Vega VEGAPULS 66 User manual

Operating Instructions
VEGAPULS 66
4…20 mA/HART two-wire
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
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity ............................. 6
2.7Fulfillment of NAMUR recommendations . . . . . . . . . . 6
2.8FCC and IC conformity (only for USA/Canada) . . . . . . 6
2.9Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 7
2.10 Environmental instructions..................... 7
3Product description
3.1Configuration .............................. 8
3.2Principle of operation ........................ 9
3.3Operation................................. 10
3.4Packaging,transport and storage ............... 10
4Mounting
4.1General instructions ......................... 12
4.2Mounting instructions ........................ 14
5Connecting to power supply
5.1Preparing the connection ..................... 22
5.2Connection procedure........................ 23
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 24
5.4Wiring plan,double chamber housing . . . . . . . . . . . . 26
5.5Wiring plan 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 PLICSCOM
6.1Short description ........................... 31
6.2Insert indicating and adjustment module. . . . . . . . . . . 31
6.3Adjustment system .......................... 33
6.4Setup procedure............................ 34
6.5Menu schematic............................ 40
6.6Saving the parameter adjustment data . . . . . . . . . . . . 42
7Setup with PACTware and other adjustment programs
7.1Connecting the PC .......................... 43
7.2Parameter adjustment with PACTware . . . . . . . . . . . . 44
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7.3Parameter adjustment with AMS™and PDM . . . . . . . 45
7.4Saving the parameter adjustment data . . . . . . . . . . . . 45
8Maintenance and fault rectification
8.1Maintenance .............................. 46
8.2Remove interferences........................ 46
8.3Exchanging the electronics module . . . . . . . . . . . . . . 47
8.4Software update ............................ 48
8.5Instrument repair ........................... 48
9Dismounting
9.1Dismounting steps .......................... 50
9.2Disposal ................................. 50
10 Supplement
10.1Technical data ............................. 51
10.2Dimensions ............................... 59
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your VEGAPULS 66,we
offer accessories and replacement parts.The associated documents
are:
l27835 -Indicating and adjustment module PLICSCOM
l32628 -Interface adapter VEGACONNECT
l27720 -External indication VEGADIS 61
l34296 -Protective cover
l30176 -Electronics module VEGAPULS series 60
l31088 -Flanges according to DIN-EN-ASME-JIS
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Contents
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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 66 •4…20 mA/HART two-wire
1About 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 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 66 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.
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.
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 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 as well as all prevailing safety
regulations and accident prevention rules.
Depending on the model,the emitting frequencies of all radar sensors
are either in the Cor Kband range.The low transmitting power lies far
below the internationally permitted limit values.When the instrument is
used correctly,it presents no danger to human health.It may be
operated without restriction outside of closed metallic vessels.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
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2For your safety
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During the entire duration of use,the user is obliged to determine the
compliance of the required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This 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.
2.7Fulfillment of NAMUR recommendations
With respect to compatibility,the NAMUR recommendation NE 53 is
fulfilled.This applies also to the corresponding indicating and
adjustment components.VEGA instruments are generally upward and
downward compatible.
lSensor software for DTM VEGAPULS 66 HART,PA or FF
lDTM VEGAPULS 66 for adjustment software PACTware
lIndicating and adjustment module for sensor software
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
The software version of VEGAPULS 66 can be determined as follows:
lvia PACTware
lon the type label of the electronics
lvia the indicating and adjustment module
You can view all software histories on our website www.vega.com.
Make use of this advantage and get registered for update information
via e-mail.
2.8FCC and IC conformity (only for USA/Canada)
VEGAPULS 66 is FCC and IC approved:
lFCC ID:O6QPULS6566
lIC:3892A-PS6566
Modifications not expressly approved by VEGA will lead to expiry of
the operating licence according to FCC.
VEGAPULS 66 is in conformity with part 15 of the FCC regulations.
