Vega VEGATOR 632 User manual

Operating Instructions
VEGATOR 632
Signal conditioning instrument
Document ID:
35243
Signal
conditioning instruments
and communication

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
2.6Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.7Environmental instructions..................... 6
3Product description
3.1Structure ................................. 7
3.2Principle of operation ........................ 7
3.3Operation................................. 8
3.4Packaging,transport and storage ............... 8
4Mounting
4.1General instructions ......................... 10
4.2Instructions for installation ..................... 10
5Connecting to power supply
5.1Preparing the connection ..................... 12
5.2Connection procedure........................ 13
5.3Wiring plan................................ 13
6Adjustment elements
6.1Adjustment elements -Overview . . . . . . . . . . . . . . . . 19
7Set up -Single channel control (level detection)
7.1Adjust relay function ......................... 23
7.2Sensitivity adjustment ........................ 25
7.3Adjust switching delay ....................... 27
7.4Activate line break monitoring . . . . . . . . . . . . . . . . . . 27
7.5Master/Slave function ........................ 28
8Set up -Two-point control Δs(pump control)
8.1Adjust relay function ......................... 29
8.2Adjustment................................ 31
8.3Adjust switching delay ....................... 33
8.4Activate line break monitoring . . . . . . . . . . . . . . . . . . 34
8.5Master/Slave function ........................ 34
9Set up -Two-channel control
9.1Adjust relay function ......................... 35
2VEGATOR 632 •Signal conditioning instrument
Contents
35243-EN-120228

9.2Adjustment................................ 37
9.3Adjust switching delay ....................... 39
9.4Activate line break monitoring . . . . . . . . . . . . . . . . . . 39
9.5Master/Slave function ........................ 40
10 Set up -Four-channel control
10.1General information ......................... 41
10.2Adjust relay function ......................... 41
10.3Adjustment................................ 41
10.4Adjust switching delay ....................... 41
10.5Activate line break monitoring . . . . . . . . . . . . . . . . . . 41
10.6Master/Slave function ........................ 42
11 Switching examples
11.1Single channel operation...................... 43
11.2Two-channel operation ....................... 45
11.3Two-point control ........................... 46
11.4Four-channel operation ....................... 48
11.5Two-point control and two-channel operation . . . . . . . 49
12 Maintenance and fault rectification
12.1Maintaining ............................... 50
12.2Remove interferences ........................ 50
12.3Function test .............................. 51
12.4Instrument repair ........................... 52
13 Dismounting
13.1Dismounting steps .......................... 53
13.2Disposal ................................. 53
14 Supplement
14.1Technical data ............................. 54
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Editing status:2012-02-20
VEGATOR 632 •Signal conditioning instrument 3
Contents
35243-EN-120228

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.
4VEGATOR 632 •Signal conditioning instrument
1About this document
35243-EN-120228

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
VEGATOR 632 is a universal signal conditioning instrument for
connection of a level switch.
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.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for 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.
VEGATOR 632 •Signal conditioning instrument 5
2For your safety
35243-EN-120228

2.5CE 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.
2.6Safety 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.
2.7Environmental 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"
6VEGATOR 632 •Signal conditioning instrument
2For your safety
35243-EN-120228

3Product description
3.1Structure
The scope of delivery encompasses:
lVEGATOR 632 signal conditioning instrument
lDocumentation
-this operating instructions manual
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
VEGATOR 632 consists of:
lVEGATOR 632 signal conditioning instrument
1
1
Fig.1:VEGATOR 632
1Pluggable terminal blocks
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
lArticle numbers,documentation
lInformation about connection and adjustment of the instrument
The serial number allows you to access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".
3.2Principle of operation
VEGATOR 632 is a single signal conditioning instrument with two
channels (relay)for processing the signals of conductive probes.
Scope of delivery
Constituent parts
Type label
Application area
VEGATOR 632 •Signal conditioning instrument 7
3Product description
35243-EN-120228

The following switching functions are possible:
lSingle channel control (simple level detection)
lTwo-point control (pump control)
lTwo-channel control (two separate switching points)
lFour-channel control or combination of two-point and two-channel
control (with two VEGATOR 632)
The VEGATOR 632 signal conditioning instrument powers connected
sensors and simultaneously processes their measuring signals.
It delivers a small alternating current to the measuring cell via the
signal cable.Electrolytic decomposition of the electrode rods and the
medium is avoided by using alternating current.
The cable is connected to the measurement loop or the metallic vessel
and the probe.
When the medium reaches the switching point of the sensor,the
voltage on the sensor drops.The output relays then switch according
to the set mode.
Detailed information about the power supply can be found in chapter
"Technical data".
3.3Operation
The damping and the mode can be adjusted on the signal conditioning
instrument via the slide switch.The instrument function can be
preadjusted with a DIL switch block.
The switching point can be adjusted with a potentiometer.
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.
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.
Functional principle
Voltage supply
Packaging
Transport
Transport inspection
8VEGATOR 632 •Signal conditioning instrument
3Product description
35243-EN-120228

