Vega VEGAWAVE 63 User manual

Operating Instructions
Vibrating level switch with tube
extension for powders
VEGAWAVE 63
- two-wire
Document ID: 32260

2
Contents
VEGAWAVE 63 • - two-wire
32260-EN-140625
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 SIL conformity .................................................................................................................. 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 Storage and transport....................................................................................................... 9
4 Mounting
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 15
5.2 Connection procedure.................................................................................................... 15
5.3 Wiring plan, single chamber housing.............................................................................. 16
5.4 Wiring plan - version IP 66/IP 68, 1 bar........................................................................... 18
6 Setup
6.1 General information........................................................................................................ 19
6.2 Adjustment elements...................................................................................................... 19
6.3 Function chart ................................................................................................................ 20
6.4 Recurring test and function test (SIL) ............................................................................. 22
7 Maintenanceandfaultrectication
7.1 Maintenance .................................................................................................................. 26
7.2 Rectify faults................................................................................................................... 26
7.3 Exchanging the electronics module................................................................................ 27
7.4 How to proceed if a repair is needed.............................................................................. 28
8 Dismount
8.1 Dismounting steps.......................................................................................................... 29
8.2 Disposal ......................................................................................................................... 29
9 Supplement
9.1 Technical data ................................................................................................................ 30
9.2 Dimensions .................................................................................................................... 33

3
Contents
VEGAWAVE 63 • - two-wire
32260-EN-140625
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
withthedelivery.Yo u 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 VEGAWAVE 63, we of-
fer accessories and replacement parts. The corresponding documen-
tations are:
•32357 - External housing - VEGAWAVE
•32356 - Electronics module VEGAWAVE series 60
•34296 - Protective cover
•32359-LockttingforVEGAWAVE63unpressurized
•32360-LockttingforVEGAWAVE6316bar
Editing status:2014-05-26

4
1 About this document
VEGAWAVE 63 • - two-wire
32260-EN-140625
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
VEGAWAVE 63 • - two-wire
32260-EN-140625
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
The VEGAWAVE 63 is a sensor for point level detection.
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
VEGAWAVE 63 • - two-wire
32260-EN-140625
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 CE conformity
ThisdevicefulllsthelegalrequirementsoftheapplicableECguide-
lines.ByattachingtheCEmark,VEGAprovidesaconrmationof
successfultesting.Yo u canndtheCEconformitydeclarationinthe
downloadareaof"www.vega.com".
2.7 SIL conformity
VEGAWAVE 63 meets the requirements to the functional safety ac-
cording to IEC 61508. Further information is available in the Safety
Manual"VEGAWAVE series 60".
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
VEGAWAVE 63 • - two-wire
32260-EN-140625
3 Product description
3.1 Conguration
The scope of delivery encompasses:
•VEGAWAVE 63 point level switch
•Documentation
– this operating instructions manual
– SafetyManual"Functional safety (SIL)"(optional)
– Supplementaryinstructionsmanual"Plug connector for level
sensors"(optional)
– Ex-specic"Safety instructions"(withExversions)
– ifnecessary,furthercerticates
The VEGAWAVE 63 consists of the components:
•Housing cover
•Housing with electronics
•Processttingwithtuningfork
1
2
3
Fig. 1: VEGAWAVE 63 - with plastic housing
1 Housing cover
2 Housing with electronics
3 Processtting
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
•Article number
•Serial number
•Technical data
•Article numbers, documentation
•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".
Scope of delivery
Constituent parts
Type label

