Vega VEGASON 61 User manual

Operating Instructions
Ultrasonic sensor for continuous level
measurement
VEGASON 61
4 … 20 mA/HART - two-wire
Document ID: 28775

2
Contents
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
Contents
1 About this document
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety
2.1 Authorised personnel ....................................................................................................... 5
2.2 Appropriate use................................................................................................................ 5
2.3 Warning about incorrect use............................................................................................. 5
2.4 General safety instructions............................................................................................... 5
2.5 Safety label on the instrument .......................................................................................... 6
2.6 CE conformity................................................................................................................... 6
2.7 FulllmentofNAMURrecommendations ......................................................................... 6
2.8 Safety instructions for Ex areas ........................................................................................ 6
2.9 Environmental instructions ............................................................................................... 6
3 Product description
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Operation ......................................................................................................................... 8
3.4 Packaging, transport and storage..................................................................................... 9
4 Mounting
4.1 General instructions ....................................................................................................... 10
4.2 Mountinginstructions ..................................................................................................... 11
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 18
5.2 Connection procedure.................................................................................................... 19
5.3 Wiring plan, single chamber housing.............................................................................. 20
5.4 Wiring plan, double chamber housing ............................................................................ 22
5.5 Wiring plan - version IP 66/IP 68 (1 bar) ......................................................................... 24
5.6 Switch-on phase............................................................................................................. 24
6 Set up with the display and adjustment module PLICSCOM
6.1 Short description ............................................................................................................ 25
6.2 Insert display and adjustment module............................................................................ 25
6.3 Adjustment system......................................................................................................... 26
6.4 Setup steps .................................................................................................................... 27
6.5 Menuplanultrasonicsensor .......................................................................................... 32
6.10 Saving the parameter adjustment data........................................................................... 34
7 Set up with PACTware and other adjustment programs
7.1 Connect the PC via VEGACONNECT ............................................................................ 35
7.2 Parameter adjustment with PACTware............................................................................ 36
7.3 ParameteradjustmentwithAMS™andPDM................................................................. 37
7.4 Saving the parameter adjustment data........................................................................... 38
8 Maintenanceandfaultrectication
8.1 Maintenance .................................................................................................................. 39
8.2 Rectify faults................................................................................................................... 39
8.3 Exchanging the electronics module................................................................................ 40

3
Contents
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
8.4 Software update............................................................................................................. 40
8.5 How to proceed if a repair is needed.............................................................................. 41
9 Dismount
9.1 Dismounting steps.......................................................................................................... 43
9.2 Disposal ......................................................................................................................... 43
10 Supplement
10.1 Technical data ................................................................................................................ 44
10.2 Dimensions .................................................................................................................... 48
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
withthedelivery.Youcanndthemlistedinchapter"Product descrip-
tion".
Instructions manuals for accessories and replacement parts
Tip:
ToensurereliablesetupandoperationofyourVEGASON61,weoer
accessories and replacement parts.The corresponding documenta-
tions are:
• 27835-DisplayandadjustmentmodulePLICSCOM
• 32628 - Interface adapter VEGACONNECT
• 27720 - External indication VEGADIS 61
• 34296 - Protective cover
• 30176 - Electronics module VEGASON series 60
Editing status: 2014-09-29

4
1 About this document
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
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 Symbols 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.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant 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.

5
2 For your safety
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
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
VEGASON 61 is a sensor for continuous level measurement.
Youcannddetailedinformationabouttheareaofapplication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.
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.
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.

