Operating Instructions Ultrasonic sensor for continuous level measurement VEGASON 61 Foundation Fieldbus Document ID: 28790
Contents Contents About this document 1.1 Function............................................................................................................................ 4 1.2 Target group...................................................................................................................... 4 1.3 Symbolism used................................................................................................................ 4 2 For your safety 2.1 Authorised personnel....................
Contents 8.4 8.5 9 Software update.............................................................................................................. 38 Instrument repair............................................................................................................. 39 Dismounting 9.1 Dismounting steps.......................................................................................................... 40 9.2 Disposal............................................................................
1 About this document 1 About this document 1.1 Function 1.2 Target group 1.3 Symbolism used 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. This operating instructions manual is directed to trained specialist 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 VEGASON 61 is a sensor for continuous level measurement. You can find detailed information on the application range in chapter "Product description".
2 For your safety successful testing. You can find the CE conformity declaration in the download area of "www.vega.com". 2.7 Fulfillment of NAMUR recommendations NAMUR is the automation technology user association in the process industry in Germany. The published NAMUR recommendations are accepted as the standard in field instrumentation.
3 Product description 3 Product description 3.
3 Product description product surface and received back by the transducer as echoes. The running time of the ultrasonic pulses from emission to reception is proportional to the distance and hence the level. The determined level is converted into an appropriate output signal and outputted as measured value. Power supply and bus communication Power is supplied via the H1 Fieldbus. A two-wire cable according to Fieldbus specification serves as carrier of both power and digital data for multiple sensors.
3 Product description Transport Transport must be carried out under consideration of the notes on the transport packaging. Nonobservance of these instructions can cause damage to the device. Transport inspection The delivery must be checked for completeness and possible transit damage immediately at receipt. Ascertained transit damage or concealed defects must be appropriately dealt with.
4 Mounting 4 4.1 Mounting General instructions Suitability for the process Make sure that all parts of the instrument coming in direct contact conditions with the process, especially the sensor element, process seal and process fitting, are suitable for the existing process conditions, such as process pressure, process temperature as well as the chemical properties of the medium. You can find the specifications in chapter "Technical data" and on the nameplate.
4 Mounting 1 2 Fig. 3: Minimum distance to the max. level 1 2 Dead band Reference plane Information: If the medium reaches the transducer, buildup can form on it and cause faulty measurements later on. 1 2 3 100% 0% Fig. 4: Measuring range (operating range) and max. measuring distance 1 2 3 28790-EN-130417 Pressure/Vacuum Screwing in full empty (max. measuring distance) Measuring range Gauge pressure in the vessel does not influence VEGASON 61.
4 Mounting Installation position When mounting the sensor, keep a distance of at least 200 mm (7.874 in) to the vessel wall. If the sensor is installed in the center of dished or round vessel tops, multiple echoes can arise. These can, however, be suppressed by an appropriate adjustment (see chapter "Setup"). 2 1 > 200 mm Fig. 5: Mounting on round vessel tops 1 2 Reference plane Vessel center or symmetry axis If you cannot keep this distance you should carry out a false echo storage before setup.
ca. 10 mm 4 Mounting Fig. 7: Recommended socket mounting If the reflective properties of the medium are good, you can mount VEGASON 61 on sockets which are higher than the length of the transducer. You will find recommended values for socket heights in the following illustration. The socket end should be smooth and burr-free, if possible also rounded. Carry out a false echo storage. h d 80 mm/3" 100 mm/4" 150 mm/6" h 150 mm/6" 300 mm/12" 400 mm/16" d Fig.
~4 00 x4 45° 4 Mounting 00 ~200 Fig. 10: Beam deflector Vessel installations The ultrasonic sensor should be installed at a location where no installations cross the ultrasonic beam. Vessel installations such as for example, ladders, limit switches, heating spirals, struts etc. can cause false echoes that interfere with the useful echo. Make sure when planning your measuring site that the ultrasonic signals have a "clear view" to the measured product.
4 Mounting Fig. 12: Agitators Inflowing medium Do not mount the instruments in or above the filling stream. Make sure that you detect the product surface, not the inflowing product. Fig. 13: Inflowing liquid Foam Through the action of filling, stirring and other processes in the vessel, dense foams which considerably damp the emitted signals may form on the product surface.