8
3 Product description
VEGAWAVE 63 • - two-wire
32260-EN-140625
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
VEGAWAVE 63 is a point level sensor with tuning fork for point level
detection.
It is designed for industrial use in all areas of process technology and
is preferably used for bulk solids.
Typicalapplicationsareoverllanddryrunprotection.Thankstoits
simple and robust measuring system, VEGAWAVE 63 is virtually unaf-
fected by the chemical and physical properties of the bulk solid.
It also works when subjected to strong external vibrations or changing
products.
Solid detection in water
If VEGAWAVE 63 was ordered for solids detection in water, the tuning
fork is set to the density of water. In air or when immersed in water
(density:1g/cm³/0.036lbs/in),VEGAWAVE63signals"uncovered".
Only when the vibrating element is also covered with solids (e.g.
sand,sludge,graveletc.)willthesensorsignal"covered".
Function monitoring
The electronics module of VEGAWAVE 63 monitors continuously the
following criteria:
•Correct vibrating frequency
•Linebreaktothepiezodrive
If one of these faults is detected, the electronics signals this via a
denedcurrenttothesignalconditioninginstrument.Theconnection
cable to the vibrating element is also monitored.
Thetuningforkispiezoelectricallyenergisedandvibratesatits
mechanicalresonancefrequencyofapprox.150Hz.Whenthetuning
fork is submerged in the product, the vibration amplitude changes.
This change is detected by the integrated electronics module and
converted into a switching command.
Depending on your requirements, VEGAWAVE 63 with two-wire elec-
tronicscanbeconnectedtodierentsignalconditioninginstruments.
Compatible signal conditioning instruments are listed in chapter
"Technical data".
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Operation
With the factory setting, products with a density of > 0.02 g/cm³
(0.0008 lbs/in³) can be measured. The instrument can also be
adapted to products with lower density > 0.008 g/cm³ (0.0003 lbs/in³).
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
•Signal lamp for indication of the switching condition (green/red)
Application area
Functional principle
Voltage supply

9
3 Product description
VEGAWAVE 63 • - two-wire
32260-EN-140625
•Potentiometer for adaptation to the product density
•Mode changeover for selection of the output current
3.4 Storage and transport
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 carton material. The sensing element is additional-
ly protected with a cardboard cover. For special versions, PE foam or
PE foil is also used. Please dispose of the packaging material through
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
VEGAWAVE 63 • - two-wire
32260-EN-140625
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.
In general, VEGAWAVE 63 can be installed in any position. The instru-
ment only has to be mounted in such a way that the vibrating element
is at the height of the desired switching point.
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
Do not hold VEGAWAVE 63 on the vibrating element. Especially with
angeandtubeversions,thesensorcanbedamagedbytheweight
of the instrument.
Remove the protective cover just before mounting.
Theprocesstting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speciedinchapter"Technical
data"oronthetypelabelofthesensor.
The vibrating level switch is a measuring instrument and must be
treated accordingly. Bending the vibrating element will destroy the
instrument.
Suitability for the process
conditions
Switching point
Moisture
Transport
Pressure/Vacuum
Handling

11
4 Mounting
VEGAWAVE 63 • - two-wire
32260-EN-140625
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Use the hexagon above the thread for screwing in.
4.2 Mounting instructions
Duetotheeectsofagitators,equipmentvibrationorsimilar,thelevel
switch can be subjected to strong lateral forces. For this reason, do
not use an overly long extension tube for VEGAWAVE 63, but check
if you can mount a short level switch on the side of the vessel in
horizontalposition.
Extreme vibration caused by the process or the equipment, e.g. agita-
torsorturbulenceinthevessel,e.g.byuidisation,cancausethe
extension tube of VEGAWAVE 63 to vibrate in resonance. This leads
to increased stress on the upper weld joint. Should a longer tube ver-
sion be necessary, you can provide a suitable support directly above
the vibrating element to secure the extension tube.
This measure applies mainly to applications in Ex areas. Make sure
that the tube is not subject to bending stress due to this measure.
IfVEGAWAVE63ismountedinthellingstream,unwantedfalse
measurement signals can be generated. For this reason, mount
VEGAWAVE 63 at a position in the vessel where no disturbances, e.g.
fromllingopenings,agitators,etc.,canoccur.
This applies particularly to instrument types with long extension tube.
Fig.3:Inowingmedium
VEGAWAVE63canbemountedwithalockttingforheightadjust-
ment.Ta kenoteofthepressureinformationofthelocktting.
Agitatorsanduidization
Inowingmedium
Locktting

