Vega VEGAPULS 61 User manual

Operating Instructions
VEGAPULS 61
Foundation Fieldbus
Document ID:
36502
Radar

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 ............................. 6
2.6Fulfillment of NAMUR recommendations .......... 6
2.7Radio approval for Europe .................... 6
2.8Radio approval for USA/Canada ................ 6
2.9Environmental instructions..................... 6
3Product description
3.1Structure ................................. 7
3.2Principle of operation ........................ 8
3.3Packaging,transport and storage ............... 8
3.4Accessories and replacement parts .............. 9
4Mounting
4.1General instructions ......................... 11
4.2Collar or adapter flange ...................... 11
4.3Mounting preparations,mounting strap............ 12
4.4Mounting instructions ........................ 13
5Connecting to the bus system
5.1Preparing the connection ..................... 24
5.2Connection................................ 25
5.3Wiring plan,single chamber housing ............. 26
5.4Wiring plan,double chamber housing ............ 27
5.5Wiring plan with double chamber housing Ex d . . . . . 28
5.6Wiring plan -version IP 66/IP 68,1bar ........... 30
5.7Switch on phase............................ 30
6Set up with the indicating and adjustment module
6.1Insert indicating and adjustment module........... 31
6.2Adjustment system .......................... 32
6.3Parameter adjustment........................ 33
6.4Saving the parameter adjustment data ............ 45
7Setup with PACTware
7.1Connecting the PC .......................... 46
7.2Parameter adjustment with PACTware ............ 46
7.3Saving the parameter adjustment data ............ 47
2VEGAPULS 61 •Foundation Fieldbus
Contents
36502-EN-110127

8Set up with other systems
8.1DD adjustment programs ..................... 48
8.2Communicator 375,475 ...................... 48
9Diagnosis and service
9.1Maintenance .............................. 49
9.2Measured value and event memory .............. 49
9.3Status messages ........................... 50
9.4Fault rectification ........................... 53
9.5Exchanging the electronics module .............. 54
9.6Software update ............................ 54
9.7How to proceed in case of repair................ 55
10 Dismounting
10.1Dismounting steps .......................... 56
10.2Disposal ................................. 56
11 Supplement
11.1Technical data ............................. 57
11.2Supplementary information Foundation Fieldbus . . . . . 65
11.3Dimensions ............................... 77
Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
VEGAPULS 61 •Foundation Fieldbus 3
Contents
36502-EN-110127

1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2Target group
This operating instructions manual is directed to trained qualified
personnel.The contents of this manual should be made available to
these personnel and put into practice by them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution:If this warning is ignored,faults or malfunctions can
result.
Warning:If this warning is ignored,injury to persons and/or serious
damage to the instrument can result.
Danger:If this warning is ignored,serious injury to persons and/or
destruction of the instrument can result.
Exapplications
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.
4VEGAPULS 61 •Foundation Fieldbus
1About this document
36502-EN-110127

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
VEGAPULS 61 is a sensor for continuous level measurement.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to system
components through incorrect mounting or adjustment.
2.4General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines.The instrument must only be operated in a
technically flawless and reliable condition.The operator is responsible
for the trouble-free operation of the instrument.
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
regulations.
The safety instructions in this operating instructions manual,the
national 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.Arbitrary
conversions or modifications are explicitly forbidden.
The safety approval markings and safety tips on the device must also
be observed.
VEGAPULS 61 •Foundation Fieldbus 5
2For your safety
36502-EN-110127

Depending on the instrument version,the emitting frequencies are in
the Cor Kband range.The low emitting frequencies are far below the
internationally approved limit values.When used correctly,there is no
danger to health.
2.5CE conformity
The device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,VEGA provides a confirmation
of successful testing.You can find the CE conformity declaration in the
download area of www.vega.com.
2.6Fulfillment of NAMUR recommendations
The device fulfills the requirements of the applicable NAMUR
recommendations.
2.7Radio approval for Europe
The instrument is approved according to EN 302372-1/2(2006-04)for
use in closed vessels.
2.8Radio approval for USA/Canada
The instrument is in conformity with part 15 of the FCC regulations.
Take note of the following two regulations:
lThe device must not generate interference emissions,and
lThe device must be insensitive to interfering immissions,including
those that may cause undesirable operating conditions.
Modifications not expressly approved by the manufacturer will lead to
expiry of the operating licence according to FCC/IC.
The instrument is in conformity with RSS-210 of the IC regulations.
The instrument may only be operated in closed vessels made of metal,
concrete,or fibre-reinforced plastic.
2.9Environmental instructions
Protection of the environment is one of our most important duties.That
is why we have introduced an environment management system with
the goal of continuously improving company environmental protection.
The environment management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
6VEGAPULS 61 •Foundation Fieldbus
2For your safety
36502-EN-110127

