Operating Instructions VEGAPULS 41 4 … 20 mA; HART® compact sensor
Contents Contents Safety information ........................................................................ 3 Note Ex area ................................................................................ 3 1 Product description .................................................................. 4 1.1 Function ................................................................................. 4 1.2 Application features ............................................................. 6 1.3 Adjustment ..........
Contents 6 Technical data .......................................................................... 51 6.1 Technical data ..................................................................... 51 6.2 Approvals ........................................................................... 56 6.3 Dimensions ......................................................................... 57 Supplement ..................................................................................... 59 Safety Manual ...............
Product description 1 Product description Radar sensors usually come with horn or rod antennas. PTFE rod antennas are suitable for many applications with chemically aggressive products, but are unsuitable for small vessels due to their size. Also the reception efficiency of the rod antenna is lower than that of the (less resistant) horn antenna.
Product description Meas. distance Hence, it is possible for the radar sensors to process the slow-motion pictures of the sensor environment precisely and in detail in cycles of 0.5 to 1 second without using timeconsuming frequency analysis (e.g. FMCW, required by other radar techniques).
Product description With standard flanges of DN 50 to DN 150, ANSI 2“ to ANSI 6“ or G 1½ A and 1½“ NPT, the sensor antenna systems can be adapted to various products and measuring environments. The high-quality materials can also withstand extreme chemical and physical conditions. The sensors deliver stable, reproducible analogue or digital level signals with reliability and precision and have a long useful life.
Product description 1.3 Adjustment Each measuring situation is unique. For that reason, every radar sensor needs some basic information on the application and the environment, e.g. which level means "empty“ and which level "full“. Beside this "empty and full adjustment“, many other settings and adjustments are possible with VEGAPULS radar sensors.
Product description Adjustment with the adjustment module MINICOM With the small (3.2 cm x 6.7 cm) 6-key adjustment module with display, the adjustment can be carried out in clear text dialogue. The adjustment module can be plugged into the radar sensor or into the optional, external indicating instrument. Tank 1 m (d) 12.345 - + Adjustment with the HART® handheld Series 40 sensors with 4 … 20 mA output signal can also be adjusted with the HART® handheld.
Types and versions 1.4 Type survey VEGAPULS 41 sensors are manufactured with process connection G 1½ A or 1½“ NPT. Features • Application preferably for liquids in storage tanks and process vessels with increased accuracy requirements. • Measuring range 0 … 10 m • Ex approved in Zone 1 (IEC) or Zone 1 (ATEX) classification mark EEx ia [ia] IIC T6. • Integrated measured value display.
Types and versions 1.5 Antennas The antenna is the eye of the radar sensor. An uninitiated observer would probably not realise how carefully the antenna geometry must be adapted to the physical properties of electromagnetic fields. VEGAPULS 41 radar sensors are equipped with a completely encapsulated antenna. PTFE is commonly found in hygienic applications. The small plastic cone of the VEGAPULS 41 radar sensor, operating as antenna, consists of a TFM-PTFE material.
Mounting and installation 2 Mounting and installation 2.1 General installation instructions Measuring range The reference plane for the measuring range of the sensor is the lower edge of the flange. Reference plane empty full max. Note: The series 40 sensors are suitable for measurement of solids only under certain conditions. Meas. range Keep in mind that in measuring environments where the medium can reach the sensor flange, buildup may form on the antenna and later cause measurement errors. max.
Mounting and installation Emission cone and false echoes The radar signals are focused by the antenna system. The signals leave the antenna in a conical path similar to the beam pattern of a spotlight. This emission cone depends on the antenna used. Any object in this beam cone will reflect the radar signals. Within the first few meters of the beam cone, tubes, struts or other installations can interfere with the measurement.
Mounting and installation Empty vessel ¼ filling When the vessel is empty, you see the echoes of the vessel installations around the emission cone. Beside the large bottom echo, you see a number of additional false echoes. The false echoes of the vessel installations are saved during a false echo recording. For this reason, the false echo recording must be done in an empty vessel. After filling, the bottom echo is replaced by the product echo.