6
2 For your safety
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 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.
2.7 Fulllmentof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
For further information see www.namur.de.
2.8 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.
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"

7
3 Product description
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• VEGASON 61 ultrasonic sensor
• Documentation
– this operating instructions manual
– SafetyManual28983"VEGASON 61, 62 - 4 … 20 mA/HART"
(optional)
– Operatinginstructionsmanual27835"Display and adjustment
module PLICSCOM"(optional)
– Supplementaryinstructionsmanual31708"Heating for display
and adjustment module PLICSCOM"(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
1
2
3
Fig. 1: VEGASON 61 - version with plastic housing
1 Housing cover with integrated PLICSCOM (optional)
2 Housing with electronics, optionally available with plug connector
3 Processttingwithtransducer
The VEGASON 61 consists of the components:
• Transducer with integrated temperature sensor
• Housing with electronics, optionally available with plug connector
• Housing cover, optionally available with display and adjustment
modulePLICSCOM
Thecomponentsareavailableindierentversions.
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
Scope of delivery
Constituent parts
Type label

8
3 Product description
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
• Instrument type
• Article and serial number device
• Article numbers, documentation
• Technical data: For example approvals, process temperature,
processtting/material,signaloutput,powersupply,protection
• SILidentication(withSILratingexworks)
With the serial number, you can access the delivery data of the instru-
ment via www.vega.com,"VEGA Tools"and"serial number search".
Youcanndtheserialnumberontheinsideoftheinstrumentaswell
as on the type label on the outside.
3.2 Principle of operation
VEGASON 61 is an ultrasonic sensor for continuous level measure-
ment. It is suitable for liquids and solids in virtually all industries,
particularly in the water and waste water industry.
The transducer of the ultrasonic sensor transmits short ultrasonic
pulsestothemeasuredproduct.Thesepulsesarereectedby
product surface and received back by the transducer as echoes.
The running time of the ultrasonic pulses from emission to reception
is proportional to the distance and hence the level. The determined
level is converted into an appropriate output signal and outputted as
measured value.
4 … 20 mA/HART two-wire electronics for voltage supply and meas-
ured value transmission on the same cable.
Thesupplyvoltagerangecandierdependingontheinstrument
version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The optional background lighting of the display and adjustment
module is powered by the sensor. A certain level of operating voltage
isrequiredforthis.Youcanndtheexactvoltagespecicationsin
chapter"Technical data".
Theoptionalheatingrequiresitsownoperatingvoltage.Youcannd
detailsinthesupplementaryinstructionsmanual"Heating for display
and adjustment module".
This function is generally not available for approved instruments.
3.3 Operation
The instrument can be adjusted with the following adjustment media:
• With the display and adjustment module
• withthesuitableVEGADTMinconjunctionwithanadjustment
softwareaccordingtotheFDT/DTMstandard,e.g.PACTwareand
PC
• withmanufacturer-specicadjustmentprogramsAMS™orPDM
• With a HART handheld
Application area
Functional principle
Voltage supply

9
3 Product description
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
3.4 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 in due 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.
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 %
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature

10
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
4 Mounting
4.1 General instructions
Makesurethatallpartsoftheinstrumentcomingindirectcontact
with the process, especially the sensor element, process seal and
processtting,aresuitablefortheexistingprocessconditions,such
as process pressure, process temperature as well as the chemical
properties of the medium.
Youcanndthespecicationsinchapter"Technical data"andonthe
nameplate.
Select an installation position you can easily reach for mounting and
connectingaswellaslaterretrottingofadisplayandadjustment
module.The housing can be rotated by 330° without the use of any
tools.You can also install the display and adjustment module in four
dierent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o.Thisap-
plies 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 ingress
The reference plane for the measuring range is the lower edge of the
transducer.
Makesurethataminimumdistancefromthereferenceplane-the
so-calleddeadzone,inwhichmeasurementisnotpossible-is
maintained.Theexactvalueofthedeadzoneisstatedinchapter
"Technical data".
Suitability for the process
conditions
Installation position
Moisture
Measuring range

11
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
1
2
Fig. 3: Minimum distance to the max. level
1 Dead zone
2 Reference plane
Information:
If the medium reaches the transducer, buildup can form on it and
cause faulty measurements later on.
1 32
100%
0%
Fig. 4: Measuring range (operating range) and max. measuring distance
1 full
2 empty (max. measuring distance)
3 Measuring range
GaugepressureinthevesseldoesnotinuenceVEGASON61.Low
pressure or vacuum does, however, damp the ultrasonic pulses.This
inuencesthemeasuringresult,particularlyifthelevelisverylow.
Withpressuresunder-0.2bar(-20kPa)youshoulduseadierent
measuring principle, e.g. radar or guided microwave.
4.2 Mounting instructions
Screw VEGASON 61 into the mounting socket with an appropriate
spannerappliedtothehexagonoftheprocesstting.Max.torquesee
chapter"Technical data".
Pressure/Vacuum
Screwing in