3Product description
3.1Structure
The type label contains the most important data for identification and
use of the instrument:
2
1
12
11
5
3
6
4
7
8
9
10
Fig.1:Structure of the type label (example)
1Instrument type
2Product code
3Approvals
4Electronics
5Protection rating
6Measuring range
7Process and ambient temperature,process pressure
8Material,wetted parts
9Hardware and software version
10 Order number
11 Serial number of the instrument
12 ID numbers,instrument documentation
The serial number on the type label of the instrument allows you to call
up the order data,operating instructions manuals,sensor data for the
service DTM as well as the test certificate (depending on the
instrument). To do this,open under www.vega.com,"VEGA Tools"and
"serial number search".
This operating instructions manual applies to the following instrument
versions:
lHardware from 2.1.1
lSoftware from 4.4.0
lModification status electronics from -20
The instrument is available in two different electronics versions.Each
version can be identified via the product code on the type label as well
as on the electronics.
lStandard electronics type PS60FFC.-
Type label
Serial number
Scope of the operating
instructions manual
Versions
VEGAPULS 61 •Foundation Fieldbus 7
3Product description
36502-EN-110127

lElectronics with increased sensitivity type PS60FFS.-
The scope of delivery encompasses:
lRadar sensor
lDocumentation
-this operating instructions manual
-Test certificate measuring accuracy,depending on the
instrument VEGAPULS 61 (optional)
-Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM"(optional)
-Supplementary instructions "GSM/GPRS radio module"(op-
tional)
-Supplementary instructions manual "Heating for indicating and
adjustment module"(optional)
-Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
3.2Principle of operation
The instrument is suitable for applications in liquids in vessels under
ordinary process conditions.There are application possibilities in
nearly all areas of industry.
The version with encapsulated antenna system is particularly suitable
for level measurement of aggressive liquids in small vessels.
The version with plastic horn antenna is particularly suitable for flow
measurement in open flumes or gauge measurement in bodies of
water.
The standard electronics enables the use of instruments in products
with an ε
r
-Wert ≥1.8.The electronics version with increased sensitivity
enables the use of the instrument also in applications with very poor
reflective properties or products with an ε
r
value ≥1.5.The values that
can be actually reached depend on the measurement conditions,the
antenna system or the standpipe or bypass tube.
The antenna of the radar sensor emits short radar pulses with a
duration of approx.1ns.These pulses are reflected by the product
and received by the antenna as echoes.The running time of the radar
pulses from emission to reception is proportional to the distance and
hence to the level.The determined level is converted into an
appropriate output signal and outputted as measured value.
3.3Packaging,transport and storage
Your instrument was protected by packaging during transport.Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
Scope of delivery
Application area
Functional principle
Packaging
8VEGAPULS 61 •Foundation Fieldbus
3Product description
36502-EN-110127

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.
Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt.Ascertained transit damage or
concealed defects must be appropriately dealt with.
Up to the time of installation,the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated,the packages must be stored only under
the following conditions:
lNot in the open
lDry and dust free
lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
3.4Accessories and replacement parts
The indicating and adjustment module PLICSCOM is used for
measured value indication,adjustment and diagnosis.It can be
inserted into the sensor and removed at any time.
You can find further information in the operating instructions "Indicating
and adjustment module PLICSCOM"(Document-ID 27835).
The interface adapter VEGACONNECT enables the connection of
communication-capable instruments to the USB interface of a PC.For
parameter adjustment of these instruments,an adjustment software
such as PACTware with VEGA-DTM is required.
You can find further information in the operating instructions "Interface
adapter VEGACONNECT"(Document-ID 32628).
VEGADIS 61 is an external indicating and adjustment unit for sensors
with single chamber housing and double chamber housing Ex d.
Transport
Transport inspection
Storage
Storage and transport
temperature
Indicating and adjust-
ment module
Interface adapter
External indicating and
adjustment unit
VEGAPULS 61 •Foundation Fieldbus 9
3Product description
36502-EN-110127

Itis suitable for measured value indication and adjustment of plics®
sensors and is connected to the sensor with a four-wire,screened
standard cable up to 50 m long.
You can find further information in the operating instructions
"VEGADIS 61"(Document-ID 27720).
The PLICSMOBILE T61 is an external GSM/GPRS radio unit for
transmission of measured values and for remote parameter adjust-
ment of plics®sensors.The adjustment is carried out via PACTware/
DTM by using the integrated USB connection.
You can find further information in the supplementary instructions
"PLICSMOBILE T61"(Document-ID 36849).
The protective cover protects the sensor housing against soiling and
intense heat from solar radiation.
You will find additional information in the supplementary instructions
manual "Protective cover"(Document-ID 34296).
The electronics module VEGAPULS series 60 is a replacement part
for radar sensors of VEGAPULS series 60.Aseparate version is
available for each type of signal output.
You can find further information in the operating instructions
"Electronics module VEGAPULS series 60 "(Document-ID 36801).
External radio unit
Protective cover
Electronics module
10 VEGAPULS 61 •Foundation Fieldbus
3Product description
36502-EN-110127