Mounting and installation Filled vessel 2.2 Measurement of liquids Most commonly, the mounting of radar sensors is done on short DIN socket pieces. The lower side of the instrument flange is the reference plane for the measuring range. The socket piece should be as short as possible, max. 70 mm. When mounting on dished vessel tops, the antenna length should at least correspond to the length of the socket. On dished vessel tops, please do not mount the instrument in the centre or close to the vessel wall.
Mounting and installation 2.3 Measurement in standpipe (surge or bypass tube) General instructions Measurement in a standpipe is preferred in vessels which contain many installations, e.g. heating tubes, heat exchangers or fast-running stirrers. Measurement is then possible when the product surface is very turbulent, and vessel installations can cause no false echoes. Due to the concentration of the radar signals within the measuring tube, even products with small dielectric constants (εr= 1.
Mounting and installation Connections to the bypass tube The connections to the bypass tubes must be fashioned in such a way that only minimal reflections are caused by the walls of the connecting tubes. This is especially important for the breather connection in the upper part of the tube. Observe the following points: • Use small openings for the connection. • The diameter of the connecting tubes should not exceed 1/3 of the bypass diameter. • The tube connections must not protrude into the bypass.
Mounting and installation Seals on tube connections and tube extensions Standpipe measurement of inhomogeneous products Microwaves are very sensitive to gaps in flange connections. If connections are made without proper care, distinct false echoes as well as increased signal noise can result. Observe the following points: • The applied seal should correspond to the tube inner diameter. • If possible, conductive seals such as conductive PTFE or graphite should be used.
Mounting and installation Guidelines for standpipe construction Type label The measuring pipe must be smooth inside (average roughness Rz ≤ 30). Use stainless steel tubing (drawn or welded lengthwise) for construction of the measuring pipe. Extend the measuring pipe to the required length with weld-on flanges or with connecting sleeves. Make sure that no shoulders or projections are created during welding. Before welding, join pipe and flange with their inner surfaces flush and exactly fitting. ø 5...
Mounting and installation Instead of a deflector, the standpipe or surge pipe can be equipped with a quadrant pipe at the end. This reflects the radar signals that penetrate the medium diffusely to the side and diminishes strong echoes from the tube end or the vessel bottom. 100 % Welding of the connecting sleeves 0,0...0,4 150...500 5...10 2,9...6 Connecting sleeve Welding neck flanges 2,9 Welding of the welding neck flanges 0,0...0,4 1,5...2 Deburr the holes ø 51,2 0% Meas.
Mounting and installation 2.4 False echoes Vessel installations The installation location of the radar sensor must be at a spot where no installations or inflowing material cross the radar impulses. The following examples and instructions show the most frequent measuring problems and how to avoid them. Vessel installations, such as e.g. ladders, often cause false echoes. Make sure when planning your measuring location that the radar signals have free access to the measured product.
Mounting and installation Inflowing material Strong product movements Do not mount the instrument in or above the filling stream. Ensure that you detect the product surface and not the inflowing material. Strong turbulence in the vessel, e.g. caused by powerful stirrers or strong chemical reactions, can seriously interfere with the measurement.
Mounting and installation 2.5 Common installation mistakes Parabolic effects on dished or arched vessel tops Socket piece too long If the sensor is mounted in a socket extension that is too long, strong false echoes are generated which interfere with the measurement. Make sure that the horn antenna protrudes out of the socket piece. Round or parabolic tank tops act on the radar signals like a parabolic mirror.
Mounting and installation If there are good reflection conditions (liquids without vessel installations), we recommend locating the sensor where there is no vessel wall within the inner emission cone. For products in less favourable reflection environments, it is a good idea to also keep the outer emission cone free of interfering installations. Note chapter "3.1 General installation instructions“.
Mounting and installation Wrong polarisation direction When measuring in a surge pipe, especially if there are holes or slots for mixing in the tube, it is important that the radar sensor is aligned with the rows of holes. The two rows of holes (displaced by 180°) of the measuring tube must be in one plane with the polarisation direction of the radar signals. The polarisation direction is always in the same plane as the type label.
