Operating Instructions VEGAFLEX 63 4 … 20 mA/HART two-wire Document ID: 31841 Guided Microwave
Contents Contents 1 About this document 1.1 1.2 1.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. .. .. 5 5 5 5 6 6 6 6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. 7 8 9 9 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . 11 12 Structure . . . . . . . . . . . . . . . . . . Principle of operation . . . . . . . . .
Contents 8 Maintenance and fault rectification 8.1 8.2 8.3 8.4 8.5 9 .. .. .. .. .. 39 39 41 41 42 Dismounting steps . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 43 Maintenance . . . . . . . . . . Rectify malfunctions . . . . . Exchanging the electronics Software update . . . . . . . . Instrument repair . . . . . . . ...... ...... module ...... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 About this document 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 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. 1.2 Target group This operating instructions manual is directed to trained qualified personnel.
2 For your safety 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 VEGAFLEX 63 is a sensor for continuous level measurement. You can find detailed information on the application range in chapter "Product description".
2 For your safety 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 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. 2.7 Fulfillment of NAMUR recommendations With respect to compatibility, the NAMUR recommendation NE 53 is fulfilled.
3 Product description 3 Product description 3.
3 Product description 1 2 3 Fig.
3 Product description The supply voltage range can differ depending on the instrument version. The data for power supply are specified in chapter "Technical data". The optional background lighting of the indicating and adjustment module is powered by the sensor. A certain level of operating voltage is required for this. You can find the exact voltage specifications in chapter "Technical data". The optional heating requires its own operating voltage.
3 Product description Storage and transport temperature l l l l Dry and dust free Not exposed to corrosive media Protected against solar radiation Avoiding mechanical shock and vibration l Storage and transport temperature see chapter "Supplement Technical data - Ambient conditions" Relative humidity 20 … 85 % l 31841-EN-100426 10 VEGAFLEX 63 • 4 … 20 mA/HART two-wire
4 Mounting 4 Mounting 4.1 General instructions Suitability for the process conditions 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.
4 Mounting Measuring range The reference plane for the measuring range of the sensors is the lower edge of the flange. Keep in mind that a min. distance must be maintained below the reference plane and possibly also at the end of the probe measurement in these areas is not possible (dead band). Keep in mind that the cable length cannot be used all the way to the end because measurement in the area of the gravity weight is not possible. These min.
4 Mounting Torque with PTFE plated flanges To compensate the normal bias voltage loss due to the seal materials, you have to use also disc springs in addition to the flange screws for fastening PTFE plated flanges. The flange screws of VEGAFLEX 63 must always be tightened with a torque of approx. 60 Nm (44 lbf ft) so that the PTFE washer seals reliably. Socket If possible, avoid sockets. Mount the sensor flush with the vessel top. If this is not possible, use short sockets with small diameter.
4 Mounting Depending on the tube diameter or tube length, one or several spacers can be mounted. With cable probes, the cable can also be strained to avoid contact with the tube. Keep in mind that buildup can form on the spacers. Strong buildup can influence the measurement. Microwaves can penetrate plastics. For process technical reasons, plastic standpipes are problematic. If durability is no problem, then we recommend the use of metal standpipes. 1 Fig.
4 Mounting 31841-EN-100426 Fig.
5 Connecting to power supply 5 Connecting to power supply 5.1 Preparing the connection Safety instructions Always keep in mind the following safety instructions: l l Connect only in the complete absence of line voltage If overvoltage surges are expected, overvoltage arresters should be installed Tip: We recommend using VEGA overvoltage arresters B63-48 and ÜSB 62-36G.X.
5 Connecting to power supply Caution: No grease should be used when screwing the NPT cable gland or steel tube into the threaded insert. Standard grease can contain additives that corrode the connection between threaded insert and housing. This would influence the stability of the connection and the tightness of the housing. Cable screening and grounding If screened cable is necessary, connect the cable screen on both ends to ground potential.
5 Connecting to power supply 7 Insert the wire ends into the open terminals according to the wiring plan Fig. 7: Connection steps 6 and 7 8 Press down the opening levers of the terminals, you will hear the terminal spring closing 9 Check the hold of the wires in the terminals by lightly pulling on them 10 Connect the screen to the internal ground terminal, connect the outer ground terminal to potential equalisation 11 Tighten the compression nut of the cable entry.