12
4 Mounting
VEGAWAVE 63 • - two-wire
32260-EN-140625
The vibrating element should protrude into the vessel to avoid
buildup.Forthatreason,avoidusingmountingbossesforanges
andscrewedttings.Thisappliesparticularlytousewithadhesive
products.
In silos for bulk solids, material cones can form and change the
switching point. Please keep this in mind when installing the sensor
in the vessel. We recommend selecting an installation location where
the vibrating fork detects an average value of the material cone.
The tuning fork must be mounted in a way that takes the arrangement
ofthelling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.
dd
d
6
d
6
Fig. 4: Filling and emptying centred
Socket
Material cone

13
4 Mounting
VEGAWAVE 63 • - two-wire
32260-EN-140625
d
d
6
1
2
3
Fig. 5: Filling in the centre, emptying laterally
1 VEGAWAVE 63
2 Discharge opening
3 Filling opening
To make sure the tuning fork of VEGAWAVE 63 generates as little
resistanceaspossibletoproductow,mountthesensorsothatthe
surfaces are parallel to the product movement.
Productow

14
4 Mounting
VEGAWAVE 63 • - two-wire
32260-EN-140625
1
2
Fig. 6: Flow orientation of the tuning fork
1 Marking with screwed version
2 Directionofow
In applications such as grit chambers or settling basins for coarse
sediments, the vibrating element must be protected against damage
withasuitablebae.
Thisbaemustbemanufacturedbyyou.
> 125 mm
(> 5")
> 120 mm
(> 4.7")
Fig.7:Baeforprotectionagainstmechanicaldamage
Baeprotectionagainst
falling rocks

15
5 Connecting to power supply
VEGAWAVE 63 • - two-wire
32260-EN-140625
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
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Connect the operating voltage according to the following diagrams.
Take note of the general installation regulations. As a rule, connect
VEGAWAVE 63 to vessel ground (PA), or in case of plastic vessels,
to the next ground potential. On the side of the instrument housing
there is a ground terminal between the cable entries. This connection
servestodrainoelectrostaticcharges.InExapplications,theinstal-
lationregulationsforhazardousareasmustbegivenpriority.
Thedataforpowersupplyarespecied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.
Inhazardousareas,useonlyapprovedcableconnectionsforVEGA-
WAVE 63.
Take note of the corresponding installation regulations for Ex applica-
tions.
Cover all housing openings conforming to standard according to
EN 60079-1.
5.2 Connection procedure
With Ex instruments, the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1. Unscrew the housing cover
2. Loosen compression nut of the cable entry gland
3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1cm (0.4 in) of insulation from the ends of the individual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Connection cable
for Ex applications

16
5 Connecting to power supply
VEGAWAVE 63 • - two-wire
32260-EN-140625
Fig. 8: Connection steps 5 and 6
6. Insert the wire ends into the open terminals according to the wir-
ing plan
7. Press down the opening levers of the terminals, you will hear the
terminal spring closing
8. Check the hold of the wires in the terminals by lightly pulling on
them
9. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
10. If necessary, carry out a fresh adjustment
11. Screw the housing cover 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-d
version.

