Vega VEGAKON 66 User manual

Operating Instructions
VEGAKON 66
with relay output
Conductive

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 . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6Environmental instructions . . . . . . . . . . . . . . . . 6
3Product description
3.1Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2Principle of operation. . . . . . . . . . . . . . . . . . . . 8
3.3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4Storage and transport . . . . . . . . . . . . . . . . . . . 9
4Mounting
4.1General instructions. . . . . . . . . . . . . . . . . . . . . 10
4.2Mounting information . . . . . . . . . . . . . . . . . . . . 10
5Connecting to power supply
5.1Preparing the connection . . . . . . . . . . . . . . . . . 12
5.2Connection instructions . . . . . . . . . . . . . . . . . . 12
5.3Wiring plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6Set up
6.1General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2Adjustment elements . . . . . . . . . . . . . . . . . . . . 14
6.3Switching point adjustment. . . . . . . . . . . . . . . . 15
6.4Function chart . . . . . . . . . . . . . . . . . . . . . . . . . 18
7Maintenance and fault rectification
7.1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2Electronics exchange. . . . . . . . . . . . . . . . . . . . 20
7.3Simulation of switching functions . . . . . . . . . . . 21
7.4Instrument repair . . . . . . . . . . . . . . . . . . . . . . . 21
8Dismounting
8.1Dismounting steps . . . . . . . . . . . . . . . . . . . . . . 22
8.2Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2VEGAKON 66 -with relay output
Contents
32649-EN-070615

9Supplement
9.1Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 23
9.2Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.3Industrial property rights. . . . . . . . . . . . . . . . . . 27
9.4Trademark . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
VEGAKON 66 -with relay output 3
Contents
32649-EN-070615

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
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 malfunc-
tions 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.
4VEGAKON 66 -with relay output
About this document
32649-EN-070615

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 operator.
During work on and with the device the required personal
protection equipment must always be worn.
2.2Appropriate use
VEGAKON 66 is a sensor for level detection.
You can find detailed information on the application range in
chapter "Product description".
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.
The user is also obliged to determine,during the entire
duration of use,the compliance of the necessary occupational
safety measures with the current valid regulations and take
note of new regulations.
2.5CE conformity
VEGAKON 66 is in CE conformity with EMC (89/336/EWG)
and LVD (73/23/EWG).
Conformity has been judged according to the following
standards:
VEGAKON 66 -with relay output 5
For your safety
32649-EN-070615

lEMC:
-Emission EN 50081-1
-Susceptibility EN 50082-2
lLVD:EN 61010
2.6Environmental 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 man-
agement system is certified according to DIN EN ISO 14001.
Please help us fulfil this obligation by observing the environ-
mental instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
6VEGAKON 66 -with relay output
For your safety
32649-EN-070615

3Product description
3.1Configuration
The scope of delivery encompasses:
lVEGAKON 66 compact level switch
lDocumentation
-this operating instructions manual
VEGAKON 66 consists of the following components:
lHousing cover
lHousing with electronics
lProcess fitting with electrodes
1
2
3
Fig.1:VEGAKON 66
1Housing cover
2Housing with electronics
3Process fitting with electrodes
Scope of delivery
Components
VEGAKON 66 -with relay output 7
Product description
32649-EN-070615

3.2Principle of operation
The conductive VEGAKON 66 compact level switches detect
levels of conductive liquids.
If at least two electrodes are covered with a conductive
medium,small alternating currents (<1mA)flow from the
measuring electrode to the ground electrode.
1
3
2
Fig.2:Functional principle
1Ground probe
2Max.level (max.electrode)
3Min.level (min.electrode)
These alternating currents are measured in respect to their
amplitude and phase position and converted into a switching
command.
VEGAKON 66 can be used for reliable detection of products
over a very wide conductivity and viscosity range.
Alevel detection can be realised with two measuring electro-
des,e.g.a pump or two-point control with three measuring
electrodes.
VEGAKON 66 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,aPLC,a pump etc.).
The data for power supply are stated in chapter "Technical
data"in the "Supplement".
Area of application
Functional principle
Supply
8VEGAKON 66 -with relay output
Product description
32649-EN-070615