5 Connecting to power supply Electronics and connection compartment Display I²C 1 4 2 5 6 7 8 1 2 3 Fig. 8: Electronics and connection compartment with single chamber housing 1 2 3 4 Plug connector for VEGACONNECT (I²C interface) Spring-loaded terminals for connection of the external indication VEGADIS 61 Ground terminal for connection of the cable screen Spring-loaded terminals for voltage supply Wiring plan Display I2C 1 2 5 6 7 8 1 Fig.
5 Connecting to power supply Electronics compartment 1 Display I²C 1 2 5 6 7 8 2 3 Fig. 10: Electronics compartment, double chamber housing 1 2 3 Plug connector for VEGACONNECT (I²C interface) Internal connection cable to the connection compartment Terminals for VEGADIS 61 Display Connection compartment 1 3 1 2 I²C 2 Fig.
5 Connecting to power supply Wiring plan I2C 1 2 1 Fig. 12: Wiring plan with double chamber housing 1 Voltage supply/Signal output 5.5 Wiring plan with double chamber housing Ex d Electronics compartment 1 Display I²C 1 2 5 6 7 8 3 2 Fig.
5 Connecting to power supply Connection compartment 1 1 2 2 Fig. 14: Connection compartment with double chamber housing Ex d 1 2 Spring-loaded terminals for power supply and cable screen Ground terminal for connection of the cable screen Wiring plan 1 2 1 Fig.
5 Connecting to power supply 5.6 Wiring plan - version IP 66/IP 68, 1 bar Wire assignment connection cable + 1 2 Fig.
6 Set up with the indicating and adjustment module PLICSCOM 6 Set up with the indicating and adjustment module PLICSCOM 6.1 Short description Function/Configuration The indicating and adjustment module is used for measured value display, adjustment and diagnosis.
6 Set up with the indicating and adjustment module PLICSCOM Fig. 17: Insert indicating and adjustment module 31841-EN-100426 Note: If you intend to retrofit the instrument with an indicating and adjustment module for continuous measured value indication, a higher cover with an inspection glass is required.
6 Set up with the indicating and adjustment module PLICSCOM 6.3 Adjustment system 2 1 1.1 3 Fig.
6 Set up with the indicating and adjustment module PLICSCOM 6.4 Setup steps Switch on phase After connecting VEGAFLEX 63 to power supply or after a voltage recurrence, the instrument carries out a self-check for approx. 30 seconds: l l l Internal check of the electronics Indication of the instrument type, the firmware as well as the sensor TAGs (sensor designation) Output signal jumps briefly (approx.
6 Set up with the indicating and adjustment module PLICSCOM Keep in mind that interfaces can cause faulty measurements. If you want to measure the total height of both liquids reliably, please contact our service department or use an instrument specially designed for interface measurement. Start your parameter adjustment with the following menu items of the basic adjustment: Carry out min. adjustment Proceed as follows: 1 ▶ 2 Move from the measured value display to the main menu by pushing [OK].
6 Set up with the indicating and adjustment module PLICSCOM Application 2 Enter the appropriate distance value in m (corresponding to the percentage value) for the full vessel. Keep in mind that the max. level must lie below the dead band. 3 Save the settings with [OK]. Each product has different reflective properties.
6 Set up with the indicating and adjustment module PLICSCOM these vessels. They represent the correlation between the level percentage and vessel volume. By activating the appropriate curve, the volume percentage of the vessel is displayed correctly. If the volume should not be displayed in percent but e.g. in l or kg, a scaling can be also set in the menu item "Display".
6 Set up with the indicating and adjustment module PLICSCOM Proceed as follows: 1 Move from the measured value display to the main menu by pushing [OK]. 2 Select the menu item "Service" with [->] and confirm with [OK]. Now the menu item "False signal suppression" is displayed. 3 Confirm "False signal suppression - Change now" with [OK] and select in the below menu "Create new". Enter the actual distance from the sensor to the product surface.
6 Set up with the indicating and adjustment module PLICSCOM Reset Basic adjustment If the function "Reset" is carried out, the sensor resets the values of the following menu items to the reset values (see chart):1) The following values will be reset: Function Reset value Max. adjustment Distance, upper dead zone Min. adjustment - Rod/Coax version Distance, supplied sensor length Min.