17
5 Connecting to power supply
VEGAWAVE 63 • - two-wire
32260-EN-140625
5
5
55
1 2
4
3
Fig. 9: Material versions, single chamber housing
1 Plastic (not with EEx d)
2 Aluminium
3 Stainless steel (not with EEx d)
4 Stainless steel, electropolished (not with EEx d)
5 Filter element for pressure compensation or blind plug with version IP 66/
IP 68, 1 bar (not with EEx d)
For connection to a signal conditioning instrument. The sensor is
powered via the connected signal conditioning instrument. For further
informationseethe"Technical data"inthe"Supplement".
The wiring example is applicable for all suitable signal conditioning
instruments.
IfthemodeswitchofVEGAWAVE63iscorrectlysetto"max.",the
control lamp on VEGAWAVE 63 lights.
•red - with submerged vibrating element
•green - with uncovered vibrating element
Take note of the operating instructions manual of the signal condition-
ing instrument. Suitable signal conditioning instruments are listed in
chapter"Technical data".
Housing overview
Wiring plan

18
5 Connecting to power supply
VEGAWAVE 63 • - two-wire
32260-EN-140625
1
Fig. 10: Wiring plan
1 Voltage supply
5.4 Wiring plan - version IP 66/IP 68, 1 bar
1
2
Fig. 11: Wire assignment, connection cable
1 brown (+) and blue (-) to power supply or to the processing system
2 Shielding
Wire assignment, con-
nection cable

19
6 Setup
VEGAWAVE 63 • - two-wire
32260-EN-140625
6 Setup
6.1 General information
Theguresinbracketsrefertothefollowingillustrations.
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
•Potentiometer for adaptation to the product density (1)
•DIL switch for mode adjustment - min./max. (2)
•Signal lamp (5)
Note:
As a rule, always set the mode with mode switch (2) before starting
the setup of VEGAWAVE 63 . If the instrument is used in conjunction
with a signal conditioning instrument, always set the mode switch (2)
on VEGAWAVE 63 to max. mode.
The mode is selected on the signal conditioning instrument with the
mode switch.
The switching output will change if you set one of the two mode
switches afterwards. This could possibly trigger other connected
instruments or devices.
6.2 Adjustment elements
3
4
1
2
5
Fig. 12: Electronics and connection compartment - two-wire output
1 Potentiometer for switching point adaptation
2 DIL switch for mode adjustment
3 Ground terminal
4 Connection terminals
5 Control lamp
Function/Conguration
Electronics and terminal
compartment

20
6 Setup
VEGAWAVE 63 • - two-wire
32260-EN-140625
With the potentiometer you can adapt the switching point to the solid.
Itisalreadypresetandmustonlybemodiedinspecialcases.
By default, the potentiometer of VEGAWAVE 63 is set to the right stop
(> 0.02 g/cm³ or 0.0008 lbs/in³). In case of very light-weight solids,
turn the potentiometer to the left stop (> 0.008 g/cm³ or 0.0003 lbs/
in³). VEGAWAVE 63 will thus be more sensitive and can detect light-
weight solids more reliably.
For instruments detecting solids in water, these settings are not
applicable. The switching point adaptation is preset and must not be
changed.
With the mode adjustment (min./max.) you can determine the output
current.
When using a signal conditioning instrument, always set the mode
switch to max. mode.
Inthiscase,youselecttherequestedmodeaccordingtothe"Func-
tion chart"(max.-max.detectionoroverllprotection,min.-min.
detection or dry run detection) on the signal conditioning instrument.
When used on a control system, the following values apply:
•Mode min.
– Vibrating element uncovered - 16 mA ±1 mA
– Vibrating element covered - 8 mA ±1 mA
•Mode max.
– Vibrating element uncovered - 8 mA ±1 mA
– Vibrating element covered - 16 mA ±1 mA
Control lamp for indication of the switching status
•green = 8 mA
•red = 16 mA
•red(ashing)=Failure(<2.3mA)
6.3 Function chart
Level switch VEGAWAVE 63
The following chart provides an overview of the switching conditions
depending on the set mode and the level.
Mode on the
sensor
Level Signal current -
Sensor
Signal lamp -
sensor
Max.
Overowprotec-
tion
8mA
Green
Max.
Overowprotec-
tion
approx. 16 mA
Red
Switching point adapta-
tion (1)
Mode adjustment (2)
Signal lamp (5)