3.3Operation
The VEGAKON 66 is a compact level switch with integrated
oscillator.
On the electronics module you will find the following indicating
and adjustment elements:
lControl lamp for indication of the switching condition
lMode changeover for selection of the output signal
lDIL switch for adjustment of the integration time
lRotary switch for adjustment of the conductivity value
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 environ-
ment-friendly,recyclable cardboard.In addition,the sensor is
provided with a protective cover of cardboard.For special
versions PE foam or PE foil is also used.Dispose of the
packaging material via specialised recycling companies.
lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Storage and transport tem-
perature
VEGAKON 66 -with relay output 9
Product description
32649-EN-070615

4Mounting
4.1General instructions
Use the recommended cables (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your VEGAKON 66 additional protection against
moisture penetration by leading the connection cable down-
ward in front of the cable entry.Rain and condensation water
can thus drain off.This applies mainly to mounting outdoors,in
areas where moisture is expected (e.g.by cleaning processes)
or on cooled or heated vessels.
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 stated in chapter "Technical
data"in the "Supplement"or on the type label of the sensor.
4.2Mounting information
Due to agitators,equipment vibration or similar,the probe can
be subjected to strong lateral forces.
During operation,the probe must not touch any installations or
the vessel wall.If necessary,secure the end of the probe
(insulated). Provide a suitable insulated support directly above
the probe end.
Moisture
Pressure/Vacuum
Agitators
10 VEGAKON 66 -with relay output
Mounting
32649-EN-070615

1
2
1
2
Fig.4:Fasten the probe
1Probe
2Plastic socket on the probe end
3Probe
4Plastic socket laterally mounted
VEGAKON 66 -with relay output 11
Mounting
32649-EN-070615

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 KONE60Ris designed in protection class 1.To
maintain this protection class,it is absolutely necessary that
the ground conductor be connected to the internal ground
terminal.Take note of the general installation regulations.As a
rule,connect VEGAKON 66 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 stated in chapter "Technical
data"in the "Supplement".
VEGAKON 66 is connected with standard cable with round
cross section.An outer cable diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
5.2Connection instructions
Danger:
Switch offpower supply before starting connection work.
Connect mains voltage according to the connection diagrams.
5.3Wiring plan
Is used to switch external voltage sources to relays,
contactors,magnetic valves,horns etc.
Note safety instructions
Select power supply
Selecting connection cable
Floating relay output
12 VEGAKON 66 -with relay output
Connecting to power supply
32649-EN-070615

1 2
-
+
L1 N
3 4 5 6 7 8
1
2
Fig.5:Electronics with relay output
1Relay output
2Power supply
VEGAKON 66 -with relay output 13
Connecting to power supply
32649-EN-070615

6Set up
6.1General
On the electronics module you will find the following indicating
and adjustment elements:
lDIL switch for mode adjustment
lDIL switch for adjustment of the integration time
lRotary switch for adjustment of the conductivity value
lControl lamp for indication of the switching condition
6.2Adjustment elements
876
5
4
3
12
max. 250V AC 5A 750VA
max. 250V DC 1A 54W
20...72V DC
20...250V AC
LN
+ -
R
KON E66R max
min
K
TEST
0.1 TEST
300
100
30
0.3
1
310
A
2s
6s
12s
B
off
off
off
1
27
6
3
45
1Screwed terminals
2Signal lamp (LED)
3Rotary switch:Adjustment of the conductivity value
4Selection switch:Integration time
5Selection switch:Mode (A/B)VEGAKON 66
6Type label
7Tensile proving ring
The switching condition of the signal lamp can be checked
when the housing is closed.To adjust VEGAKON 66 loosen
the four screws with a wrench on the upper side of the
instrument and remove the housing cover.
Function/Configuration
Signal lamp (2)
14 VEGAKON 66 -with relay output
Set up
32649-EN-070615