Take note of the respective operating regulations:
6VEGAPULS 66 •4…20 mA/HART two-wire
2For your safety
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lThe instrument must not cause any interfering emissions
lThe device must be insensitive to interfering immissions,including
those that may cause undesirable operating conditions.
The instrument was tested and meets the limit values for a digital
instrument of class B,according to part 15 of the FCC regulations.The
limit values are predefined to ensure protection against interfering
emissions during operation in industrial environments.
The instrument can generate,use and emit high frequency energy and
can generate interfering emissions if not used as described in the
operator's manual.Because interfering emissions have to be reckoned
with when the instrument is used in residential areas,the user must
make sure necessary countermeasures are implemented.
2.9Safety 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.
2.10 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 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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3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGAPULS 66 radar sensor
lDocumentation
-this operating instructions manual
-Safety Manual 31338 "VEGAPULS series 60 -4…20 mA/
HART"(optionally)
-Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM"(optional)
-Supplementary instructions manual 31708 "Heating for in-
dicating 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
VEGAPULS 66 consists of the following components:
lProcess fitting with antenna system
lHousing with electronics,optionally available with plug connector,
optionally available with connection cable
lHousing cover,optionally available with indicating and adjustment
module PLICSCOM
The components are available in different versions.
Scope of delivery
Components
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3
2
1
Fig.1:VEGAPULS 66 -flange version with plastic housing
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics
3Process fitting with antenna system
The type label contains the most important data for identification and
use of the instrument:
lSensor type
lArticle and serial number device
lArticle numbers documentation
lTechnical data:Approvals,antenna type,process fitting,process
seal/temperature,signal output,voltage supply,protection,pro-
tection class
lSIL identification (with SIL rating ex works)
With the serial number,you can access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".In addition to the type label outside,you can also find the
serial number on the inside of the instrument.
3.2Principle of operation
VEGAPULS 66 is a radar sensor in C-band (emitting frequency
approx.6GHz)for continuous level measurement.
Aspecial version of VEGAPULS 66 is available for each area of
application.The version with flange and horn antenna is particularly
suitable for measurement of liquids and solids under extremely difficult
process conditions such as buildup,condensate and foam generation
as well as vigorous product movement.
Type label
Application area
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3Product description
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With the version without antenna horn,the antenna system is formed
in conjunction with a measuring tube (surge or bypass tube). This
version is particularly suitable for measurement of solvents and liquid
gases.
For pressures up to 160 bar (2320 psi)and temperatures up to 400 °C
(752 °F)there are graphite seals and ceramic antenna cones
available.
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.
Two-wire electronics 4…20 mA/HART for power supply and
measured value transmission over the same cable.
The supply voltage range can differ depending on the instrument
version.
The data for power supply are specified in chapter "Technical data".
The backlight of the indicating and adjustment module is powered by
the sensor.The prerequisite for this is a supply voltage at a certain
level.The exact voltage specifications are stated in chapter "Technical
data".
The optional heating requires its own operating voltage.You can find
detailed information in the supplementary instructions manual "Heating
for indicating and adjustment module".This function is generally not
available for approved instruments.
3.3Operation
VEGAPULS 66 can be adjusted with different adjustment media:
lwith indicating and adjustment module
lwith the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard,e.g.PACTware and
PC
lwith manufacturer-specific adjustment programs AMS™or PDM
lWith a HART handheld
The entered parameters are generally saved in VEGAPULS 66,
optionally also in the indicating and adjustment module or in
PACTware.
3.4Packaging,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.
Functional principle
Power supply
Packaging
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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 %
Transport
Transport inspection
Storage
Storage and transport
temperature
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4Mounting
4.1General instructions
Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module.The housing can be rotated by 330°without the use of any
tools.You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).
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.
Fig.2:Measures against moisture penetration
The reference plane for the measuring range is the lower edge of the
flange or the seal surface of the thread.
Mounting position
Moisture
Measuring range
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1 32
100%
0%
4
Fig.3:Measuring range (operating range), max.measuring distance and
reference plane
1full
2empty (max.measuring distance)
3Measuring range
4Reference plane
Information:
If the medium reaches the antenna,buildup can form on it and cause
faulty measurements later on.