6 Set up with the indicating and adjustment module PLICSCOM 6.5 Menu schematic Basic adjustment ▶ Basic adjustment Display Diagnostics Service Info 1 Min. adjustment 0.00 % = 10.000 m(d) 8.000 m(d) 1.1 Sensor-TAG 1.5 Max. adjustment 100.00 % = 1.000 m(d) 2.000 m(d) 1.2 Unit 2.2 1.3 Damping Linearisation curve 0s 1.4 linear Sensor Display ▶ Basic adjustment Display Diagnostics Service Info Displayed value 2 2.1 Volume hl Scaled Scaling 2.3 Lighting 2.4 Switched on 0 % = 000.
6 Set up with the indicating and adjustment module PLICSCOM Service ▶ Basic adjustment Display Diagnostics Service Info Sensor 4 4.1 5.00 m(d) ▼ Rod ▼ Simulation 4.2 Gating out of false signals 4.3 Change now? Standard (DK ≥ 2) ▼ 4.5 Start simulation? 4.6 Reset Select reset? 4.9 SIL Application Liquid ▼ Activated! ▼ HART mode Standard Address 0 Unit of measurement 4.7 Current output 4.4 Output mode: 4-20 mA ▼ Failure mode: 20.5 mA ▼ min. current: 4 mA ▼ max. current: 20.
6 Set up with the indicating and adjustment module PLICSCOM 6.6 Saving the parameter adjustment data It is recommended noting the adjusted data, e.g. in this operating instructions manual and archive them afterwards. They are hence available for multiple use or service purposes. If VEGAFLEX 63 is equipped with an indicating and adjustment module, the most important data can be read out of the sensor into indicating and adjustment module.
7 Set up with PACTware and other adjustment programs 7 Set up with PACTware and other adjustment programs 7.1 Connecting the PC VEGACONNECT directly on the sensor 2 1 3 Fig. 19: Connection of the PC via VEGACONNECT directly to the sensor 1 2 3 VEGACONNECT externally USB cable to the PC VEGACONNECT Sensor 1 2 EN USB CK LO OP TWIST 3 4 1 2 3 4 36 I²C bus (com.
7 Set up with PACTware and other adjustment programs Necessary components: l l l l VEGAFLEX 63 PC with PACTware and suitable VEGA DTM VEGACONNECT Power supply unit or processing system VEGACONNECT via HART 2 4 N OPE 3 USB TWIST LO CK 1 Fig.
7 Set up with PACTware and other adjustment programs Note: Keep in mind that for setup of VEGAFLEX 63, DTM-Collection in the actual version must be used. All currently available VEGA DTMs are included as a DTM Collection on a CD. They can be purchased for a token fee from the responsible VEGA agency. In addition, the actual PACTware version is also available on this CD. In addition, this DTM Collection incl. the basic version of PACTware can be downloaded free of charge from the Internet. Move via www.
8 Maintenance and fault rectification 8 Maintenance and fault rectification 8.1 Maintenance When used as directed in normal operation, VEGAFLEX 63 is completely maintenance free. 8.2 Rectify malfunctions Reaction when malfunctions occur The operator of the system is responsible for taking suitable measures to remove interferences. Causes of malfunction VEGAFLEX 63 offers maximum reliability. Nevertheless, faults can occur during operation. These may be caused by the following, e.g.
8 Maintenance and fault rectification Error Cause Removal Voltage supply missing Check cables for breaks; repair if necessary Operating voltage Check, adapt if necessary too low or load resistance too high Current signal Oscillator in the greater than 22 mA sensor defective or less than 3.6 mA Exchange the instrument or send it in for repair In Ex applications, the regulations for the wiring of intrinsically safe circuits must be observed.
8 Maintenance and fault rectification 8.3 Exchanging the electronics module If the electronics module is defective, it can be replaced by the user. In Ex applications only one instrument and one electronics module with respective Ex approval may be used. If there is no electronics module available on site, one can be ordered from the VEGA agency serving you. Sensor serial number The new electronics module must be loaded with the settings of the sensor.
8 Maintenance and fault rectification Load sensor software to PC At "www.vega.com/downloads" go to "Software". Select under "plics instruments and sensors" the suitable instrument series. Load the zip file via the right mouse key with "Save target as" e.g. on the desktop of your PC. Extract all files available in the zip file, e.g. to the desktop. Prepare update Connect the sensor to power supply and provide connection from PC to the instrument via VEGACONNECT.