Electrical connection 3 Electrical connection 3.1 Connection and connection cable Safety information As a rule, do all connecting work in the complete absence of line voltage. Always switch off the power supply before you carry out connecting work on the radar sensors. Protect yourself and the instruments, especially when using sensors which do not operate with low voltage.
Electrical connection Wiring instructions The signal cables should be wired close to the ground potential. Wiring in well-grounded metal cable channels is an effective protection against interference. Obviously, signal cables should not be wired directly together with high-energy cables, but should be separated from them, e.g., with sheet metal strips in the cable channels. Twisted cable (twisted pair) is especially suitable for signal circuits, as it compensates coupled voltage vectors.
Electrical connection Ex protection If an instrument is used in hazardous areas, the respective regulations, conformity certificates and type approvals for systems in Ex areas must be noted (e.g. DIN 0165). Intrinsically safe circuits with more than one active instrument (instrument delivering electrical energy) are not allowed. Special installation regulations (DIN 0165) must be noted. Note! Due to the possibility of potential transfer, earthing on both ends is prohibited in Ex applications.
Electrical connection Version with plastic housing Power supply Power supply 4 … 20 mA (passive) 1) + + - 4 … 20 mA (active) 2) - + - To the indicating instrument in the sensor lid or to the external indicating instrument VEGADIS 50 To the display in the lid or the external indicating instrument Cable entry M20 x 1.5 +3 1 2 24-20mA 5 Communication 6 Display 7 8 (+) L1 2.23272 +1 Sockets for connection of the HART ® handheld or the VEGACONNECT Tank 1 m (d) 12.
Electrical connection Version with aluminium housing Two-wire technology (loop powered) Four-wire technology 4 … 20 mA active 2) + 4 … 20 mA passive 1) To the indicating instrument in the + sensor lid or to the external indicating instrument VEGADIS 50 M20 x 1.5 (diameter of the connection cable 5…9 mm) 1 2 C 3 4 5 6 7 8 1 2 C 3 4 5 6 7 8 (+) (-) L1 N Communication - +4...
Electrical connection Version with aluminium housing and pressure-tight encapsulated terminal compartment Two-wire EEx d terminal compartment (opening in Ex atmosphere not allowed) Power supply -+ Exd safe connection to the Exd terminal compartment Locking of the cover ser.no ******** R ATEX Two-wire adjustment module terminal compartment (opening in Ex area permitted) 1 /2“ NPT EEx d diameter of the connection cable to the Exd terminal compartment 3.1…8.7 mm (0.12…0.
Electrical connection 3.3 Connection of the external indicating instrument VEGADIS 50 Loosen the four screws of the housing lid on VEGADIS 50. The connection procedure can be facilitated by fixing the housing cover during connection work with one or two screws on the right of the housing. VEGADIS 50 Adjustment module + - Tank 1 m (d) 12.
Electrical connection 3.4 Configuration of measuring systems A measuring system consists of a sensor with 4 … 20 mA signal output and a unit that evaluates and further processes the levelproportional current signal. On the following pages, you will see a number of instrument configurations, designated as "measuring systems“, some of which are shown with signal processing units.
Electrical connection Measuring system with VEGAPULS 41 on active PLC • • • • Two-wire technology, power supply from active PLC. Output signal 4 … 20 mA (passive). Measured value display integrated in the sensor. Optional external indicating instrument (can be mounted up to 25 m away from the sensor in Ex area). • Adjustment with PC, HART® handheld or the adjustment module MINICOM (can be plugged into the sensor or into the external indication instrument).
Electrical connection Measuring system with VEGAPULS 41 in four-wire technology • Four-wire technology, power supply and output signal via two separate two-wire cables. • Output signal 4 … 20 mA active. • Optional external indicating instrument with analogue and digital indication (can be mounted up to 25 m away from the sensor). • Adjustment with PC, HART® handheld or adjustment module MINICOM (can be plugged into the sensor or into the indicating instrument VEGADIS 50). • max.