12
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
When mounting the sensor, keep a distance of at least 200 mm
(7.874 in) to the vessel wall. If the sensor is installed in the center of
dished or round vessel tops, multiple echoes can arise.These can,
however, be suppressed by an appropriate adjustment (see chapter
"Setup").
1
2
> 200 mm
Fig. 5: Mounting on round vessel tops
1 Reference plane
2 Vessel center or symmetry axis
If this distance cannot be maintained, a false signal storage should
be carried out during setup. This applies particularly if buildup on the
vessel wall is expected. In such cases, we recommend repeating the
false signal storage at a later date with existing buildup.
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.
Installation position

13
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
Fig. 6: Vessel with conical bottom
Socket pieces should be dimensioned so that the lower end of the
transducer protrudes at least 10 mm (0.394 in) out of the socket.
ca. 10 mm
Fig. 7: Recommended socket mounting
Ifthereectivepropertiesofthemediumaregood,youcanmount
VEGASON 61 on sockets which are higher than the length of the
transducer.Youwillndrecommendedvaluesforsocketheightsinthe
following illustration. The socket end should be smooth and burr-free,
if possible also rounded. Carry out a false echo storage.
Socket

14
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
h
dh
80 mm/3"
100 mm/4"
150 mm/6"
150 mm/6"
300 mm/12"
400 mm/16"
d
Fig. 8: Deviating socket dimensions
In liquids, direct the sensor as perpendicular as possible to the prod-
uct surface to achieve optimum measurement results.
Fig. 9: Alignment in liquids
To reduce the min. distance to the medium, you can also mount VE-
GASON61withabeamdeector.Bydoingthis,itispossibletollthe
vessel nearly to maximum. Such an arrangement is suitable primarily
foropenvesselssuchase.g.overowbasins.
~200
~400x400
45°
Fig.10:Beamdeector
The ultrasonic sensor should be installed at a location where no
installations cross the ultrasonic beam.
Vessel installations such as for example, ladders, limit switches, heat-
ing spirals, struts etc. can cause false echoes that interfere with the
usefulecho.Makesurewhenplanningyourmeasuringsitethatthe
ultrasonicsignalshave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

15
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
If large vessel installations such as struts or supports cause false
echoes, these can be attenuated through supplementary measures.
Small,inclinedsheetmetalorplasticbaesabovetheinstallations
scatter the ultrasonic signals and avoid direct false echoes.
α
α
α
α
α
α
Fig.11:Coverat,large-areaproleswithdeectors
If there are agitators in the vessel, a false signal storage should be
carried out with the agitators in motion.This ensures that the interfer-
ingreectionsfromtheagitatorsaresavedwiththebladesindierent
positions.
Fig. 12: Agitators
Donotmounttheinstrumentsinorabovethellingstream.Makesure
thatyoudetecttheproductsurface,nottheinowingproduct.
Agitators
Inowingmedium

16
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
Fig.13:Inowingliquid
Throughtheactionoflling,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 sensor should be used
in a standpipe or, alternatively, the more suitable guided radar sen-
sors (TDR) should be used.
Guidedwaveradarisunaectedbyfoamgenerationandisparticu-
larly suitable for such applications.
If there are strong air currents in the vessel, e.g. due to strong winds
in outdoor installations or air turbulence, e.g. by cyclone extraction
youshouldmountVEGASON61inastandpipeoruseadierent
measuring principle, e.g. radar or guided radar (TDR).
Byusingastandpipe(surgeorbypasstube),theinuenceofvessel
installations, foam generation and turbulence is excluded.
Standpipes must extend all the way down to the requested min. level,
as measurement is only possible within the tube.
Foam
Air turbulences
Standpipe measurement

17
4Mounting
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
max.
min.
1
Fig. 14: Standpipe in the tank
1 Vent hole: ø 5 … 10 mm (0.197 … 0.394 in)
VEGASON 61 can be used from tube diameters of 40 mm (1.575 in).
Avoid large gaps and thick welding joints when connecting the tubes.
Generally carry out a false echo storage.
Measurementinastandpipeisnotrecommendedforextremely
adhesive products.

