Vega VEGACAP 67 User manual

Operating Instructions
VEGACAP 67
-contactless electronic switch
Document ID:
31314
Capacitive

Contents
1About this document
1.1Function.................................. 4
1.2Target group .............................. 4
1.3Symbolism used............................ 4
2For your safety
2.1Authorised personnel ........................ 5
2.2Appropriate use ............................ 5
2.3Warning about misuse ....................... 5
2.4General safety instructions . . . . . . . . . . . . . . . . . . . . 5
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity ............................. 6
2.7Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.8Environmental instructions..................... 6
3Product description
3.1Configuration .............................. 7
3.2Principle of operation ........................ 9
3.3Operation................................. 10
3.4Storage and transport ....................... 10
4Mounting
4.1General instructions ......................... 12
4.2Mounting instructions ........................ 13
5Connecting to power supply
5.1Preparing the connection ..................... 17
5.2Connection procedure........................ 17
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 18
6Set up
6.1General information ......................... 21
6.2Adjustment elements ........................ 21
6.3Functional chart ............................ 23
7Maintenance and fault rectification
7.1Maintenance .............................. 24
7.2Rectify malfunctions ......................... 24
7.3Exchange of the electronics module . . . . . . . . . . . . . 26
7.4Shortening of the probe . . . . . . . . . . . . . . . . . . . . . . 27
7.5Instrument repair ........................... 28
8Dismounting
8.1Dismounting steps .......................... 29
8.2Disposal ................................. 29
9Supplement
9.1Technical data ............................. 30
2VEGACAP 67 • - contactless electronic switch
Contents
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9.2Dimensions ............................... 33
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your VEGACAP 67,we offer
accessories and replacement parts.The corresponding documenta-
tions are:
l30174 -Electronics module VEGACAP series 60
l34296 -Protective cover
l31088 -Flanges according to DIN-EN-ASME-JIS-GOST
VEGACAP 67 • - contactless electronic switch 3
Contents
31314-EN-100407