Electrical connection Measuring system with VEGAPULS 41 via separator in Ex areas on active PLC (Ex ia) • Two-wire technology (loop powered), power supply via the signal line of the PLC; output signal 4 … 20 mA (passive). • Separator transfers the non intrinsically safe PLC circuit to the intrinsically safe circuit, so that the sensor can be used in Ex zone 1 or Ex zone 0. • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).
Electrical connection Measuring system with VEGAPULS 41 via separator (Smart-Transmitter) on passive PLC (Ex ia) • Two-wire technology (loop powered), intrinsically safe ia supply via the signal cable of the separator for operation of the sensor in Ex zone 1 or Ex zone 0. • Output signal sensor 4 … 20 mA passive. • Output signal separator 4 … 20 mA active • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).
Electrical connection Measuring system with VEGAPULS 41 on VEGADIS 371 Ex indicating instrument with current and relay output (Ex ia) • Two-wire technology (loop powered), intrinsically safe ia supply via the signal cable of the VEGADIS 371 Ex indicating instrument for operation of the sensor in Ex zone 1 or Ex zone 0. • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).
Electrical connection VEGAPULS 41 Ex (loop powered) with pressure-tight encapsulated connection compartment on active PLC (Ex d) • Two-wire technology, supply via the cable from active PLC to Exd connection housing for operation in Ex-Zone 1 (VEGAPULS …Ex) or Ex-Zone 0 (VEGAPULS …Ex0). • Output signal 4 … 20 mA (passive). • Measured value display integrated in the sensor. • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor in Ex area).
Electrical connection VEGAPULS 41 Ex with pressure-tight encapsulated connection compartment in four-wire technology (Ex d) • Four-wire technology, supply and output signal via two separate two-wire cables for operation in Ex-Zone 1 (VEGAPULS …Ex) or Ex-Zone 0 (VEGAPULS …Ex0). • Output signal 4 … 20 mA (active). • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor in Ex area).
Set-up 4 Set-up 4.1 Adjustment media 4.2 Adjustment with PC Radar sensors can be adjusted with the - PC (adjustment software PACTwareTM) - detachable adjustment module MINICOM - HART ® handheld. The adjustment must be carried out with only one adjustment device. If, for example, you attempt to adjust the parameters with the MINICOM and the HART ® handheld at the same time, the adjustment will not work.
Set-up + PLC Ri ≥ 250 Ω + 250 Ω PLC Ri < 250 Ω Rx 26620-EN-041227 VEGAMET/VEGALOG VEGAPULS 41 – 4 … 20 mA 41
Set-up 4.3 Adjustment with adjustment module MINICOM Much like with the PC, you can set up and operate the sensor with the small, detachable adjustment module MINICOM. The adjustment module is simply plugged into the sensor or into the external indicating instrument (optional). Tank 1 m (d) 12.
Set-up Adjustment without medium (adjustment independent of the level) 2. Operating range Without special adjustment, the operating range corresponds to the measuring range. Generally, it is useful to choose a slightly wider range (approx. 5 %) for the operating range than for the measuring range. Key adjustment Sensor m(d) 4.700 Example: Min./max. adjustment: 1.270 … 5.850 m; adjust operating range to approx. 1.000 … 6.000 m. OK 3. Adjustment OK Max. 100 % (1.
Set-up + or OK – With the "+“ or " –“ key you can assign a level distance (example 5.85 m) to the previously adjusted percentage value. If you do not know the distance, you have to do a sounding. The adjusted product distance is written in the sensor and the display stops flashing. You thereby adjusted the lower product distance as well as the percentage filling value corresponding to the lower product distance.
Set-up • Confirm with "OK “. 7. Useful level, noise level If necessary, choose a decimal point. However, note that only max. 4 digits can be displayed. In the menu "prop. to“ you choose the physical quantity (mass, volume, distance…) and in the menu " Unit“ the physical unit (kg, l, ft3 , gal, m3 …). In the menu Ampl.: Linearisation: XX dB S-N: XX dB you get important information on the signal quality of the product echo.