4 Mounting Standpipe measurement By using a standpipe (surge or bypass tube), the influence of vessel installations, foam generation and turbulence is excluded. Standpipes must extend all the way down to the requested min. level, as measurement is only possible within the tube. max. 1 min. Fig. 14: Standpipe in the tank 1 Vent hole: ø 5 … 10 mm (0.197 … 0.394 in) VEGASON 61 can be used from tube diameters of 40 mm (1.575 in). Avoid large gaps and thick welding joints when connecting the tubes.
5 Connecting to power supply 5 Safety instructions 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 If overvoltage surges are expected, overvoltage arresters should be installed according to Foundation Fieldbus specification Tip: We recommend VEGA overvoltage arrester B63-32.
5 Connecting to power supply low frequency potential equalisation currents are thus suppressed, but the protective effect against high frequency interference signals remains. The total capacitance of the cable and of all capacitors must not exceed 10 nF in Ex applications. Take note of the corresponding installation regulations for Ex applications. In particular, make sure that no potential equalisation currents flow over the cable screen.
5 Connecting to power supply 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. The seal ring must completely encircle the cable 12. Screw the housing cover back on The electrical connection is hence finished. 5.3 Housing overview Wiring plan, single chamber housing The following illustrations apply to the non-Ex as well as to the Ex-ia version. 5 5 1 5 5 2 3 4 Fig.
5 Connecting to power supply Electronics and connection compartment Typ: Bus Display Sim. 5 1 4 2 I²C 5 6 7 8 1 2 3 Fig.
5 Connecting to power supply Housing overview 1 2 3 5 4 Fig. 19: Double chamber housing 1 2 3 4 5 Housing cover, connection compartment Blind plug or plug M12 x 1 for VEGADIS 61 (optional) Housing cover, electronics compartment Filter element for air pressure compensation Cable gland Electronics compartment 1 Typ: Sim. Bus 1 2 Display I²C 2 5 6 7 8 3 Fig.
5 Connecting to power supply Display Connection compartment 2 1 1 I2C 2 3 Fig. 21: Connection compartment, double chamber housing 1 2 3 Spring-loaded terminals for voltage supply Plug connector for VEGACONNECT (I²C interface) Ground terminal for connection of the cable screen Wiring plan I2C 1 2 1 Fig. 22: Wiring plan, double chamber housing 1 Wire assignment, connection cable Voltage supply, signal output 5.5 Wiring plan - version IP 66/IP 68, 1 bar 1 2 Fig.
5 Connecting to power supply Switch-on phase 5.6 Switch-on phase After VEGASON 61 is connected to voltage supply or after voltage recurrence, the instrument carries out a self-check for approx. 30 seconds.
6 Set up with the display and adjustment module PLICSCOM 6 Function/Configuration Set up with the display and adjustment module PLICSCOM 6.1 Short description The display and adjustment module is used for measured value display, adjustment and diagnosis.
6 Set up with the display and adjustment module PLICSCOM Fig. 24: Insert display and adjustment module Note: If you intend to retrofit the instrument with a display and adjustment module for continuous measured value indication, a higher cover with an inspection glass is required. 6.3 Adjustment system 2 1 1.1 3 28790-EN-130417 Fig.
6 Set up with the display and adjustment module PLICSCOM • • • Adjustment system Switch-on phase –– Save value [->] key to select: –– Menu change –– Select list entry –– Select editing position [+] key: –– Change value of the parameter [ESC] key: –– interrupt input –– Jump to next higher menu The sensor is adjusted via the four keys of the display and adjustment module. The LC display indicates the individual menu items. The functions of the individual keys are shown in the above illustration. Approx.
6 Set up with the display and adjustment module PLICSCOM In the main menu item "Basic adjustment", the individual submenu items should be selected one after the other and provided with the correct parameter values. Start your parameter adjustment with the following menu items of the basic adjustment: Carry out min. adjustment Proceed as follows: 1. Move from the measured value display to the main menu by pushing [OK]. ▶ Basic adjustment Display Diagnostics Service Info 2.
6 Set up with the display and adjustment module PLICSCOM generation, material cones and echoes from the vessel wall (with solids). To adapt the sensor to these different conditions, you should first select "Liquid" or "Solid". Medium Liquid With solids, you can also choose between "Powder/Dust", "Granular/ Pellets" or "Ballast/Pebbels".
6 Set up with the display and adjustment module PLICSCOM should not be displayed in percent but e.g. in l or kg, a scaling can be also set in the menu item "Display". Linearization curve Linear Enter the requested parameters via the appropriate keys, save your settings and jump to the next menu item with the [->] key. False signal suppression High sockets or vessel installations, such as e. g.
