Vega VEGAPULS SR 68 User manual

Operating Instructions
VEGAPULS SR 68
4…20 mA/HART two-wire
Document ID:
38294
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 preparations -Horn antenna ............ 11
4.3Mounting instructions ........................ 12
5Connecting to power supply
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 . . . . . 29
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........... 32
6.2Adjustment system .......................... 33
6.3Parameter adjustment........................ 34
6.4Saving the parameter adjustment data ............ 45
7Setup with PACTware
7.1Connecting the PC .......................... 47
7.2Parameter adjustment with PACTware ............ 48
7.3Saving the parameter adjustment data ............ 49
2VEGAPULS SR 68 •4…20 mA/HART two-wire
Contents
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8Set up with other systems
8.1DD adjustment programs ..................... 50
8.2Communicator 375,475 ...................... 50
9Diagnosis,fault rectification and service
9.1Maintenance .............................. 51
9.2Measured value and event memory .............. 51
9.3Error messages according to NE 107 ............ 52
9.4Fault rectification ........................... 55
9.5Exchanging the electronics module .............. 56
9.6Software update ............................ 57
9.7How to proceed in case of repair................ 58
10 Dismounting
10.1Dismounting steps .......................... 59
10.2Disposal ................................. 59
11 Supplement
11.1Technical data ............................. 60
11.2Dimensions ............................... 68
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 SR 68 •4…20 mA/HART two-wire 3
Contents
38294-EN-110209

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:Ifthis 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 SR 68 •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 SR 68 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 SR 68 •4…20 mA/HART two-wire 5
2For your safety
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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 SR 68 •4…20 mA/HART two-wire
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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 -25
The scope of delivery encompasses:
lRadar sensor
lDocumentation
-this operating instructions manual
Type label
Serial number
Scope of the operating
instructions manual
Scope of delivery
VEGAPULS SR 68 •4…20 mA/HART two-wire 7
3Product description
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-Safety Manual (SIL) (optional)
-Test certificate measuring accuracy (optional)
-Operating instructions manual "Indicating and adjustment
module"(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 designed for level measurement of bulk solids even
under difficult process conditions.Its mechanical construction and
electronics are specially optimised for such applications.Many
application possibilities can be found in the food processing industry,
in plastics processing and steel production as well as in the building
industry.
The instrument is particularly suitable for average-size silos and
vessels.
The instrument is also suitable for applications in liquids.
The use of the instrument is possible with products with an ε
r
value
≥1.5.The reachable value depends on the measurement conditions,
the antenna system,the standpipe or bypass.
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.
Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
Application area
Functional principle
Packaging
Transport
8VEGAPULS SR 68 •4…20 mA/HART two-wire
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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 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).
VEGADIS 62 is suitable for measured value indication and adjustment
of sensors with HART protocol.It is looped into the 4…20 mA/HART
signal cable.
Transport inspection
Storage
Storage and transport
temperature
Indicating and adjust-
ment module
Interface adapter
External indicating and
adjustment unit
External indicating and
adjustment unit with
HART protocol
VEGAPULS SR 68 •4…20 mA/HART two-wire 9
3Product description
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You can find further information in the operating instructions
"VEGADIS 62"(Document-ID 36469).
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).
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 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).
The antenna impedance cone is used for optimum transmission of
microwaves and for sealing against the process.
You find further information in the operating instructions "Antenna
impedance cone VEGAPULS 62 and 68"(Document-ID 31381).
External radio unit
Protective cover
Flanges
Electronics module
Antenna impedance co-
ne
10 VEGAPULS SR 68 •4…20 mA/HART two-wire
3Product description
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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.
4.2Mounting preparations -Horn antenna
The instrument is also available in versions with an antenna whose
diameter is larger than the process fitting (thread,flange). In such
cases the antenna must be disconnected from the process fitting
before mounting.Proceed as follows:
1Loosen the hexagon screws (3)on the antenna socket with an
Allen wrench (size 3)
2Remove the antenna (4)
Note:
The plastic conemust not be pulled out of the antenna socket.
3Insert the antenna from below into the vessel socket and secure it
against falling off
4Retighten the antenna with hexagon screws to the antenna socket;
torque max.10 Nm(7.5lbf ft)
Screwing in
Moisture
Suitability for the pro-
cess conditions
VEGAPULS SR 68 •4…20 mA/HART two-wire 11
4Mounting
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Note:
The radar sensor with rinsing air connection or antenna extension is
provided with a notch on the antenna socket.This notch must
correspond to the marking on the hexagon of the process fitting (the
marking specifies the position of the polarisation level of the radar
signal).
3
4
1
2
Fig.2:Dismounting of the horn antenna
1Marking of the polarisation plane
2Notch at the antenna socket
3Hexagon screws on the antenna socket
4Antenna
4.3Mounting 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
12 VEGAPULS SR 68 •4…20 mA/HART two-wire
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The position of the polarisation plane is marked on the process fitting
of the instrument.