9 Dismounting 9 Dismounting 9.1 Dismounting steps Warning: Before dismounting, be aware of dangerous process conditions such as e.g. pressure in the vessel, high temperatures, corrosive or toxic products etc. Take note of chapters "Mounting" and "Connecting to power supply" and carry out the listed steps in reverse order. 9.2 Disposal The instrument consists of materials which can be recycled by specialised recycling companies.
10 Supplement 10 Supplement 10.1 Technical data General data Material 316L corresponds to 1.4404 or 1.4435 Materials, wetted parts - Process fitting PFA and TFM PTFE 1600 - Rod: ø 10 mm (0.394 in) PFA and TFM PTFE 1600 - Cable: ø 4 mm (0.
10 Supplement - Rod: ø 10 mm (0.394 in) approx. 620 g/m (6.7 oz/ft) - Cable: ø 4 mm (0.157 in) approx. 80 g/m (0.86 oz/ft) - Gravity weight 325 g (11.5 oz) Insulation thickness - Rod version - Cable version 2 mm (0.08 in) 0.75 mm (0.03 in) On the gravity weight and beginning of the cable: 2 mm (0.08 in) Probe length L (from seal surface), cannot be shortened - Rod: ø 10 mm (0.394 in) up to 4 m (13.12 ft) - Trimming accuracy - rod < 1 mm (0.039 in) - Cable: ø 4 mm (0.
10 Supplement 1 1 4 2 4 2 3 3 5 5 Fig. 22: Measuring ranges of VEGAFLEX 63 1 2 3 4 5 Reference plane Probe length Measuring range (default setting refers to the measuring range in water) Upper dead band (see diagrams under Accuracy - grey section) Lower dead band (see diagrams under Accuracy - grey section) Output variable Output signal 4 … 20 mA/HART Cycle time min. 1 s (dependent on the parameter setting) Signal resolution 1.
10 Supplement Accuracy (similar to DIN EN 60770-1) Process reference conditions according to DIN EN 61298-1 - Temperature +18 … +30 °C (+64 … +86 °F) - Relative humidity 45 … 75 % - Air pressure +860 … +1060 mbar/+86 … +106 kPa (+12.5 … +15.4 psig) Installation reference conditions - Min. distance to installations - Vessel > 500 mm (19.69 in) metallic, ø 1 m (3.281 ft), centric installation, process fitting flush with the vessel ceiling - Medium Water/Oil (Dk value ~2.
10 Supplement L 15 mm (0.591") 3 mm (0.118") 0 -3 mm (-0.118") 1 1 -15 mm (-0.591") 0,08 m (3.15") 0,2 m (7.874") 0,04 m (1.575") 0,04 m (1.575") Fig. 23: Deviation VEGAFLEX 63 in rod version in water 1 L Dead zone - no measurement possible in this area Probe length L 15 mm (0.591") 5 mm (0.197") 0 -5 mm (-0.197") -10 mm (-0.394") 1 1 -15 mm (-0.591") 0,2 m (7.874") 0,35 m (13.78") 0,05 m (1.969") 0,1 m (3.937") Fig.
10 Supplement L 15 mm (0.591") 3 mm (0.118") 0 -3 mm (-0.118") 1 1 -15 mm (-0.591") 0,08 m (3.15") 0,2 m (7.874") 0,07 m (2.756") 0,07 m (2.756") Fig. 25: Deviation VEGAFLEX 63 in cable version, probe length L < 20 m in water 1 L Dead zone - no measurement possible in this area Probe length L 15 mm (0.591") 5 mm (0.197") 0 -5 mm (-0.197") 1 1 -15 mm (-0.591") 0,2 m (7.874") 0,35 m (13.78") 0,05 m (1.969") 0,2 m (7.874") 31841-EN-100426 Fig.
10 Supplement L 20 mm (0.787") 15 mm (0.591") 3 mm (0.118") 0 -3 mm (-0.118") 1 1 -15 mm (-0.591") 0,08 m (3.15") 0,2 m (7.874") 20 m (787.4") 0,07 m (2.756") 0,07 m (2.756") Fig. 27: Deviation VEGAFLEX 63 in cable version, probe length L > 20 m in water 1 L Dead zone - no measurement possible in this area Probe length L 20 mm (0.787") 15 mm (0.591") 5 mm (0.197") 0 -5 mm (-0.197") 1 1 -15 mm (-0.591") 0,2 m (7.874") 0,35 m (13.78") 20 m (787.4") 0,05 m (1.969") 0,2 m (7.