Set-up Menu schematic for the adjustment module MINICOM Sensor PULS 54 K 2.00 m(d) 4.700 Parameter Multidrop operation (HART ® sensor address): • Sensor address zero: The sensor outputs beside the 4…20 mA signal also a digital (HART ®) level signal. • Sensor address 1…15: the sensor delivers only a digital (HART® ) level signal. The sensor current is frozen to 4 mA (power supply). After switching on, the sensor type and the software version are displayed for a few seconds.
Set-up With these keys you move in the menu field to the left, right, top and bottom ESC OK Add’l functions Info 6. 7. False echo memory act. dist. m (d) 4.700 Ampl.: XX dB S-N: XX dB Create new Update Delete Meas. dist. m (d) X.XX Meas. dist. m (d) X.XX Delete Now! OK? Create new OK? Update Now! OK? Deleting! Learning! Learning! Reset to de fault Language English Reset Now! OK? Reset ing! Sensor Tag Sensor Sensor Serial type no. PULS54 1094 K 0213 Softw. vers. 2.00 max.
Set-up 4.4 Adjustment with HART® handheld With any HART ® handheld you can set up the VEGAPULS series 40K radar sensors like all other HART® compatible sensors. A special DDD (Data Device Description) is not necessary. Just connect the HART® handheld to the signal cable, after having connected the sensor to power supply. + Ri ≥ 250 Ω Note: If the resistance of the power supply is less than 250 Ohm, a resistor must be connected into the signal/connection loop during adjustment.
Set-up Rx VEGALOG 26620-EN-041227 VEGAMET VEGAPULS 41 – 4 … 20 mA 49
Diagnostics 5 Diagnostics 5.1 Simulation To simulate a certain filling level, you can call up the function “Simulation” in the adjustment module MINICOM, in the adjustment software PACTwareTM or in the HART® handheld. You simulate a vessel filling and thereby a certain sensor current. Please note that connected instruments, such as e.g. a PLC, react according to their adjustments and will probably activate alarms or system functions.
Technical data 6 Technical data 6.1 Technical data Power supply Supply voltage - four-wire sensor (non-Ex and Ex d ia) 24 V DC (20 … 72 V DC) 230 V AC (20 … 253 V AC), 50/60 Hz fuse 0.
Technical data Parameter and measuring range 1) Parameter Measuring range distance between product surface and process fitting (e.g. lower flange side of the sensor) 0 … 10 m Output signal Signal output 4 … 20 mA current signal in two-wire or four-wire technology; the HART® signal is modulated to the 4 … 20 mA signal Fault signal current output unchanged, 20.
Technical data Accuracy 1) (typical values under reference conditions, all statements relate to the nominal measuring range) Characteristics Resolution, general Resolution of the output signal linear max. 1 mm see diagram 10 mm 5 mm 0,5 m 10 m -5 mm -10 mm Characteristics 1) (typical values under reference conditions, all statements relate to the nominal measuring range) Min.
Technical data Ambient conditions Vessel pressure Ambient temperature on the housing - 4 … 20 mA two-wire sensor - 4 … 20 mA four-wire sensor - 4 … 20 mA four-wire sensor Ex d ia Process temperature (flange temp.
Technical data Weights Weights dependent on housing materials and Ex concepts. VEGAPULS 41 1.8 … 2.5 kg CE conformity 26620-EN-041227 VEGAPULS 41 radar sensors meet the protective regulations of EMC (89/336/EWG), NSR (73/23/EWG) and R & TTE regulation (1999/5/EC). Conformity has been judged acc. to the following standards: EN 300 683 - 1: 1997 EN 300 440 - 1: 1995 IETS 300-440 Expert opinion No. 0043052-02/SEE, Notified Body No.
Technical data 6.2 Approvals Intrinsically safe in Ex environment When radar sensors are used in Ex areas or on ships, the instruments must be suitable and approved for the explosion zones and applications. The suitability is checked by the approval authorities and is certified in approval documents. Series 40 sensors in EEx ia (intrinsically safe) version require for use in Ex areas special separators or safety barriers. The separators or safety barriers provide intrinsically safe (ia) circuits.
