Vega VEGAPULS SR 68 User manual

Operating Instructions
Radar sensor for continuous level
measurement of bulk solids
VEGAPULS SR 68
4 … 20 mA/HART two-wire
Document ID: 38294

2
Quick start
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
Quick start
The quick start procedure enables a quick setup with many applica-
tions. You can nd further information in the respective chapters of the
operating instructions manual.
1. Distance from the vessel wall > 200 mm, the antenna should
protrude > 10 mm into the vessel
ca. 10 mm
200 mm
(7.87
")
Fig. 1: Distance of the antenna to the vessel wall/vessel ceiling
2. Note min. socket diameter depending on the socket length
3. Note the instructions for sealing
For further information see chapter "Mounting".
1. Make sure that the power supply corresponds to the specica-
tions on the type label.
2. Connect the instrument according to the following illustration
5
12
+
( ) (-)
678
4...20mA
2
3
4
1
Fig. 2: Electronics and connection compartment, single chamber housing
1 Voltage supply, signal output
2 For display and adjustment module or interface adapter
3 For external display and adjustment unit
4 Ground terminal for connection of the cable screen
See also chapter "Connecting to power supply"
1. Go via the display and adjustment module to the menu "Setup".
2. Select in the menu item "Medium" the medium of your applica-
tion, for example "Powder/Dust".
Mounting
Electrical connection
Set parameters

3
Quick start
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
3. Select in the menu item "Application" the vessel, the application
and the vessel form, for example, silo.
4. Carry out the adjustment in the menu items "Min. adjustment" and
"Max. adjustment".
The radar sensor as a distance measuring instrument measures the
distance from the sensor to the product surface. For indication of the
real level, an allocation of the measured distance to the percentage
height must be carried out.
2
1
100%
0%
1 m
(39.37
")
35 m
(1378
")
Fig. 3: Parameterization example
1 Min. level ≙max. meas. distance
2 Max. level ≙min. meas. distance
For this adjustment, the distance is entered for min. and max. level.
If these values are not known, an adjustment with distances, for
example, of 10 % and 90 % is also possible. Starting point for these
distance specications is always the seal surface of the thread or
ange.
1. In the menu "Additional settings", menu item "Damping" you can
adjust the requested damping of the output signal.
2. Select the output characteristics in the menu item "Current out-
put".
The quick start is then nished. For further information see chapter
"Parameter adjustment".
Parameterization example
Further steps

4
Contents
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
Contents
1 About this document
1.1 Function ........................................................................................................................... 6
1.2 Target group ..................................................................................................................... 6
1.3 Symbolism used............................................................................................................... 6
2 For your safety
2.1 Authorised personnel ....................................................................................................... 7
2.2 Appropriate use................................................................................................................ 7
2.3 Warning about incorrect use............................................................................................. 7
2.4 General safety instructions............................................................................................... 7
2.5 CE conformity................................................................................................................... 8
2.6 NAMUR recommendations .............................................................................................. 8
2.7 Radio license for Europe .................................................................................................. 8
2.8 Radio license for USA/Canada......................................................................................... 8
2.9 Environmental instructions ............................................................................................... 9
3 Product description
3.1 Conguration.................................................................................................................. 10
3.2 Principle of operation...................................................................................................... 11
3.3 Packaging, transport and storage................................................................................... 11
3.4 Accessories and replacement parts ............................................................................... 12
4 Mounting
4.1 General instructions ....................................................................................................... 14
4.2 Mounting preparations - Parabolic antenna.................................................................... 14
4.3 Mounting preparations - Horn antenna........................................................................... 15
4.4 Mounting instructions ..................................................................................................... 16
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 30
5.2 Connecting..................................................................................................................... 31
5.3 Wiring plan, single chamber housing.............................................................................. 33
5.4 Wiring plan, double chamber housing ............................................................................ 33
5.5 Wiring plan, double chamber housing Ex d .................................................................... 35
5.6 Wiring plan - version IP 66/IP 68, 1 bar........................................................................... 36
5.7 Switch-on phase............................................................................................................. 37
6 Set up with the display and adjustment module
6.1 Insert display and adjustment module............................................................................ 38
6.2 Adjustment system......................................................................................................... 39
6.3 Parameter adjustment .................................................................................................... 40
6.4 Saving the parameter adjustment data........................................................................... 53
7 Setup with PACTware
7.1 Connect the PC.............................................................................................................. 55
7.2 Parameter adjustment .................................................................................................... 56
7.3 Saving the parameter adjustment data........................................................................... 57
8 Set up with other systems
8.1 DD adjustment programs ............................................................................................... 58
8.2 Field Communicator 375, 475 ........................................................................................ 58
9 Diagnosis, Asset Management and service