With the rotary switch you can set the sensitivity of the
instrument.Position 0.1kΩis the less sensitive and switch
position 300 kΩthe most sensitive one,see chart "Switching
point adjustment".
There are three switches on the DIL switch block by which you
can adjust the switching on and offdelay.Thus prevents,e.g.
the instrument from permanent switching if the level is within
the limits.
The delay refers to the switching status of both relay outputs.
With the switches (2s,6s,12 s)you can set the integration
time respectively in the range of 0to 20 seconds.The times of
the activated timers add up.If e.g.the switches 2s and 12 s
are activated,the integration time will be 14 s.
With the mode adjustment (A/B)you can change the switching
condition of the output.You can set the required mode
according to the "Function chart"(A-max.detection or overfill
protection,B-min.detection or dry run protection).
Loosen the holding screws of the electronics module.Fold the
tensile proving ring upward.With the tensile proving ring you
can pul the electronics module out of the instrument housing.
6.3Switching point adjustment
Rotary switch position
Switching point at approx.1cm covering.
Rotary switch position Conductivity value (medium)
Test max.Switching condition with complete
covering is simulated
0.1kΩ (insensitive)>6.6mS
0.3kΩ>1.7mS
1kΩ>540 µS
3kΩ>180 µS
10 kΩ>54 µS
30 kΩ>20 µS
100 kΩ>5.7µS
300 kΩ (sensitive)>1.6µS
Test min.Empty state is simulated
Rotary switch:Adjustment of
the conductivity value (3)
Selection switch:Integration
time (4)
Mode adjustment (5)
Tensile proving ring (7)
VEGAKON 66 -with relay output 15
Set up
32649-EN-070615

Examples of conductivity values
Medium Conductivity value Recommended rotary
switch position
Tap water 0.2mS3kΩ
Saltwater (3.5%)35 mS0.1kΩ
Beer 1.4mS1kΩ
Fruit juice 2mS0.3kΩ
Milk,yogurt 3mS0.3kΩ
Ketchup 15 mS0.1kΩ
In case of horizontally mounted instruments,the response
height is determined by the mounting height.
In case of vertically mounted instruments,the response height
is determined by the length of the probe rods.
The modification of the response height by turning the
conductivity value switch is not useful.
To adapt the response height,you can shorten the measuring
rods by sawing them off.Before shortening,unscrew the rods
out of the plastic threaded part of the sensor to avoid
damaging the probe.
The numbers of the rods are visible on the lower side of the
thread.
The ground rod (no.1)must have the same length or must
even be longer than the longest of the other rods.
The max.rod (no.2)defines the response height with single
point level switches or the upper switching level with two-point
control.It is the shortest rod.
The min.rod (no.3)defines the lower switching level,it must
hence be longer than the max.rod.It is not available with
instruments for single point level detection.
The electronics recognises if a min.rod is screwed in and
changes automatically from single to two-point control.
For products with a good conductivity (>3mS), set the rotary
switch -cnductivity setting (3)generally to switch position 3kΩ.
Hence the instrument is already completely adjusted.
Take note of the instructions in chart "Examples of conductivity
values".The recommended settings take also influences such
as e.g.condensation or slight buildup into account.
Determination of the re-
sponse height
Standard setting
16 VEGAKON 66 -with relay output
Set up
32649-EN-070615

If there is danger of strong buildup or condensation,you can
set the instrument more insensitive by one rotary switch
position.
The "Function chart"shows how to select the switching
condition of the output.
The following settings apply to products with low conductivity
(<3mS)
1Fill the vessel until the shortest probe is covered approx.
1cm
2Switch on voltage supply
3Set the A/Bswitch to mode A
4Set the rotary switch to position "TEST min."
5Turn the rotary switch slowly clockwise until the red LED
lights
The instrument is adapted to the medium,i.e.the relay
denergizes with max.level.
The following settings apply to products with low conductivity
(<3mS)
1Empty the vessel until the min.measuring electrode is only
covered approx.1cm
2Switch on voltage supply
3Set the A/Bswitch to mode B
4Set the rotary switch to position "TEST max."
5Turn the rotary switch slowly anticlockwise until the red
LED lights
The instrument is adapted to the medium,i.e.the relay
deenergized with min.level.
The following settings apply to products with low conductivity
(<3mS)
1Fill the vessel until the shortest probe is covered approx.
1cm
2Switch on voltage supply
3Set the A/Bswitch to mode A
4Set the rotary switch to position "TEST min."
5Turn the rotary switch slowly clockwise until the red LED
lights
Level detection for max.sig-
nal
Level detection for min.signal
Pump control,Amode
VEGAKON 66 -with relay output 17
Set up
32649-EN-070615

