule
• TheDTMsuitableforVEGAFLEX80inconjunctionwithan
adjustmentsoftwareaccordingtotheFDT/DTMstandard,e.g.
PAC Twa r e
• ThedevicedescriptionEDDsuitableforVEGAFLEX80
Theparameteradjustmentisdescribedintheoperatinginstructions
manual.
Thedocumentationofthedevicesettingsisonlypossiblewiththefull
versionoftheDTMCollection.
Forprotectionagainstunwantedorunauthorzedadjustment,theset
parametersmustbeprotectedagainstunauthorizedaccess.Forthis
reason,theinstrumentisshippedinlockedcondition.ThePINin
deliverystatusis"0000".
Thedefaultvaluesoftheparametersarelistedintheoperatingin-
structions.Whenshippedwithcustomer-specicparametersettings,
theinstrumentisaccompaniedbyalistofthevaluesdieringfromthe
defaultvalues.
Bymeansoftheserialnumberthislistcanalsobedownloadedat
www.vega.com/VEGA Tools/serial number search.
Toavoidordetectpossibleerrorsduringparameteradjustmentfor
unsafeoperatingenvironments,avericationprocedureisusedthat
allowsthesafety-relevantparameterstobechecked.
Parameteradjustmentproceedsaccordingtothefollowingsteps:
• Unlockadjustment
• Changeparameters
• Lockadjustmentandverifymodiedparameters
Theexactprocessisdescribedintheoperatinginstructions.
Mounting and installation
Function test
Tools
Safety-relevant param-
eters
Safe parameterization

9
5 Setup
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
Forverication,allmodied,safety-relevantandnonsafety-relevant
parameters are shown.
ThevericationtextsaredisplayedeitherinGermanor,whenany
othermenulanguageisused,inEnglish.
Warning:
Whenadjustmentisunlocked,thesafetyfunctionmustbeconsidered
asunreliable.Thisappliesuntiltheparametersareveriedandthe
adjustmentislockedagain.Iftheparameteradjustmentprocessis
notcarriedoutcompletely,thedevicestatusesdescribedintheoper-
atinginstructionsmustbetakenintoconsideration.
If necessary, you must take other measures to maintain the safety
function.
Warning:
In case a reset to "Delivery status" or "Basic adjustment"iscarried
out,allsafety-relevantparametersmustbecheckedorsetanew.
Unsafe device
status
Instrument reset

10
6Diagnosticsandservice
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
6 Diagnostics and service
6.1 Behaviour in case of failure
Theinstrumentispermanentlymonitoredbyaninternaldiagnostic
system.Ifamalfunctionisdetected,therespectiveoutputsignals
changetothestatusconguredespeciallyforthiscondition(seesec-
tion "Safe status").
Thediagnosisintervalisspeciedinchapter"Safety-related charac-
teristics".
Afaultmessagecodedaccordingtothetypeoffaultisoutputted.The
faultmessagesarelistedintheoperatinginstructions.
6.2 Repair
Iffaultsaredetected,theentiremeasuringsystemmustbeshutdown
andtheprocessheldinasafestatebyothermeasures.
Themanufacturermustbeinformedoftheoccurrenceofadanger-
ous,undetectederror(incl.faultdescription).
Theprocedureisdescribedintheoperatinginstructionsmanual.Note
theinstructionsforparameteradjustmentandsetup.
Theprocedureisdescribedintheoperatinginstructionsmanual.Note
theinstructionsforparameteradjustmentandsetup.
Internal diagnosis
Error messages
Reaction when malfunc-
tions occur
Electronics exchange
Software update