5
Contents
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
9.1 Maintenance .................................................................................................................. 59
9.2 Measured value and event memory ............................................................................... 59
9.3 Asset Management function........................................................................................... 60
9.4 Rectify faults................................................................................................................... 63
9.5 Exchanging the electronics module................................................................................ 66
9.6 Software update ............................................................................................................. 67
9.7 How to proceed in case of repair.................................................................................... 67
10 Dismounting
10.1 Dismounting steps.......................................................................................................... 68
10.2 Disposal ......................................................................................................................... 68
11 Supplement
11.1 Technical data ................................................................................................................ 69
11.2 Dimensions .................................................................................................................... 76
Safety instructions for Ex areas
Please note the Ex-specic safety information for installation and op-
eration in Ex areas. These safety instructions are part of the operating
instructions manual and come with the Ex-approved instruments.
Editing status: 2013-05-16

6
1 About this document
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tions for maintenance and fault rectication. Please read this informa-
tion before putting the instrument into operation and keep this manual
accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained specialist
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbolism 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.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

7
2 For your safety
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
2 For your safety
2.1 Authorised 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.
2.2 Appropriate use
VEGAPULS SR 68 is a sensor for continuous level measurement.
You can nd detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly
used according to the specications in the operating instructions
manual as well as possible supplementary instructions.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to
application-specic hazards, e.g. vessel overll or damage to system
components through incorrect mounting or adjustment.
2.4 General 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 awless 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 regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional 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. Arbi-
trary conversions or modications are explicitly forbidden.
The safety approval markings and safety tips on the device must also
be observed.
Depending on the instrument version, the emitting frequencies are in
the C or K band range. The low emitting frequencies are far below the
internationally approved limit values. When used correctly, there is no
danger to health.

8
2 For your safety
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
2.5 CE conformity
The device fullls the legal requirements of the applicable EC guide-
lines. By axing the CE marking, we conrm successful testing of the
product.
You can nd the CE Certicate of Conformity in the download section
of our homepage.
Electromagnetic compatibility
Instruments with plastic housing as well as in four-wire or Ex-d-ia
version are designed for use in an industrial environment. Neverthe-
less, electromagnetic interference from electrical conductors and
radiated emissions must be taken into account, as is usual with a
class A instrument according to EN 61326-1. If the instrument is used
in a dierent environment, the electromagnetic compatibility to other
instruments must be ensured by suitable measures.
2.6 NAMUR recommendations
NAMUR is the automation technology user association in the process
industry in Germany. The published NAMUR recommendations are
accepted as the standard in eld instrumentation.
The device fullls the requirements of the following NAMUR recom-
mendations:
• NE 21 – Electromagnetic compatibility of equipment
• NE 43 – Signal level for malfunction information from measuring
transducers
• NE 53 – Compatibility of eld devices and display/adjustment
components
• NE 107 – Self-monitoring and diagnosis of eld devices
For further information see www.namur.de.
2.7 Radio license for Europe
The instrument is approved according to EN 302372-1/2 (2006-04)
for use in closed vessels.
2.8 Radio license for USA/Canada
The instrument is in conformity with part 15 of the FCC regulations.
Take note of the following two regulations:
• The instrument must not cause any interfering emissions
• The device must be insensitive to interfering immissions, including
those that may cause undesirable operating conditions
Modications 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 used in closed vessels made of metal,
concrete, or bre-reinforced plastic.

9
2 For your safety
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
2.9 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 pro-
tection. The environment management system is certied according
to DIN EN ISO 14001.
Please help us fulll this obligation by observing the environmental
instructions in this manual:
• Chapter "Packaging, transport and storage"
• Chapter "Disposal"

10
3 Product description
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
3 Product description
3.1 Conguration
The nameplate contains the most important data for identication and
use of the instrument:
2
1
13
14
15
16
12
11
5
3
6
4
7
8
9
10
Fig. 4: Layout of the type label (example)
1 Instrument type
2 Product code
3 Approvals
4 Power supply and signal output, electronics
5 Protection rating
6 Measuring range
7 Process and ambient temperature, process pressure
8 Material, wetted parts
9 Hardware and software version
10 Order number
11 Serial number of the instrument
12 Symbol of the device protection class
13 ID numbers, instrument documentation
14 Reminder to observe the instrument documentation
15 NotiedauthorityforCEmarking
16 Approval directive
With the serial number of the instrument on the type label you can nd
the following data on our homepage:
• Article number of the instrument (HTML)
• Delivery date (HTML)
• Order-specic instrument features (HTML)
• Operating instructions at the time of shipment (PDF)
• Order-specic sensor data for an electronics exchange (XML)
• Test certicate pressure transmitters (PDF)
Go to www.vega.com, "VEGA Tools" and "Serial number search".
As an alternative, you can nd the data via your Smartphone:
• Download the smartphone app "VEGA Tools" from the "Apple App
Store " or the "Google Play Store"
• Scan the Data Matrix code on the type label of the instrument or
• Enter the serial number manually in the app
Type plate
Serial number