The instrument is adapted to the medium,i.e,the relay
deenergizes when the max.level is reached.Only when the
min.probe is decreased,the relay energizes again.
Example:Afilling pump is switched on when the min.signal is
decreased,fills the vessels until max.signal is reached and is
then switched off.
The following settings apply to products with low conductivity
(<3mS)
1Empty the vessel until the min.measuring electrode is only
covered approx.1cm
2Switch on voltage supply
3Set the A/Bswitch to mode B
4Set the rotary switch to position "TEST max."
5Turn the rotary switch slowly anticlockwise until the red
LED lights
The instrument is adapted to the medium,i.e.the relay
energizes at max.level.Only of the min.probe is decreased,
the relay denergizes again.
Example:An emptying pump is switched on when the max.
signal is reached,empties the vessels until min.signal is
reached and is then switched off.
In case of several measurement loops (same medium), the
adjustment of one instrument with medium is sufficient.The
determined switch position can be transferred to all other
instruments.
When the conductivity value is known,the switching point
adjustment can be carried out according to the setup in chart
"Rotary switch adjustment".
When exchanging the electronics module,it is sufficient to take
over the setting of the old electronics module.
6.4Function chart
The following chart provides an overview of the switching
conditions depending on the adjusted mode and level.
Pump control,Bmode
Dry adjustment
18 VEGAKON 66 -with relay output
Set up
32649-EN-070615

Level Switching sta-
tus,relay mod-
ule E60R
Control lamp
Mode A
Overflow protec-
tion
1
Relay energized
53 4
(8)(6) (7)
does not light
Mode A
Overflow protec-
tion
2
Relay deener-
gized
53 4
(8)(6) (7)
lights
Mode B
Dry run protection
3
Relay energized
53 4
(8)(6) (7)
does not light
Mode B
Dry run protection
4
Relay deener-
gized
53 4
(8)(6) (7)
lights
Failure of the
supply voltage
(mode A/B)
Relay deener-
gized
53 4
(8)(6) (7)
does not light
1Max.detection -Vessel empty
2Max.detection -Vessel full
3Min.detection -Vessel full
4Min.detection -Vessel empty
Note:
IfVEGAKON 66 is used for oil warning in water,the probe
must be cleaned after having responded to oil (=empty signal)
because otherwise resetting to water will not be ensured
reliably.
VEGAKON 66 -with relay output 19
Set up
32649-EN-070615

7Maintenance and fault rectification
7.1Maintenance
When used as directed in normal operation,VEGAKON 66 is
completely maintenance free.
7.2Electronics exchange
In general,all oscillators of series KONE66 can be inter-
changed.If you want to use an oscillator with a different signal
output,you can download the corresponding operating
instructions manual from our homepage under Downloads.
Proceed as follows:
1Switch offpower supply
2Unscrew the housing cover
3Loosen compression fittings with a Phillips screwdriver
4Pull the connection cables out of the terminals
5Loosen the two holding screws with a screw driver
(Phillips)
6Lift tensile proving ring and pull out the old electronics
module
7Compare the new oscillator with the old one.The type label
of the oscillator must correspond to that of the old
oscillator.
8Note settings of all adjustment elements of the old
electronics module.
Set the adjustment elements of the new electronics module
to the same settings of the old one.
9Screw in and tighten the two holding screws with a
screwdriver (Phillips)
10 Insert the wire ends into the open terminals according to
the wiring plan
11 Tighten the screw terminals
12 Check the hold of the wires in the terminals by lightly
pulling on them
13 Check the tightness of the cable entry.The seal ring must
completely encircle the cable.
14 Screw the housing cover back on
The electronics exchange is now finished.
20 VEGAKON 66 -with relay output
Maintenance and fault rectification
32649-EN-070615