Vega VEGAPULS 63 User manual

Operating Instructions
VEGAPULS 63
Profibus PA
Document ID:
36513
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
4.2Mounting instructions ........................ 11
5Connecting to the bus system
5.1Preparing the connection ..................... 21
5.2Connection................................ 22
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 23
5.4Wiring plan,double chamber housing . . . . . . . . . . . . 23
5.5Wiring plan with double chamber housing Ex d . . . . . 25
5.6Wiring plan -version IP 66/IP 68,1bar . . . . . . . . . . . 26
5.7Set instrument address ....................... 26
5.8Switch on phase............................ 27
6Set up with the indicating and adjustment module
6.1Insert indicating and adjustment module. . . . . . . . . . . 28
6.2Adjustment system .......................... 29
6.3Parameter adjustment........................ 30
6.4Saving the parameter adjustment data . . . . . . . . . . . . 39
7Setup with PACTware
7.1Connecting the PC .......................... 40
7.2Parameter adjustment with PACTware . . . . . . . . . . . . 40
7.3Saving the parameter adjustment data . . . . . . . . . . . . 41
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8Setting up with other systems
8.1DD adjustment programs ..................... 42
9Diagnosis,fault rectification and service
9.1Maintenance .............................. 43
9.2Measured value and event memory . . . . . . . . . . . . . . 43
9.3Error messages according to NE 107 . . . . . . . . . . . . 44
9.4Rectify faults .............................. 47
9.5Exchanging the electronics module . . . . . . . . . . . . . . 48
9.6Software update ............................ 48
9.7How to proceed in case of repair................ 49
10 Dismounting
10.1Dismounting steps .......................... 50
10.2Disposal ................................. 50
11 Supplement
11.1Technical data ............................. 51
11.2Communication Profibus PA ................... 59
11.3Dimensions ............................... 64
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 63 •Profibus PA 3
Contents
36513-EN-101109

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.
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.
4VEGAPULS 63 •Profibus PA
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36513-EN-101109

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 63 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.
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2For your safety
36513-EN-101109

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 may not cause harmful interference,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"
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36513-EN-101109

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 4.1.2
lModification status electronics from -21
The instrument is supplied in two different electronics versions.
The respective version can be determined via the product code on the
type label as well as on the electronics.
Type label
Serial number
Scope of the operating
instructions manual
Electronics versions
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3Product description
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lStandard electronics type PS60PAK.-
lElectronics with increased sensitivity type PS60PAS.-
The scope of delivery encompasses:
lRadar sensor
lDocumentation
-this operating instructions manual
-Test certificate measuring accuracy,depending on the
instrument VEGAPULS 63 (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 the measurement of aggressive liquids or
applications with special hygienic requirements.The application
possibilities are in the chemical industry as well as on the food
processing and pharmaceutical sector.
The electronics version with increased sensitivity enables the use of
the instrument also in applications with very poor reflective properties
and products with low ε
r
value.
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.
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.
Scope of delivery
Application area
Functional principle
Packaging
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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.
It is suitable for measured value indication and adjustment of plics®
sensors and is connected to the sensor with an up to 25 m long,four-
wire,screened standard cable.
You can find further information in the operating instructions
"VEGADIS 61"(Document-ID 27720).
Transport
Transport inspection
Storage
Storage and transport
temperature
Indicating and adjust-
ment module
Interface adapter
External indicating and
adjustment unit
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36513-EN-101109

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).
Flanges are available in different versions according to the following
standards:DIN 2501,EN 1092-1,ANSI B 16.5,JIS B 2210-1984,
GOST 12821-80.
You will find additional information in the supplementary instructions
manual "Flanges according to DIN-EN-ASME-JIS"(Document-ID
31088).
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
Flanges
Protective cover
Electronics module
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36513-EN-101109

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 antenna,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.
4.2Mounting instructions
The flange screws of VEGAPULS 63 must be always screwed with the
torque stated in the technical data so that the PTFE washer of the
encapsulated antenna system seals.
You can counteract the material-induced tension loss with PTFE by
doing the following:
1Make sure the number of flange screws corresponds to the
number of flange holes
2Use disc springs in addition to the flange screws for fastening the
flange
3Tighten the screws steadily with the torque specified in the
technical data
Screwing in
Moisture
Suitability for the pro-
cess conditions
Mounting of instruments
with PTFE-coated flan-
ges
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36513-EN-101109

The emitted radar impulses of the radar sensor are electromagnetic
waves.The polarisation level 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.
The position of the polarisation plane is marked on the process fitting
of the instrument.
1
Fig.2:Position of the polarisation plane of VEGAPULS 63
1Marking hole
When mounting the VEGAPULS 63,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.
Polarisation plane
Mounting position
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36513-EN-101109

> 200 mm
(7.87 ")
Fig.3: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.4: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
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Fig.5:Mounting of the radar sensor with inflowing medium
Flush mounting
The best way to mount the sensor,also with respect to cleanability,is
flush on a block flange (flange without socket piece)or with hygienic
fittings,e.g.Neumo Biocontrol.
Mounting on socket
If the reflective properties of the medium are good,you can mount
VEGAPULS 63 on a socket piece.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.Then carry out a
false echo storage.
d
hmax.
d
50 mm/2"
80 mm/3"
100 mm/4"
150 mm/6"
100 mm
150 mm
250 mm
400 mm
hmax.
Fig.6:Deviating socket dimensions
Socket
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36513-EN-101109

Align the sensor in liquids as vertical as possible to the product surface
to achieve optimum measurement.
Fig.7: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.
Fig.8: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.
Sensor orientation
Vessel installations
Agitators
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Fig.9: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.
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.
Foam generation
Measurement in a surge
pipe
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0%
100%
1
2
3
4
5
6
7
8
10
9
Fig.10: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:
lThe 100 %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
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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
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0 %
100 %
1
2
5
4
3
6
Fig.11:Configuration bypass
1Radar sensor
2Marking of the polarisation direction
3Instrument flange
4Distance sensor reference plane to upper tube connection
5Distance of the tube connections
6Ball valve with complete opening
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
lThe pipe connections to the vessel must be in one plane with this
marking
Instructions for the measurement:
lThe 100 %point must not be above the upper tube connection to
the vessel
lThe 0%point must not be below the lower tube connection to the
vessel
lMin.distance sensor reference plane to the upper edge upper
tube connection >300 mm
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
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lThe measurement through a ball valve with complete run is
possible
Constructional requirements on the bypass pipe:
lMaterial metal,smoother inner tube
lIn case of an extremely rough tube inner surface,use an inserted
tube (tube in tube)or a radar sensor with tube antenna
lFlanges are welded to the tube according to the orientation of the
polarisation level
lGap size with junctions ≤0.1mm,for example,when using a ball
valve or intermediate flanges with single pipe sections
lThe antenna diameter of the sensor should correspond to the
inner diameter of the tube
lDiameter should be constant over the complete length
20 VEGAPULS 63 •Profibus PA
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36513-EN-101109