11
3 Product description
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
This operating instructions manual applies to the following instrument
versions:
• Hardware version from 2.1.0
• Software version from 4.5.1
The scope of delivery encompasses:
• Radar sensor
• Documentation
– this operating instructions manual
– Test certicate measuring accuracy (optional)
– Operating instructions manual "Display and adjustment mod-
ule" (optional)
– Supplementary instructions "GSM/GPRS radio module"
(optional)
– Supplementary instructions manual "Heating for display and
adjustment module" (optional)
– Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors" (optional)
– Ex-specic "Safety instructions" (with Ex versions)
– if necessary, further certicates
3.2 Principle of operation
The VEGAPULS SR 68 is a radar sensor for continuous measurement
of bulk solids also under dicult process conditions. It is particularly
suitable for level measurement in high silos and large bunkers.
The instrument is also suitable for applications in liquids.
The antenna of the radar sensor emits short radar pulses with a
duration of approx. 1 ns. These pulses are reected by the product
and received by the antenna as echoes. The transit 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 appropri-
ate output signal and outputted as measured value.
3.3 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
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 con-
cealed defects must be appropriately dealt with.
Scope of this operating
instructions manual
Scope of delivery
Application area
Functional principle
Packaging
Transport
Transport inspection

12
3 Product description
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
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:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
• Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
• Relative humidity 20 … 85 %
3.4 Accessories and replacement parts
The display and adjustment module PLICSCOM is used for measured
value indication, adjustment and diagnosis. It can be inserted into the
sensor or the external display and adjustment unit and removed at
any time.
You can nd further information in the operating instructions "Display
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, the adjustment software
PACTware with VEGA-DTM is required.
You can nd further information in the operating instructions "Interface
adapter VEGACONNECT" (Document-ID 32628).
The VEGADIS 81 is an external display and adjustment unit for VEGA
plics®sensors.
For sensors with double chamber housing the interface adapter
"DISADAPT" is also required for VEGADIS 81.
You can nd further information in the operating instructions "VE-
GADIS 81" (Document-ID 43814).
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.
You can nd further information in the operating instructions "VE-
GADIS 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 nd further information in the supplementary instructions
"PLICSMOBILE T61" (Document-ID 37700).
Storage
Storage and transport
temperature
PLICSCOM
VEGACONNECT
VEGADIS 81
VEGADIS 62
PLICSMOBILE T61

13
3 Product description
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
The protective cover protects the sensor housing against soiling and
intense heat from solar radiation.
You will nd additional information in the supplementary instructions
manual "Protective cover" (Document-ID 34296).
Screwed anges are available in dierent versions according to the
following standards: DIN 2501, EN 1092-1, BS 10, ANSI B 16.5,
JIS B 2210-1984, GOST 12821-80.
You can nd 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. There is a dierent version
available for each type of signal output.
You can nd further information in the operating instructions "Elec-
tronics 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 nd further information in the operating instructions "Antenna
impedance cone VEGAPULS 62 and 68" (Document-ID 31381).
Protective cap
Flanges
Electronics module
Antenna impedance cone

14
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
4 Mounting
4.1 General instructions
On instruments with process tting thread, the hexagon must be tight-
ened with a suitable screwdriver. Wrench size see chapter "Dimen-
sions".
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Protect your instrument further through the following measures
against moisture penetration:
• Use the recommended cable (see chapter "Connecting to power
supply")
• Tighten the cable gland
• Loop the connection cable downward in front of the cable gland
This applies particularly to:
• Outdoor mounting
• Installations in areas where high humidity is expected (e.g. through
cleaning processes)
• Installations on cooled or heated vessels
Make sure that all parts of the instrument exposed to the process are
suitable for the existing process conditions.
These are mainly:
• Active measuring component
• Process tting
• Process seal
Process conditions are particularly:
• Process pressure
• Process temperature
• Chemical properties of the medium
• Abrasion and mechanical inuences
You can nd the specications of the process conditions in chapter
"Technical data" as well as on the nameplate.
4.2 Mounting preparations - Parabolic antenna
The instrument is also available in versions where the antenna has
a diameter larger than the process tting (thread, ange). With such
versions the antenna must be disconnected from the process tting
before mounting. Proceed as follows:
1. Clamp VEGAPULS SR 68 with the ange, e.g. in a bench vice
2. Hold the connection piece (3) with a wrench on the at surfaces
(width across ats 22 mm)
3. Loosen counter nut (2) completely with a wrench (width across
ats 36 mm) in the direction of the antenna
Screwing in
Protection against mois-
ture
Suitability for the process
conditions