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 %
Storage
Storage and transport
temperature
VEGATOR 632 •Signal conditioning instrument 9
3Product description
35243-EN-120228

4Mounting
4.1General instructions
VEGATOR 632 signal conditioning instrument for mounting on carrier
rail according to EN 60715 TH 35 x7.5or EN 60715 TH 35 x15.
The adjustment elements of VEGATOR 632 are protected under a
hinged front plate against unauthorised or inadvertent adjustment.
VEGATOR 632 must be mounted outside the hazardous area in a
switching cabinet (at least protection rating IP 55).
For moisture-protected mounting outside the switching cabinet,we
offer an insulated protective housing with transparent cover (IP 65)for
surface mounting.
4.2Instructions for installation
A VEGATOR 632 in Ex version is an auxiliary,intrinsically safe
instrument and may not be installed in explosion-endangered areas.
Please keep the following min.distances when mounting.
a
a
a
? ? ? ? ?
E
X
E
X
E
X
Fig.2:Min.distances to other instruments
aDistance ≥50 mm (1.97 in)
Installation location
Front plate
Protected mounting lo-
cation
Installation
Min.distances
10 VEGATOR 632 •Signal conditioning instrument
4Mounting
35243-EN-120228

Snap in the instrument vertically on a suitable carrier rail (EN 60715
TH 35 x7.5or EN 60715 TH 35 x15).
1
Fig.3:Mounting of the signal conditioning instrument
1Carrier rail EN 60715 TH 35
Dismount the instrument in the following sequence.
1Switch offpower supply
1
2
b
b
a
a
Fig.4:Dismounting of the signal conditioning instrument
2Remove the terminal blocks with a screwdriver ①
3Open the slide with a screwdriver ②
4Flip up the signal conditioning instrument and remove it from the
carrier rail
Carrier rail mounting
Dismounting
VEGATOR 632 •Signal conditioning instrument 11
4Mounting
35243-EN-120228

5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,overvoltage arresters should
be installed
Tip:
We recommend VEGA overvoltage arresters B61-300 (power supply
VEGATOR 632)and B62-36G(sensor supply).
In hazardous areas you must take note of the respective regulations,
conformity and type approval certificates of the sensors and power
supply units.
The power supply can be 85 …253 V AC,50/60 Hz or 20 …60 V DC.
The operating voltage of VEGATOR 632 is connected with standard
cable according to the national installation standards.The line
resistance must be max.25 Ωper wire.If electromagnetic interference
is expected which is above the test values of EN 61326 for industrial
areas,screened cable should be used.
If screened cable is necessary,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 equalisation
(low impedance).
If potential equalisation currents are expected,the connection on the
processing side must be made via a ceramic capacitor (e.g.1nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed,but the protective effect against high frequency interfer-
ence signals remains.
Take note of the corresponding installation regulations for Ex
applications.
Note safety instructions
Take note of sa-
fety instructions
for Ex applica-
tions
Select power supply
Selecting connection
cable
Cable screening and
grounding
Select connec-
tion cable for Ex
applications
12 VEGATOR 632 •Signal conditioning instrument
5Connecting to power supply
35243-EN-120228

5.2Connection procedure
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
1 2 3 4
5
6 7
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
Fig.5:Terminal assignment
1Ground
2Sensor input -Channel 1(CH 1)
3Sensor input -Channel 2(CH 2)
4Master/Slave
5Level relay 1
6Voltage supply
7Level relay 2or operating relay
Move on to electrical connection and proceed as follows:
1Snap VEGATOR 632 onto the carrier rail
2Connect the sensor cable to terminals 7to 10 (see the following
wiring plans)
3Connect relay outputs (4to 6and 15 to 17)
4Connect power supply (switched off)to terminal 1and 2
The electrical connection is finished.
5.3Wiring plan
Note:
In conductive vessels,the ground cable has contact to the grounded
vessel via the process fitting.
In non-conductive vessels,the probe requires a ground rod which is
connected to the ground terminal of VEGATOR 632.
The line break monitoring or alarm function defines the function of the
signal conditioning instrument in case of failure.
The line monitoring is required for probes with approval according to
WHG (WRA)or Ex.
To realize a line monitoring,an additional electronics must be
integrated in the connection housing of the probe.
Line monitoring
VEGATOR 632 •Signal conditioning instrument 13
5Connecting to power supply
35243-EN-120228

Fig.6:Additional electronics for line break monitoring in conjunction with a
conductive probe
1Connect the eyelet according to the following illustration.
Make sure that the eyelets have no contact to other metal parts.
2Open one of the other terminals and attach the additional
electronics.
3Tighten the terminal.
1
2
Fig.7:Mounting of the additional electronics for line break monitoring
1Connection to terminal 1(ground rod =longest rod)
2Connection to terminal 2(max.rod =shortest rod)
3Additional electronics for line break monitoring
If you are using a probe without additional electronics for line break
monitoring,a fault signal will be triggered.
Keep in mind that in case of a fault signal also the switching output will
be activated.
Only failures of channel 1are monitored.
14 VEGATOR 632 •Signal conditioning instrument
5Connecting to power supply
35243-EN-120228