4Mounting
4.1General instructions
With instruments with threaded process fitting,suitable tools must be
applied for tightening the hexagon.
Warning:
The housing must not be used to screw the instrument in!Applying
tightening force can damage internal parts of the housing.
Use the recommended cables (see chapter "Connecting to power
supply")and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry.Rain and condensation water can thus drain off.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g.through cleaning processes)or
on cooled or heated vessels.
Make sure that all parts of the instrument exposed to the process,in
particular the active measuring component,process seal and process
fitting,are suitable for the existing process conditions.These include
above all the process pressure,process temperature as well as the
chemical properties of the medium.
You can find the specifications in chapter "Technical data"or on the
type label.
4.2Collar or adapter flange
For mounting the instrument on a socket,a combi compression flange
for DN 80 (ASME 3"or JIS 80)is also available for retro fitting.
Optionally,the instrument can be also equipped with an adapter flange
from DN 100 (ASME 4"or JIS 100).
With the housing versions plastic,aluminium single chamber and
stainless steel,the collar flange can be placed directly over the
housing.With the aluminium double chamber housing,retroactive
mounting in this way is not possible -the mounting type must be
specified with the order.
You can find drawings of these mounting options in chapter
"Dimensions".
Screwing in
Moisture
Suitability for the pro-
cess conditions
VEGAPULS 61 •Foundation Fieldbus 11
4Mounting
36502-EN-110127

Fig.2:Flange mounting of the radar sensor
4.3Mounting preparations,mounting strap
The mounting strap enables easy mounting on the vessel wall or silo
top.It is suitable for wall,ceiling or boom mounting.Especially in open
vessels,this is a very easy and effective way to align the sensor to the
bulk solid surface.
The strap is supplied unassembled and must be screwed to the sensor
before setup with three hexagon nuts M5x10 and spring washers.
Max.torque,see chapter "Technical data".Required tools:Allen
wrench size 4.
There are two ways to screw the strap onto the sensor.Depending on
the selected version,the sensors can be swivelled in the strap as
follows:
lSingle chamber housing
-Angle of inclination 180°,infinitely variable
-Angle of inclination in three steps 0°,90°and 180°
lDouble chamber housing
-Angle of inclination 90°,infinitely variable
-Angle of inclination in two steps 0°and 90°
12 VEGAPULS 61 •Foundation Fieldbus
4Mounting
36502-EN-110127

Fig.3:Turning by fastening in the centre
Fig.4:Adjustment of the angle of inclination
4.4Mounting instructions
The emitted radar impulses of the radar sensor are electromagnetic
waves.The polarisation plane is the direction of the electrical wave
component.By turning the instrument in the connection flange or
mounting boss,the polarisation can be used to reduce the effects of
false echoes.
Polarisation plane
VEGAPULS 61 •Foundation Fieldbus 13
4Mounting
36502-EN-110127

The position of the polarisation plane is marked on the process fitting
of the instrument.
1
Fig.5:Position of the polarisation plane with VEGAPULS 61 with encapsulated
antenna system
1Marking hole
1
Fig.6:Position of the polarisation plane with VEGAPULS 61 with plastic horn
antenna
1Marking bars
When mounting the sensor,keep a distance of at least 200 mm
(7.874 in)to the vessel wall.If the sensor is installed in the center of
dished or round vessel tops,multiple echoes can arise.These can,
however,be suppressed by an appropriate adjustment (see chapter
"Setup").
If you cannot keep this distance you should carry out a false echo
storage before setup.This applies mainly if buildup on the vessel wall
is expected.In this case,we recommend repeating a false echo
storage later with existing buildup.
Mounting position
14 VEGAPULS 61 •Foundation Fieldbus
4Mounting
36502-EN-110127

> 200 mm
(7.87
")
Fig.7:Mounting of the radar sensor on round vessel tops
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel,as measurement is then possible
down to the lowest point of the vessel bottom.
Fig.8:Mounting of the radar sensor on vessels with conical bottom
Do not mount the instruments in or above the filling stream.Make sure
that you detect the product surface,not the inflowing product.
Inflowing medium
VEGAPULS 61 •Foundation Fieldbus 15
4Mounting
36502-EN-110127