15
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
4. Loosen compression nut (1) completely with a wrench (width
across ats 41 mm) in the direction of the antenna
5. Remove the parabolic antenna (4) axially
6. Mount sensor ange on the adapter ange and fasten it tightly
7. Check if the O-ring seal is present on the connection piece and
make sure it is not damaged.
Note:
A damaged O-ring seal must be replaced: FKM (SHS FPM 70C3
GLT), FFKM (Kalrez 6375)
8. Remount the parabolic antenna (4)
9. Fasten compression nut (1) with a wrench (width across ats 41),
torque max. 50 Nm
10. Fasten counter nut (2) with a wrench (width across ats 36),
torque max. 40 Nm
Note:
On the version with rinsing air connection, make sure that the holes
in the antenna and in the process tting coincide. This ensures a suf-
cient air ow (the air is led through the holes to the feed system. A
rinsing of the whole parabolic antenna is not intended).
1
2
3
4
Fig. 5: Dismounting, parabolic antenna
1 Connection piece
2 Compression nut
3 Locknut
4 Parabolic antenna
4.3 Mounting preparations - Horn antenna
The instrument is also available in versions with an antenna whose
diameter is larger than the process tting (thread, ange). In such
cases the antenna must be disconnected from the process tting
before mounting. Proceed as follows:
1. Loosen the hexagon socket screws (3) on the antenna socket
with an Allen wrench (size 3)
2. Remove the antenna (4)
Note:
The plastic cone may not be pulled out of the antenna socket.

16
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
3. Insert the antenna from below into the vessel socket and secure it
against falling o
4. Retighten the antenna with hexagon screws to the antenna
socket; torque max. 2.5 Nm (1.8 lbf ft)
Note:
The radar sensor with rinsing air connection or antenna extension
is provided with a notch on the antenna socket. This notch must be
aligned with the marking on the process tting (the marking species
the position of the polarisation of the radar signal).
3
4
1
2
Fig. 6: Dismounting of the horn antenna
1 Marking for the polarisation
2 Marking at the antenna socket
3 Hexagon screws on the antenna socket
4 Antenna
4.4 Mounting instructions
The emitted radar impulses of the radar sensor are electromagnetic
waves. The polarisation is the direction of the electrical wave compo-
nent. By turning the instrument in the connection ange or mounting
boss, the polarisation can be used to reduce the eects of false
echoes.
The position of the polarisation is marked on the process tting of the
instrument.
Polarisation

17
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
12
Fig. 7: Position of the polarisation
1 Marking with screwed version
2 Markingwithangeversion
Mount the sensor at least 200 mm (7.874 in) away from the vessel
wall.
200 mm
(7.87
")
Fig. 8: Mounting of the radar sensor on the vessel top
If you cannot maintain this distance, you should carry out a false
signal storage during setup. This applies particularly if buildup on the
vessel wall is expected. In such a case, it is recommended to repeat
the false signal storage at a later date with existing buildup.
Mounting should not be too close to the inowing material as the
microwave signal will be interferred. The optimum mounting position is
on the opposite of the lling. To avoid strong pollution, the distance to
the lter or dust extraction must be as big as possible.
Installation position
Inowingmedium

18
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
Fig.9:Mountingoftheradarsensorwithinowingmedium
With bulk solids silos with lateral pneumatic lling, mounting should
not be in the lling stream as the microwave signal will be interferred.
The optimum mounting position is next to the lling. To avoid strong
pollution, the distance to the lter or dust extraction must be as big as
possible.

19
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
Fig.10:Mountingoftheradarsensorwithinowingmedium
The socket piece should be dimensioned in such a way that the
antenna end protrudes slightly out of the socket.
Socket

20
4 Mounting
VEGAPULS SR 68 • 4 … 20 mA/HART two-wire
38294-EN-130624
ca. 10 mm
Fig. 11: Recommended socket mounting with horn antenna
> 10 mm
(0.39")
Fig. 12: Recommended socket mounting with parabolic antenna
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 reections may be generated which
can inuence the measuring result at close range.