Take note of the operating instructions of the conductive probe.
1 2
21
6
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
3
5
4
Fig.8:Level detection in metallic (conductive)vessels
1Ground
2max. - channel 1(CH 1)
3Level relay 1
4Level relay 2or fail safe relay
5Voltage supply
6Probe,e.g.EL1
You can find detailed information under "Set up -Single point control"
as well as under "Switching examples".
Level detection in con-
ductive vessels
VEGATOR 632 •Signal conditioning instrument 15
5Connecting to power supply
35243-EN-120228

12
21
6
12
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
3
5
4
Fig.9:Level detection in non-conductive vessels
1Ground
2max. - channel 1(CH 1)
3Level relay 1
4Level relay 2or fail safe relay
5Voltage supply
6Probe,e.g.EL3
You can find detailed information under "Set up -Single point control"
as well as under "Switching examples".
Level detection in non-
conductive vessels
16 VEGATOR 632 •Signal conditioning instrument
5Connecting to power supply
35243-EN-120228

1 3
2
2
3
1
7
123
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
4
6
5
Fig.10:Two-point control
1Ground
2max. - channel 1(CH 1)
3min. - channel 2(CH 2)
4Level relay 1
5Level relay 2or fail safe relay
6Voltage supply
7Probe,e.g.EL3
You can find detailed information under "Set up -Two-point control"as
well as under "Switching examples".
Two-point control (min./
max.control)
VEGATOR 632 •Signal conditioning instrument 17
5Connecting to power supply
35243-EN-120228

1
2 3
4
5
1
4
2
5
3
3
45
1
9
A B
2
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
6
8
7
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR 149A
ON
L1
L+
N
L–
7 8 9 10
4 5 6 17
1 2 15 16
CH2 CH1 Master/
Slave
6
8
7
Fig.11:Four-channel control with two signal conditioning instruments VEGATOR
632
1Ground
2max. - channel 1(CH 1)
3min. - channel 2(CH 2)
4min. - channel 2(CH 2)
5max. - channel 1(CH 1)
6Level relay 1
7Level relay 2or fail safe relay
8Voltage supply
9Probe,e.g.EL3
A Min./max.control (signal conditioning instrument 1-Master)
B Min./max.control (signal conditioning instrument 2-Slave)
You can find detailed information under "Set up -Four-channel control"
as well as under "Switching examples".
Four-channel control
with two signal conditio-
ning instruments
18 VEGATOR 632 •Signal conditioning instrument
5Connecting to power supply
35243-EN-120228

6Adjustment elements
6.1Adjustment elements -Overview
The following adjustment elements are located below the cover.
1 2 3 4 5 6 7 8
O N
78
456
15 16
L1 N
L+ L-
12
910
CH 2
CH 1
master/
slave
output
mode delay
s
alarm
master/
slave
range
1 2 3 4 5 6 7 8
calibration
CH1
CH2
17
min/
max
31
3362
C
B
A
D
E
Fig.12:VEGATOR 632 -Adjustment elements
A DIL switch block
B Potentiometer for switching point adjustment
C Control lamps
D Slid switch for mode adjustment
E Slide switch for setting the switching delay
SIL switch block with 8switches.The individual switches are assigned
as follows:
DIL switch block (A)
VEGATOR 632 •Signal conditioning instrument 19
6Adjustment elements
35243-EN-120228

(numbering from top to bottom)
1 KΩ
10 KΩ
200 KΩ
s
CH1
CH2
Alarm
Slave/Master
min.
min.
max.
max.
off on
1
2
3
4
5
6
7
8
Fig.13:DIL switch block (A)
1Sensitivity adjustment -range up to 1kΩ
2Sensitivity adjustment -range up to 10 kΩ
3Sensitivity adjustment -range up to 200 kΩ
4Two-point control
5Mode -channel 1(CH 1)
6Mode -channel 2(CH 2)
7Line monitoring (alarm)
8Master/Slave adjustment
lA1-Sensitivity adjustment -range up to 1kΩ
lA2-Sensitivity adjustment -range up to 10 kΩ
lA3-Sensitivity adjustment -range up to 200 kΩ
lA4-Two-point control
lA5-Mode -Channel 1(CH 1)
-off:Max.detection or overflow protection
-on:Min.detection or dry run detection
lA6-Mode -Channel 2(CH 2)
-off:Max.detection or overflow protection
-on:Min.detection or dry run detection
lA7-Line monitoring (alarm)
lA8-Master/Slave adjustment (on =Master)
Apotentiometer for switching point adaptation is located below the
cover of the signal conditioning instrument.With this potentiometer you
can adapt the measuring system to the conductivity of the product.
Calibration
31
Fig.14:Potentiometer for switching point adjustment (B)
Potentiometer for swit-
ching point adjustment
(B)
20 VEGATOR 632 •Signal conditioning instrument
6Adjustment elements
35243-EN-120228