10 Supplement Influence of the ambient temperature to the sensor electronics Temperature drift 0.03 %/10 K relating to the max. measuring range or max. 0.3 % Temperature drift - Digital output 3 mm/10 K relating to the max. measuring range or max. 10 mm Ambient conditions Ambient, storage and transport temperature -40 … +80 °C (-40 … +176 °F) Process conditions Process pressure - Flange version ≤ 2"/DN 50 - -0.5 … +16 bar/-50 … +1600 kPa (-7.
10 Supplement or: l 1 x closing cap ½ NPT, 1 x blind plug ½ NPT or: - Double chamber housing l 1 x plug (depending on the version), 1 x blind stopper M20 x 1.5 l 1 x cable entry M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind stopper M20 x 1.5; 1 x blind stopper M16 x 1.5 or optionally available with 1 x plug M12 x 1 for VEGADIS 61 or: l 1 x closing cap ½ NPT, 1 x blind stopper ½ NPT, 1 x blind stopper M16 x 1.
10 Supplement Protection rating - unassembled - IP 20 mounted into the sensor without cover Materials - Housing - IP 40 ABS Inspection window Polyester foil Voltage supply Operating voltage - Non-Ex instrument 14 … 36 V DC - EEx-ia instrument 14 … 30 V DC - EEx-d-ia instrument 20 … 36 V DC Operating voltage with lighted indicating and adjustment module - Non-Ex instrument 20 … 36 V DC - EEx-ia instrument 20 … 30 V DC - EEx-d-ia instrument 20 … 36 V DC Permissible residual ripple - < 10
10 Supplement - - Aluminium housing, stainless steel housing - investment casting, stainless steel housing - electro-polished IP 66/IP 68 (0.2 bar)4) Aluminium and stainless housing, investment casting (optionally available) IP 66/IP 68 (1 bar) Overvoltage category III Protection class II Functional safety (SIL) Functional safety is already activated on instruments with SIL qualification ex factory.
10 Supplement 10.2 Dimensions The following dimensional drawings represent only an extract of the possible versions. Detailed dimensional drawings can be downloaded on www.vega.com under "Downloads" and "Drawings". Plastic housing ~ 69 mm (2.72") ø 77 mm (3.03") ~ 87 mm (3.43") ø 84 mm (3.31") 112 mm (4.41") 120 mm (4.72") M16x1,5 M20x1,5/ ½ NPT M20x1,5/ ½ NPT 1 1 2 2 Single chamber version Double chamber version Aluminium housing ~ 87 mm (3.43") ~ 116 mm (4.57") ø 84 mm (3.31") ø 84 mm (3.
10 Supplement Aluminium housing in protection rating IP 66/IP 68, 1 bar ~ 105 mm (4.13") ~ 150 mm (5.91") ø 84 mm (3.31") ø 84 mm (3.31") M20x1,5 120 mm (4.72") 116 mm (4.57") M16x1,5 M20x1,5 M20x1,5/ ½ NPT 1 1 2 2 Single chamber version Double chamber version Stainless steel housing ~ 69 mm (2.72") ø 77 mm (3.03") ~ 59 mm (2.32") ø 80 mm (3.15") ~ 87 mm (3.43") ø 84 mm (3.31") M20x1,5/ ½ NPT 1 2 2 120 mm (4.72") 112 mm (4.41") 117 mm (4.
10 Supplement 4 L 3 L L 71,4 mm (2.81") 70 mm (2.76") 69,4 mm (2.73") VEGAFLEX 63 115 mm (4.53") ø 4 mm (0.16") ø 20 mm (0.79") 1 ø 10 mm (0.39") 2 Fig.
10 Supplement 10.3 Industrial property rights VEGA product lines are global protected by industrial property rights. Further information see http://www.vega.com. Only in U.S.A.: Further information see patent label at the sensor housing. VEGA Produktfamilien sind weltweit geschützt durch gewerbliche Schutzrechte. Nähere Informationen unter http://www.vega.com. Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellectuelle.
31841-EN-100426 10 Supplement VEGAFLEX 63 • 4 … 20 mA/HART two-wire 59
Printing date: VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone +49 7836 50-0 Fax +49 7836 50-201 E-mail: info@de.vega.com www.vega.com ISO 9001 All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing.