6 Set up with the display and adjustment module PLICSCOM Copy sensor data This function enables reading out parameter adjustment data as well as writing parameter adjustment data into the sensor via the display and adjustment module. A description of the function is available in the operating instructions manual "Display and adjustment module".
6 Set up with the display and adjustment module PLICSCOM Peak value The min. and max. distance and temperature values are reset to the actual value. Additional adjustment and diagnosis options such as e.g. scaling, simulation or trend curve presentation are shown in the following menu schematic. You will find a detailed description of these menu items in the operating instructions manual "Display and adjustment module". Optional settings 6.
6 Set up with the display and adjustment module PLICSCOM Diagnostics Basic adjustment Display 3 ▶ Diagnostics Service Info Peak value Distance min.: 0.580 m(d) 3.1 Dist. max.: 16.785 m(d) Meas. reliability 36 dB Sensor status T-max.: 30.6 °C T-min.: 4.5 °C 3.2 Curve selection 3.3 Echo curve OK Echo curve 3.4 Presentation of the echo curve Service Basic adjustment Display 4 Diagnostics ▶ Service Info False signal suppression 4.1 Change now? Extended setting Fast 4.
6 Set up with the display and adjustment module PLICSCOM 6.10 Saving the parameter adjustment data We recommended noting the adjusted data, e.g. in this operating instructions manual, and archiving them afterwards. They are thus available for multiple use or service purposes. If VEGASON 61 is equipped with a display and adjustment module, the most important data can be read out of the sensor into the display and adjustment module.
7 Set up with PACTware and other adjustment programs 7 Set up with PACTware and other adjustment programs 7.1 Connect the PC via VEGACONNECT VEGACONNECT directly on the sensor 2 1 3 Fig. 26: Connection of the PC via VEGACONNECT directly to the sensor 1 2 3 USB cable to the PC VEGACONNECT Sensor VEGACONNECT externally 1 2 TWIST OP EN CK LO USB 3 4 Fig. 27: Connection via VEGACONNECT externally 1 2 3 4 I²C bus (com.
7 Set up with PACTware and other adjustment programs 7.2 Parameter adjustment with PACTware Further setup steps are described in the operating instructions manual "DTM Collection/PACTware" attached to each CD and which can also be downloaded from our homepage. A detailed description is available in the online help of PACTware and the VEGA DTMs. Note: Keep in mind that for setup of VEGASON 61, DTM-Collection in the actual version must be used.
8 Maintenance and fault rectification 8 Maintenance and fault rectification 8.1 Maintenance 8.2 Rectify faults If the instrument is used properly, no special maintenance is required in normal operation. Reaction when malfunctions occur The operator of the system is responsible for taking suitable measures to rectify faults. Failure reasons VEGASON 61 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 Rectification Profibus DP cable Check cable and correct, if necessary Instrument does not appear during pole-reversed connection setup Incorrect termiCheck termination at the beginning nation and end points of the bus and terminate, if necessary, according to the specification Instrument not connected to the segment Error messages via the display and adjustment module Reaction after fault rectification Check and correct, if necessary In Ex application
8 Maintenance and fault rectification Information: When loading on site, first of all the order data must be downloaded from the Internet (see operating instructions manual "Electronics module"). Assignment The electronics modules are adapted to the respective sensor and distinguish also in the signal output or power supply. 8.
8 Maintenance and fault rectification 8.5 Instrument repair If a repair is necessary, please proceed as follows: You can download a return form (23 KB) from our Internet homepage www.vega.com under: "Downloads - Forms and certificates - Repair form". By doing this you help us carry out the repair quickly and without having to call back for needed information.
9 Dismounting 9 9.1 Dismounting 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 Materials, wetted parts ƲƲ Process fitting, transducer PVDF ƲƲ Seal between transducer and process EPDM, FKM (Viton) fitting Materials, non-wetted parts ƲƲ Housing ƲƲ Seal between housing and housing cover ƲƲ Inspection window in housing cover ƲƲ Ground terminal Weight Max. torque mounting boss Output variable Output ƲƲ Signal NBR (stainless steel housing), silicone (Alu/plastic housing) Polycarbonate 316Ti/316L 1.8 … 4 kg (4 … 8.