The emitted radar pulses of VEGAPULS 66 are electromagnetic
waves.The polarisation plane is the direction of the electrical wave
component.Its position is marked on the instrument.
Polarisation plane
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1
Fig.4:Position of the polarisation plane with VEGAPULS 66
1Marking hole
Make sure that all parts of the instrument in contact with the measured
product,especially the sensor element,process seal and process
fitting,are suitable for the existing process conditions such as process
pressure,process temperature as well as the chemical properties of
the medium.
You can find the specifications in chapter "Technical data"in the or on
the type label.
4.2Mounting instructions
When mounting VEGAPULS 66,keep a distance of at least 500 mm
(19.69 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.
Suitability for process
conditions
Mounting position
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1
2
> 500 mm
Fig.5:Mounting on round vessel tops
1Reference plane
2Vessel center or symmetry axis
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.6:Vessel 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.7:Inflowing liquid
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.8:Recommended socket mounting
If the socket height cannot be maintained,an antenna extension will be
necessary.This prevents from false reflections of the socket piece.
Socket
16 VEGAPULS 66 •4…20 mA/HART two-wire
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ca. 10 mm
Fig.9:Tube extension
Tip:
VEGAPULS 66 is optionally also available with antenna extension.
Hence the antenna length can be selected such that the antenna end
protrudes 10 mm (0.4in)out of the socket.
Align the sensor in liquids as vertical as possible to the product surface
to achieve optimum measurement.
Fig.10: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,for example,ladders,limit switches,
heating spirals,struts,etc.can cause false echoes that get super-
imposed on 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.
Sensor orientation
Vessel installations
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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.11:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false echo storage 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.12:Agitators
Through the action of filling,stirring and other processes in the vessel,
dense foams which considerably damp the emitted signals may form
on the product surface.
If foams are causing measurement errors,the biggest possible radar
antenna 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
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By using a standpipe,the influence of vessel installations and
turbulence can be excluded.Under these prerequisites,the meas-
urement of products with low dielectric values (from DK value 1.6)is
possible.
Note:
Measurement in a standpipe is not recommended for very adhesive
products.
Surge or bypass tubes must extend all the way down to the requested
min.level,as measurement is only possible within the tube.
Surge pipe
Make sure you provide the necessary upper vent hole in the surge
pipe.The hole must be aligned so that it and the polarisation marking
on the sensor flange are in the same plane (see illustration:"Pipe
antenna system in a tank").
max.
min.
2
1
Fig.13:Pipe antenna system in a tank.The vent hole in the surge pipe must be
in one plane with the polarisation marking on the sensor.
1Marking of the polarisation direction
2Vent holde max.ø5mm (0.2in)
If possible,the diameter of the sensor antenna should correspond to
the inner diameter of the tube.With VEGAPULS 66 this is approx.
50 mm (1.969 in)depending on the antenna.The sensor can be used
with tube diameters between 50 …250 mm (1.969 …9.843 in).
Bypass tube
As an alternative to the surge pipe in the vessel,a tube system outside
of the vessel is possible as a bypass tube.Select during setup the
function "Bypass tube".
Measurement in the
standpipe (surge or by-
pass tube)
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Align the sensor in such a way that the polarisation marking on the
sensor flange is in the same plane as the tube holes or the tube
connection openings (see illustration:"VEGAPULS in a bypass tube").
100%
0%
1
> 500 mm
Fig.14:VEGAPULS 66 in a bypass tube.The polarisation marking on the
process fitting must be in one plane with the tube holes or the tube connection
openings.
1Marking of the polarisation direction
When the sensor is mounted on a bypass tube,the distance from
VEGAPULS 66 to the upper tube connection should be approx.
500 mm (19.69 in)or more.In case of extremely rough tube inner
walls,you should use an inserted tube (tube in tube)or a radar sensor
with tube antenna.
Information:
With VEGAPULS 66 the polarisation level is always in the centre
between two flange holes.
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