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.
4VEGACAP 67 • - contactless electronic switch
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
The VEGACAP 67 is a sensor for level detection.
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 required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
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2For your safety
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2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,VEGA provides a confirmation
of successful testing.You can find the CE conformity declaration in the
download area of www.vega.com.
2.7Safety 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.
2.8Environmental 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"
6VEGACAP 67 • - contactless electronic switch
2For your safety
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3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGACAP 67 point level sensor
lDocumentation
-this operating instructions manual
-Supplementary instructions manual "Plug connector for level
sensors"(optional)
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
The VEGACAP 67 consist of the following components:
lHousing cover
lHousing with electronics
lProcess fitting with electrode
Scope of delivery
Constituents
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3Product description
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1
2
3
5
4
Fig.1:VEGACAP 67 -with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
4Supporting tube
5Ceramic insulator
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
lArticle numbers,documentation
With the serial number,you can access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".In addition to the type label outside,you can also find the
serial number on the inside of the instrument.
Type label
8VEGACAP 67 • - contactless electronic switch
3Product description
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3.2Principle of operation
VEGACAP 67 is a point level sensor with capacitive probe for level
detection under high process temperatures.
VEGACAP 67 is very rugged and maintenance-free and can be used
in all areas of industrial process technology.
Probes such as VEGACAP 67 are used in solids applications.
The range of the process temperature is at -50 …+300 °C
(-58 …+572 °F). With external housing of -50 …+400 °C
(-58 …+752 °F).
Typical applications are overfill and dry run protection.
The capacitive measuring principle places no special requirements on
installation.Hence,many different applications can be equipped with
VEGACAP 67.
Probe,measured product and vessel wall form an electrical capacitor.
The capacitance is influenced by three main factors.
Fig.2:Functional principle -Plate capacitor
1Distance between the electrode surfaces
2Size of the electrode surfaces
3Type of dielectric between the electrodes
Application area
Functional principle
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3Product description
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The probe and the vessel wall are the capacitor plates.The measured
product is the dielectric.Due to the higher dielectric constant (DK
value)of the product compared to air,the capacitance increases as
the probe is gradually covered.
The capacitance change is converted by the electronics module into a
switching command.
VEGACAP 67 is a compact instrument,i.e.it can be operated without
external evaluation system.The integrated electronics evaluates the
level signal and outputs a switching signal.With this switching signal,a
connected device can be operated directly (e.g.a warning system,a
PLC,a pump etc.).
The data for power supply are specified in chapter "Technical data".
3.3Operation
The probe can be adapted to the dielectric constant of the product
directly on the electronics module.
Aswitching command can be triggered when the probe is covered or
laid bare.
On the electronics module you will find the following indicating and
adjustment elements:
lSignal lamp for indication of the switching condition (green/red)
lPotentiometer for switching point adaptation
lDIL switch for measuring range selection
lDIL switch for mode adjustment
3.4Storage and transport
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.
Voltage supply
Packaging
Transport
Transport inspection
10 VEGACAP 67 • - contactless electronic switch
3Product description
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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
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4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,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.
In general,VEGACAP 67 must be mounted vertically.The instrument
must be mounted in such a way that the probe is at the height of the
requested switching point.
Before beginning the welding work,remove the electronics module
from the sensor.By doing this,you avoid damage to the electronics
through inductive coupling.
With threaded versions,the housing must not be used to screw in the
instrument!Applying tightening forces on the housing can damage its
internal parts.
Use the hexagon for screwing in.
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.
Suitability for the pro-
cess conditions
Switching point
Welding work
Handling
Moisture
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4Mounting
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Fig.3:Measures against moisture penetration
The process fitting must be sealed if there is gauge or low pressure in
the vessel.Before use,check if the seal material is resistant against
the measured product and the process temperature.
The max.permissible pressure is specified in chapter "Technical data"
or on the type label of the sensor.
4.2Mounting instructions
Agitators,equipment vibration,etc., can cause the level switch to be
subjected to strong lateral forces.For this reason,do not use an overly
long probe for VEGACAP 67,but check if you can mount a short level
switch on the side of the vessel in horizontal position.
If the instrument is mounted in the filling stream,unwanted false
measurement signals can be generated.For this reason,mount the
instrument at a position in the vessel where no disturbances,e.g.from
filling openings,agitators,etc., can occur.
This applies particularly to instrument versions with a longer probe.
Pressure/Vacuum
Agitators and fluidiza-
tion
Inflowing medium
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4Mounting
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Fig.4:Inflowing medium
The probe should protrude into the vessel to avoid buildup.For that
reason,avoid using mounting bosses for flanges and screwed fittings.
This applies particularly to use with adhesive products.
In silos with bulk solids,material cones can form which change the
switching point.Please keep this in mind when installing the sensor in
the vessel.We recommend selecting an installation location where the
probe detects the average value of the material cone.
The probe must be mounted in a way that takes the arrangement of the
filling and emptying apertures into account.
To compensate measurement errors caused by the material cone in
cylindrical vessels,the sensor must be mounted at a distance of d/6
from the vessel wall.
Socket
Material cone
14 VEGACAP 67 • - contactless electronic switch
4Mounting
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d d
d
6
d
6
Fig.5:Filling and emptying centred
VEGACAP 67 • - contactless electronic switch 15
4Mounting
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d
d
6
1
2
3
Fig.6:Filling in the centre,emptying laterally
1VEGACAP 67
2Discharge opening
3Filling opening
Make sure that the max.permissible tensile load of the suspension
cable is not exceeded.The danger of this happening exists particularly
with very heavy solids and large meas.lengths.The max.permissible
load is stated in chapter "Technical data".
Tensile load
16 VEGACAP 67 • - contactless electronic switch
4Mounting
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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
Connect the power supply according to the following diagrams.
Oscillator CP60Cis designed in protection class 1.To maintain this
protection class,it is absolutely necessary that the ground conductor is
connected to the internal ground terminal.Take note of the general
installation regulations.As a rule,connect VEGACAP 67 to vessel
ground (PA), or in case of plastic vessels,to the next ground potential.
On the side of the housing there is a ground terminal between the
cable entries.This connection serves to drain offelectrostatic charges.
The data for power supply are specified 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.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
5.2Connection procedure
With Ex instruments,the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)of insulation from the ends of the individual wires
4Insert the cable through the cable gland into the sensor
5Lift the opening levers of the terminals with a screwdriver (see
following illustration)
6Insert the wire ends into the open terminals according to the wiring
plan
7Press down the opening levers of the terminals,you will hear the
terminal spring closing
8Check the hold of the wires in the terminals by lightly pulling on
them
Note safety instructions
Voltage supply
Connection cable
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5Connecting to power supply
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9Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
10 If necessary,carry out a fresh adjustment
11 Screw the housing cover on
The electrical connection is finished.
Fig.7:Connection steps 5and 6
5.3Wiring plan,single chamber housing
1
4
44
2 3
Fig.8:Material versions,single chamber housing
1Plastic (not with dust-Ex)
2Aluminium
3Stainless steel
4Filter element for air pressure compensation
Housing overview
18 VEGACAP 67 • - contactless electronic switch
5Connecting to power supply
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Fig.9:Electronics and connection compartment
1Potentiometer for switching point adaptation
2DIL switch for measuring range selection
3DIL switch for mode adjustment
4Ground terminal
5Connection terminals
6Control lamp
We recommend connecting VEGACAP 67 in such a way that the
switching circuit is open when there is a level signal,line break or
failure (safe condition).
The contactless electronic switch is always shown in non-operative
condition.
Warning:
The instrument must not be operated without an intermediately
connected load,because the electronics would be destroyed if
connected directly to the mains.It is not suitable for connection to low
voltage PLC inputs.
For direct control of relays,contactors,magnet valves,warning lights,
horns etc.
Domestic current is temporarily lowered below 1mAafter switching off
the load so that contactors,whose holding current is lower than the
constant domestic current of the electronics,are reliably switched off.
When VEGACAP 67 is used as part of an overfill protection system
according to WHG,also note the regulations of the general type
approval.
Electronics and connec-
tion compartment
Wiring plan
VEGACAP 67 • - contactless electronic switch 19
5Connecting to power supply
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1
Fig.10:Wiring plan
1Voltage supply
20 VEGACAP 67 • - contactless electronic switch
5Connecting to power supply
31314-EN-100407