10 Supplement ƲƲ Temperature +18 … +30 °C (+64 … +86 °F) ƲƲ Air pressure 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) ƲƲ Relative humidity 45 … 75 % Other reference conditions ƲƲ Reflector ideal reflector, e.g. metal plate 2 x 2 m (6.56 x 6.
10 Supplement Electromechanical data - version IP 66/IP 67 and IP 66/IP 68; 0.2 bar Cable entry/plug10) ƲƲ Single chamber housing –– 1 x cable gland M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind plug M20 x 1.5 or: –– 1 x closing cap M20 x 1.5; 1 x blind plug M20 x 1.5 or: –– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT or: ƲƲ Double chamber housing –– 1␣x plug (depending on the version), 1␣x blind stopper M20␣x␣1.5 –– 1 x cable entry M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind plug M20 x 1.
10 Supplement Display and adjustment module Voltage supply and data transmission through the sensor Adjustment elements 4 keys Indication Protection rating ƲƲ unassembled LC display in dot matrix IP 20 ƲƲ mounted into the sensor without cover IP 40 Material ƲƲ Housing ƲƲ Inspection window Voltage supply Operating voltage ABS Polyester foil ƲƲ Non-Ex instrument 9 … 32 V DC ƲƲ Exd instrument 16 … 32 V DC ƲƲ Ex-ia instrument 9 … 24 V DC Operating voltage with illuminated display and adjust
10 Supplement 10.2 Foundation Fieldbus Block diagram, measured value processing The following illustration shows the Transducer Block (TB) and Function block (FB) in simplified form.
10 Supplement Secondary_value_1 cal_level_hi cal_level_lo Calibration Calibration Lowest Point Highest Point Sensor_value Sensor reference plane cal_level_hi [%] Calibration Highest Point cal_level_lo [%] Calibration Lowest Point Fig. 30: Adjustment VEGASON 61 Parameter list for Device revision 3.
10 Supplement • • • • • • • • • • • • • • • • • • 28790-EN-130417 • • • CURVE_STATUS –– Result of table plausibility check SUB_DEVICE_NUMBER SENSOR_ELEMENT_TYPE display_source_selector –– Selects the type of value, which is displayed on the indicating and adjustment module max_peak_sensor_value –– Holds the maximum sensor value. Write access resets to current value. Unit derives from 'Sensor_range.unit' min_peak_sensor_value –– Holds the minimum sensor value. Write access resets to current value.
10 Supplement • • • • • • • • • • • • • solids_vessel_type –– Set up to suit the process conditions. If Special-Parameter adjustment has been utilized this parameter cannot be written fast_level_change –– Set up to suit the process conditions.
10 Supplement 10.3 Dimensions Housing in protection IP 66/IP 68 (0.2 bar) 116 mm (4.57") 112 mm (4 13/32") ø 77 mm (3.03") M20x1,5/ ½ NPT M20x1,5/ ½ NPT 1 ~ 59 mm (2.32") ~ 87 mm (3.43") ~ 116 mm (4.57") ø 84 mm (3.31") M16x1,5 M20x1,5 M20x1,5/ ½ NPT 2 ~ 69 mm (2.72") ø 80 mm (3.15") ø 84 mm (3.31") 120 mm (4.72") ~ 69 mm (2.72") ~ 87 mm (3.43") ø 77 mm (3.03") 3 ø 84 mm (3.31") M20x1,5/ ½ NPT 4 M20x1,5/ ½ NPT 5 120 mm (4.72") 112 mm (4.41") 117 mm (4.
10 Supplement Housing in protection IP 66/IP 68 (1 bar) ~ 103 mm (4.06") ~ 150 mm (5.91") ø 84 mm (3.31") ø 84 mm (3.31") M16x1,5 M20x1,5 120 mm (4.72") 117 mm (4.61") 116 mm (4.57") M20x1,5 ~ 105 mm (4.13") ø 77 mm (3.03") M20x1,5 1 M20x1,5/ ½ NPT 2 3 Fig. 32: Housing versions in protection IP␣66/IP␣68 (1␣bar) - with integrated display and adjustment module the housing is 9␣mm/0.
10 Supplement 10.4 Industrial property rights VEGA product lines are global protected by industrial property rights. Further information see 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 www.vega.com. Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellectuelle. Pour plus d'informations, on pourra se référer au site www.
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. Subject to change without prior notice © VEGA Grieshaber KG, Schiltach/Germany 2013 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.