Fig.9:Mounting of the radar sensor with inflowing medium
The socket piece should be dimensioned in such a way that the
antenna end protrudes at least 10 mm (0.4in)out of the socket.
ca. 10 mm
Fig.10:Recommended socket mounting
If the reflective properties of the medium are good,you can mount
VEGAPULS 61 on sockets which are higher than the length of the
antenna.You will find recommended values for socket heights in the
following illustration.The socket end should be smooth and burr-free,if
possible also rounded.After installation you must carry out a false
echo storage.
Socket
16 VEGAPULS 61 •Foundation Fieldbus
4Mounting
36502-EN-110127

d
h
dh
1½"
50 mm/2"
80 mm/3"
100 mm/4"
150 mm/6"
200 mm
250 mm
300 mm
500 mm
800 mm
Fig.11:Deviating socket dimensions
Align the sensor in liquids as vertical as possible to the product surface
to achieve optimum measurement results.
Fig.12:Alignment in liquids
The mounting location of the radar sensor should be a place where no
other equipment or fixtures cross the path of the microwave signals.
Vessel installations,such as e.g.ladders,limit switches,heating
spirals,struts,etc., can cause false echoes and impair the useful echo.
Make sure when planning your measuring site that the radar sensor
has a "clear view"to the measured product.
In case of existing vessel installations,a false echo storage should be
carried out during setup.
If large vessel installations such as struts or supports cause false
echoes,these can be attenuated through supplementary measures.
Small,inclined sheet metal baffles above the installations scatter the
radar signals and prevent direct interfering reflections.
Sensor orientation
Vessel installations
VEGAPULS 61 •Foundation Fieldbus 17
4Mounting
36502-EN-110127

Fig.13:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false signal memory should be
carried out with the agitators in motion.This ensures that the interfering
reflections from the agitators are saved with the blades in different
positions.
Fig.14:Agitators
Through the action of filling,stirring and other processes in the vessel,
compact foams that considerably damp the emitted signals may form
on the product surface.
If foams are causing measurement errors,the biggest possible radar
antennas,the electronics with increased sensitivity or low frequency
radar sensors (Cband)should be used.
As an alternative,sensors with guided microwave can be used.These
are unaffected by foam generation and are best suited for such
applications.
Agitators
Foam generation
18 VEGAPULS 61 •Foundation Fieldbus
4Mounting
36502-EN-110127

When using a surge pipe in a vessel,influences from vessel
installations and turbulences can be excluded.Under these prereq-
uisites,the measurement of products with low dielectric values (ε
r
value ≥1.6)is possible.In very adhesive products,measurement in a
surge pipe is not recommended.
1
2
3
100%
4
5
8
6
7
0%
9
Fig.15:Configuration surge pipe
1Radar sensor
2Marking of the polarisation direction
3Thread or flange on the instrument
4Vent hole
5Holes
6Weld joint
7Welding neck flange
8Ball valve with complete opening
9Fastening of the surge pipe
Instructions for orientation:
lNote marking of the polarisation plane on the sensor
lWith threaded fitting,the marking is on the hexagon,with flange
connection between the two flange holes
lAll holes in the surge pipe must be in one plane with this marking
Instructions for the measurement:
Measurement in a surge
pipe
VEGAPULS 61 •Foundation Fieldbus 19
4Mounting
36502-EN-110127

lThe100 %point must be below the upper vent hole and the
antenna edge
lThe 0%point is the end of the surge pipe
lThe tube diameter must be at least DN 40 or 1½" with antenna
size 40 mm (1½")
lFor the parameter adjustment,select "Application standpipe"and
enter the tube diameter to compensate errors due to running time
shift
lAfalse signal suppression with integrated sensor is recommended
but not mandatory
lThe measurement through a ball valve with complete run is
possible
Constructional requirements on the surge pipe:
lMaterial metal,smoother inner tube
lPreferably pultruded or straight beaded stainless steel tube
lWelded joint should be straight and lie in one axis with the holes
lFlanges are welded to the tube according to the orientation of the
polarisation level
lIn case of a extension with a welding neck flange or pipe collar as
well as when a ball valve is used,the inner surfaces should be
aligned and accurately joined together
lGap size with junctions ≤0.1mm
lDo not weld through the pipe wall.The surge pipe must remain
smooth inside.Roughness and beads on the inside caused by
unintentional penetration should be removed since they cause
strong false echoes and encourage buildup
lSurge pipes must extend all the way down to the requested min.
level,as measurement is only possible within the tube.
lDiameter of holes ≤5mm,any number OK,on one side or
completely through
lThe antenna diameter of the sensor should correspond to the
inner diameter of the tube
lDiameter should be constant over the complete length
An alternative to measurement in a surge pipe is measurement in a
bypass tube outside of the vessel.
Measurement in the by-
pass
20 VEGAPULS 61 •Foundation Fieldbus
4Mounting
36502-EN-110127