1
1
Fig.3:Position of the polarisation level
1Marking hole
Mount the sensor at least 200 mm (7.874 in)away from the vessel
wall.
1
> 200 mm
(7.87
")
Fig.4:Mounting of the radar sensor on round vessel tops
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 should not be too close to the inflowing material as the
microwave signal will be interferred.The optimum mounting position is
on the opposite of the filling.To avoid strong pollution,the distance to
the filter or dust extraction must be as big as possible.
Mounting position
Inflowing medium
VEGAPULS SR 68 •4…20 mA/HART two-wire 13
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Fig.5:Mounting of the radar sensor with inflowing medium
The socket piece should be dimensioned in such a way that the
antenna end protrudes slightly out of the socket.
ca. 10 mm
Fig.6:Recommended socket mounting with horn antenna
Socket
14 VEGAPULS SR 68 •4…20 mA/HART two-wire
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When using a swivelling holder,keep in mind that the distance
between antenna and socket gets smaller as the inclination of the
sensor increases.Additional false reflections may be generated which
can influence the measuring result at close range.
Fig.7:Distance between antenna and socket with horn antenna
If the medium has good reflective properties,VEGAPULS SR 68 with
horn antenna can also be mounted on a longer socket piece.
Recommended values for socket heights are specified in the following
illustration.You must carry out a false echo storage afterwards.
d
hmax.
Fig.8:Deviating socket dimensions
VEGAPULS SR 68 •4…20 mA/HART two-wire 15
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Socket diameter d Socket length h
40 mm 100 mm
50 mm 150 mm
80 mm 250 mm
100 mm 500 mm
150 mm 800 mm
Socket diameter d Socket length h
1½" 3.9in
2"5.9in
3"9.8in
4"19.7in
6"31.5in
Tip:
The instrument is also optionally available with an antenna extension.
The antenna length can be selected (either ex works or later)to allow
the antenna to protrude slightly out of the end of the mounting socket.
Due to the antenna extension however,disturbing reflections are
generated in the close-up range.This can lead to an increase in the
required minimum distance,especially with poorly reflecting media
such as plastic powder.In practice,a cleanly constructed mounting
socket,if necessary with rounded edges,introduces fewer disturbing
influences than an antenna extension.
To measure as much of the vessel volume as possible,the sensor
should be aligned so that the measuring beam reaches the lowest
level in the vessel.In a cylindrical silo with conical outlet,the easiest
way is to mount the instrument in the center of the silo.
Orientation
16 VEGAPULS SR 68 •4…20 mA/HART two-wire
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Fig.9:Orientation
If mounting in the center of the silo is not possible,the sensor can be
directed to the vessel center by means of an optional swivelling holder.
The following description gives an overview on the determination of
the necessary angle of inclination.
VEGAPULS SR 68 •4…20 mA/HART two-wire 17
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d
a
α
Fig.10:Proposal for installation after orientation VEGAPULS SR 68
The angle of inclination depends on the vessel dimensions.It can be
easily checked with a suitable level or water leve on the sensor.
The following chart specifies the distance "a"between installation
position and vessel centre dependent on the measuring distance for
inclination angles of 2°…10°.
Distance d
(m)
2°4°6°8°10°
2 0.1 0.1 0.2 0.3 0.4
4 0.1 0.3 0.4 0.6 0.7
6 0.2 0.4 0.6 0.8 1.1
8 0.3 0.6 0.8 1.1 1.4
10 0.3 0.7 1.1 1.4 1.8
15 0.5 1.0 1.6 2.1 2.6
20 0.7 1.4 2.1 2.8 3.5
25 0.9 1.7 2.6 3.5 4.4
30 1.0 2.1 3.2 4.2 5.3
Example:
18 VEGAPULS SR 68 •4…20 mA/HART two-wire
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In a vessel 20 mhigh,the installation position of the sensor is 1.4m
from the vessel centre.
The necessary angle of inclination of 4°can be read out from this
chart.
Proceed as follows to adjust the angle of inclination with the swivelling
holder:
1Loosen terminal screw of the swivelling holder with a fork spanner
SW 13
2Direct the sensor,check angle of inclination
Information:
The max.angle of inclination of the swivelling holder is approx.15°
3Tighten the terminal screw,torque max.20 Nm.
Information:
The hexagon screws must not be loosened.
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.11:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false signal suppression 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.
Vessel installations
Agitators
VEGAPULS SR 68 •4…20 mA/HART two-wire 19
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Fig.12:Agitators
Large material heaps are detected with several sensors,which can be
mounted on e.g.traverse cranes.For this type of application,it is best
to orient the sensor toward the solid surface.Amutual infuence of the
sensors is not possible.
Fig.13:Radar sensors on traverse crane
Information:
Keep in mind that for these applications,the sensors are designed for
relatively slow level changes.When using VEGAPULS SR 68 on a
movable bracket,the max.measuring rate must be observed (see
chapter "Technical data").
Material heaps
20 VEGAPULS SR 68 •4…20 mA/HART two-wire
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