18
5 Connecting to power supply
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
• Connect only in the complete absence of line voltage
• If overvoltage surges are expected, overvoltage arresters should
be installed
Tip:
We recommend using VEGA overvoltage arresters B63-48 and
ÜSB 62-36G.X.
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Power supply and current signal are carried on the same two-wire
cable.Thevoltagesupplyrangecandierdependingontheinstru-
ment version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
Provide a reliable separation between the supply circuit and the
mains circuits according to DIN EN 61140 VDE 0140-1.The VEGA
power supply units VEGATRENN 149A Ex, VEGASTAB 690 as well
asallVEGAMETsandVEGASCANsmeetthisrequirement.
Keepinmindthefollowingadditionalfactorsthatinuencetheoperat-
ing voltage:
• Output voltage of the power supply unit can be lower under nomi-
nal load (with a sensor current of 20.5 mA or 22 mA in case of fault
message)
• Inuenceofadditionalinstrumentsinthecircuit(seeloadvaluesin
chapter"Technical data")
The instrument is connected with standard two-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas, screened cable should
be used.
Usecablewithroundcross-section.Acableouterdiameterof
5…9mm(0.2…0.35in)ensuresthesealeectofthecablegland.
Ifyouareusingcablewithadierentdiameterorcross-section,
exchange the seal or use a suitable cable gland.
We generally recommend the use of screened cable for HART multi-
drop mode.
On the instrument with cable entry ½ NPT and plastic housing there is
ametallic½"threadedinsertmouldedintotheplastichousing.
Caution:
No grease should be used when screwing the NPT cable gland or
steel tube into the threaded insert. Standard grease can contain
additives that corrode the connection between threaded insert and
Safety instructions
Voltage supply
Connection cable
Cablegland½NPT

19
5 Connecting to power supply
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
housing.Thiswouldinuencethestabilityoftheconnectionandthe
tightness of the housing.
If screened cable is required, connect the cable screen on both ends
to ground potential. In the sensor, the screen must be connected
directly to the internal ground terminal.The ground terminal on the
outside of the housing must be connected to the potential equalisa-
tion (low impedance).
If potential equalisation currents are expected, the connection on the
processing side must be made via a ceramic capacitor (e. g. 1 nF,
1500 V).The low-frequency potential equalisation currents are thus
suppressed,buttheprotectiveeectagainsthighfrequencyinterfer-
ence signals remains.
Take note of the corresponding installation regulations for Ex applica-
tions. In particular, make sure that no potential equalisation currents
owoverthecablescreen.Incaseofgroundingonbothsidesthis
can be achieved by the use of a capacitor or a separate potential
equalisation.
5.2 Connection procedure
Proceed as follows:
1. Unscrewthehousingcover
2. If a display and adjustment module is installed, remove it by turn-
ing it to the left.
3. Loosen compression nut of the cable entry gland
4. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
5. Insert the cable into the sensor through the cable entry
6. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
7. Insert the wire ends into the open terminals according to the wir-
ing plan
Cable screening and
grounding

20
5 Connecting to power supply
VEGASON 61 • 4 … 20 mA/HART - two-wire
28775-EN-141015
Fig. 15: Connection steps 6 and 7
8. Press down the opening levers of the terminals, you will hear the
terminal spring closing
9. Check the hold of the wires in the terminals by lightly pulling on
them
10. Connect the screen to the internal ground terminal, connect the
outer ground terminal to potential equalisation
11. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
12. Screw the housing lid back on
Theelectricalconnectionisnished.
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.