11
7 Proof test
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
7 Proof test
7.1 General information
Toidentifypossibleundetected,dangerousfailures,thesafetyfunc-
tionmustbecheckedinadaquateintervalsbyaprooftest.Itisthe
user'sresponsibilitytochoosethetypeoftesting.Thetimeintervals
aresubjecttothePFDAVG in chapter "Safety-related characteristics".
Fordocumentationofthesetests,thetestprotocolintheappendix
canbeused.
Ifoneofthetestsprovesnegative,theentiremeasuringsystemmust
beswitchedoutofserviceandtheprocessheldinasafestateby
means of other measures.
In a multiple channel architecture this applies separately to each
channel.
• Determinesafetyfunction(mode,switchingpoints)
• Ifnecessary,removetheinstrumentsfromthesafetychainand
maintainthesafetyfunctionbyothermeans
• Provideanapprovedadjustmentunit
Warning:
Duringthefunctiontest,thesafetyfunctionmustbetreatedasunreli-
able.Takeintoaccountthatthefunctiontestinuencesdownstream
connecteddevices.
If necessary, you must take other measures to maintain the safety
function.
Afterthefunctiontest,thestatusspeciedforthesafetyfunctionmust
berestored.
7.2 Test 1 - without checking the level
• Instrumentininstalledcondition
• Distance from the sensor reference point to the level > 300 mm
• Outputsignalcorrespondstothelevel
• DevicestatusinthemenuDiagnosis:"OK"
1. Carryoutarestart(switchtheinstrumentoandthenonagain)
2. Press the menu item "Start proof test"inthemenuDiagnosison
theadjustmentunit
• To 1:
– Outputsignalcorrespondstothelevel
– DevicestatusinthemenuDiagnosis:"OK"
• To 2:
– Adjustmentunitsignals"Test successful"
Remainingdangerous,undetectedfailures:11FIT(PTC=93%)
7.3 Test 2 - with checking the level
• Instrumentininstalledcondition
• Distance from the sensor reference point to the level > 300 mm
• Outputsignalcorrespondstothelevel
Objective
Preparation
Unsafe device
status
Conditions
Procedure
Expected result
Coverage of the test
Conditions

12
7 Proof test
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
• DevicestatusinthemenuDiagnosis:"OK"
1. Carryoutarestart(switchtheinstrumentoandthenonagain)
2. Press the menu item "Start proof test"inthemenuDiagnosison
theadjustmentunit
3. Carryoutthefunctiontestaccordingtotheoperatinginstructions
justlikeduringinitialoperation.
• To 1:
– Outputsignalcorrespondstothelevel
– DevicestatusinthemenuDiagnosis:"OK"
• To 2:
– Adjustmentunitsignals"Test successful"
• To 3:
– Successful function test
Remainingdangerous,undetectedfailures:4FIT(PTC=98%)
Procedure
Expected result
Coverage of the test

13
8AppendixA-Testreport
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
8 Appendix A - Test report
Identication
Company/Tester
Plant/Instrument TAG
Meas.loopTAG
Instrumenttype/Ordercode
Instrumentserialnumber
Date, setup
Date, last function test
Test reason/Test scope
Setup without function test
Setup with function test
Proof test without function test
Proof test with function test
Mode
Overowprotection
Dry run protection
Rangemonitoring
Adjusted parameters of the safety function are documented
Ye s
No
Test result (if necessary)
Test point Level Expected measured
value
Real value Test result
Level 1
Level 2
Level 3
Level 4
Level 5
Conrmation
Date: Signature:

14
9AppendixB-Termdenitions
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
9 AppendixB-Termdenitions
SIL SafetyIntegrityLevel
HFT HardwareFaultTolerance
SFF Safe Failure Fraction
PFDAVG AverageProbabilityofdangerousFailureonDemand
PFH Averagefrequencyofadangerousfailureperhour(Ed.2)
FMEDA FailureMode,EectsandDiagnosticsAnalysis
FIT FailureInTime(1FIT=1failure/109h)
λSD Rateforsafedetectedfailure
λSU Rateforsafeundetectedfailure
λSλS=λSD+λSU
λDD Ratefordangerousdetectedfailure
λDU Ratefordangerousundetectedfailure
λHRateforfailure,whocausesahighoutputcurrent(>21mA)
λLRateforfailure,whocausesalowoutputcurrent(≤3.6mA)
λAD Ratefordiagnosticfailure(detected)
λAU Ratefordiagnosticfailure(undetected)
DC DiagnosticCoverage
PTC ProofTestCoverage
T1 Proof Test Interval
LT Useful Life Time
MTBF MeanTimeBetweenFailure
MTTF MeanTimeToFailure
MTTR MeanTimeToRestoration(Ed.2)
MTTFdMeanTimeTodangerousFailure(ISO13849-1)
PL PerformanceLevel(ISO13849-1)
Abbreviations

15
10 Supplement C - SIL conformity
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924
10 Supplement C - SIL conformity

16
10 Supplement C - SIL conformity
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924

17
Notes
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924

18
Notes
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924

19
Notes
VEGAFLEX 80 series • 4 … 20 mA/HART - two-wire
42960-EN-140924

Printing date:
VEGA Grieshaber KG
Am Hohenstein 113
77761 Schiltach
Germany
42960-EN-140924
All statements concerning scope of delivery, application, practical use and operat-
ing conditions of the sensors and processing systems correspond to the information
available at the time of printing.
Subject to change without prior notice
© VEGA Grieshaber KG, Schiltach/Germany 2014
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