Technical data 6.3 Dimensions External indicating instrument VEGADIS 50 85 82 38 85 118 108 135 10 48 ø5 Note: The cable diameter of the connection cable should be min. 5 mm and max. 9 mm. Otherwise the seal effect of the cable entry would not be ensured. Pg 13,5 Mounting on carrier rail 35 x 7.5 acc. to EN 50 022 or flat screwed Flange dimensions acc. to ANSI (RF) D = outer flange diameter d2 flange thickness diameter of hole circle seal ledge diameter seal ledge thickness 1 / 16" = approx.
Technical data Sensor dimensions PBT Aluminium Aluminium with Exd terminal compartment 201 165 215 215 185 116 25 116 25 205 205 322 182 185 370 101 370 10˚ M20x1,5 M20x1,5 135 125 ½" NPT 20 83 130 SW 60 G1½ A 1½" NPT 26620-EN-041227 58 VEGAPULS 41 – 4 … 20 mA
Supplement Supplement Safety Manual Functional safety acc. to IEC 61508 / IEC 61511 VEGAPULS series 40 radar sensors; 4 … 20 mA/HART® compact sensor 1 1.1 General Validity This safety manual applies to VEGAPULS series 40 radar sensors in two-wire version 4 … 20 mA/HART®, called “measuring system”. 1.
Supplement 1.4 Determination of safety-related characteristics The failure limit values for a safety function, depending on the SIL class. Safety integrity level Low demand mode High demand or continuous mode SIL PFDavg PFH 4 >10-5 up to <10 -4 >10-9 up to <10-8 3 >10-4 up to <10 -3 >10-8 up to <10-7 2 -3 -2 >10-7 up to <10-6 -2 -1 >10-6 up to <10-5 >10 up to <10 1 >10 up to <10 (from IEC 61508, part 1/7.6.
Supplement 2 2.1 Planning Low demand mode If the demand rate is only once a year, then the measuring system can be used as safetyrelevant subsystem in „low demand mode“ (see IEC 61508-4, 3.5.12). Corresponding characteristics : PFDavg (average probability of dangerous failure on demand). It is dependent on the test interval TProof between the function tests of the protective function. 2.
Supplement 3 3.1 Set-up Mounting and installation The prevailing plant conditions influence the safety of the measuring system. Therefore note the mounting and installation instructions of the appropriate operating instructions manual. 3.2 Adjustment instructions and parameter adjustment Adjustment instructions The activation of the measuring system as safety-relevant subsystem is only possible via PC adjustment programs.
Supplement 4 Reaction during operation and in case of failure In case of modifications during operation, you have to take note of the safety functions. It must be ensured that the safety-relevant parameter adjustments remain activated. Occurring fault signals are described in the appropriate operating instructions manual. In case of detected failures or fault signals, the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures.
Supplement 6 Safety-related characteristics The failure rate of the electronics and the antenna system was determined by an FMEDA (Failure Mode, Effects and Diagnostics Analysis) acc. to IEC 61508. The number values are based on an output current tolerance of max. 2 %. Architecture 1oo1D VEGAPULS VEGAPULS VEGAPULS VEGAPULS VEGAPULS 41 42 43 44 45 SIL 2 Overfill protection Dry run protection Individual level Max Min HFT 0 SFF PFDavg > 88% 1) PFH [1/h] < 0.10 •10 -2 < 0.
Supplement SIL declaration of conformity Füllstand - Grenzstand - Druck SIL d e c l a r a t i o n of c o n f o r m i t y Functional safety according to IEC 61508 / IEC 61511 VEGA Grieshaber KG, Am Hohenstein 113, D-77761 Schiltach declares as manufacturer, that for the radar sensors of the product families VEGAPULS series 40 and 50 ( 4 ... 20 mA HART® ) the reliability (“proven in use”) was verified according to IEC 61508 / IEC 61511.
Supplement CE conformity declaration 26620-EN-041227 66 VEGAPULS 41 – 4 … 20 mA
26620-EN-041227 Supplement VEGAPULS 41 – 4 … 20 mA 67
VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone (07836) 50-0 Fax (07836) 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.
