Operating Instructions VEGAPULS 54K enamel
Contents Contents Sicherheitshinweise ..................................................................... 3 Safety information ........................................................................ 3 Note Ex area ................................................................................ 3 1 Product description .................................................................. 4 1.1 Function ................................................................................. 4 1.
Sicherheitshinweise 6 Technical data .......................................................................... 39 6.1 Technical data ..................................................................... 39 6.2 Approvals ........................................................................... 43 6.3 Dimensions ......................................................................... 44 Supplement ..................................................................................... 46 Safety Manual ....
Product description 1 Product description VEGAPULS series 50 sensors are a newly developed generation of extremely compact, small radar sensors. Due to their small housing dimensions and process fittings, the compact sensors are an unobstrusive, and most of all, very costeffective solution for your level measurement applications.
Product description All products which are electrically conductive reflect radar signals very well. Even slightly conductive products provide a sufficiently strong reflection for a reliable measurement. Puls 1 ns 278 ns All products with a dielectric constant ε r greater than 2.0 reflect radar pulses sufficiently (note: air has a dielectric constant εr of 1). Pulse break Pulse sequence VEGAPULS can achieve this through a special time transformation procedure which spreads out the more than 3.
Product description Continuous and accurate Unaffected by temperature, pressure and atmosphere content, VEGAPULS radar sensors measure quickly and accurately the levels of widely varying products. % 0,03 0,023 % 0,018 % 0,02 0,01 0 0 100 500 1000 1300 % 10 3,89 % 2,8 % 1,44 % 0,29 % 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 bar Pressure influence: Error with pressure increase very low (e.g. at 50 bar 1.
Product description Adjustment with the PC Adjustment with the adjustment module MINICOM The set-up and adjustment of the radar sensors is generally done on the PC with the adjustment software PACTwareTM . The program leads quickly through the adjustment and parameter setting by means of pictures, graphics and process visualisations. 2 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.
Product description Adjustment with the HART® handheld 1.4 Antennas Series 50 sensors with 4 … 20 mA output signal can also be adjusted with the HART ® handheld. A special DDD (Data Device Description) is not necessary - the sensors can be adjusted with the HART® standard menus of the handheld. The antenna is the eye of the radar sensor.
Mounting and installation 2 Mounting and installation 2.1 General installation instructions False echoes Measuring range Flat obstructions and struts cause strong false echoes. They reflect the radar signal with high energy density. The reference plane for the measuring range of the sensor is the enamelled sensor seal shoulder, against which the enamelled vessel seal is placed. The measuring range is 0 … 20 m. For measurements in surge or bypass tubes (pipe antenna) the max.
Mounting and installation Emission cone and false echoes 2.2 Measurement of liquids 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. Horn antenna on DIN socket piece 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 On dished vessel tops, please do not mount the instrument in the centre or close to the vessel wall, but approx.½ vessel radius from the centre or from the vessel wall. Dished tank tops can act as paraboloidal reflectors. If the radar sensor is placed in the focal point of the parabolic tank top, the radar sensor receives amplified false echoes. The radar sensor should be mounted outside the focal point. Parabolically amplified echoes are thereby avoided. 2.
Mounting and installation Vessel installations Inflowing material 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. Do not mount the instrument in or above the filling stream. Ensure that you detect the product surface and not the inflowing material.
Mounting and installation Strong product movements 2.4 Common installation mistakes Strong turbulence in the vessel, e.g. caused by powerful stirrers or strong chemical reactions, can seriously interfere with the measurement. A surge or bypass tube (see illustration) of sufficient size always enables reliable and problem-free measurement even if strong turbulence occurs in the vessel, provided there is no product buildup in the tube.
Mounting and installation Wrong orientation to the product Weak measuring signals are generated if the sensor is not directly pointed at the product surface. Orient the sensor axis perpendicularly to the product surface to achieve optimum measuring results. Correct If there are good reflection conditions (liquid medium, no vessel installations), we recommend locating the sensor where there is no vessel wall within the inner emission cone.
Electrical connection 3 Electrical connection 3.1 Connection and connection cable Note! In Ex applications, grounding on both ends is not allowed due to potential transfer. 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 3.2 Connecting the sensor After mounting the sensor at the measurement location according to the instructions in chapter "4 Mounting and installation“, loosen the closing screw on top of the sensor. The sensor lid with the optional indication display can then be opened. Unscrew the sleeve nut and slip it over the connection cable (after removing about 10 cm of cable mantle). The sleeve nut of the cable entry has a self-locking ratchet that prevents it from opening on its own.
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 Two-wire adjustment module terminal (opening in Ex atmosphere not allowed) compartment (opening in Ex area permitted) Exd safe connection to the Exd terminal compartment - + Power supply 1 Locking of the cover Exd terminal compartment ser.no ******** R ATEX FM APPROVED Supply: 20...36V DC/4...
Electrical connection 3.3 Connecting 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 Measuring systems in two-wire technology: • 4 … 20 mA shown without processing unit • 4 … 20 mA on active PLC • 4 … 20 mA on active PLC (Ex area), • 4 … 20 mA on passive PLC • 4 … 20 mA on indicating instrument VEGADIS 371 Ex 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.
Electrical connection Measuring system with VEGAPULS 54K 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 54K 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 54K 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 54K via separator (Smart-Transmitter) on passive PLC • 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 • 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 54K on VEGADIS 371 Ex indicating instrument with current and relay output • 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 • Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).
Electrical connection VEGAPULS 54K Ex (loop powered) with pressure-tight encapsulated connection compartment on active PLC • Two-wire technology, supply via the cable from active PLC to Exd connection housing for operation in Ex-Zone 1 (VEGAPULS …K Ex) or Ex-Zone 0 (VEGAPULS …K 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 54K Ex with pressure-tight encapsulated connection compartment in four-wire technology • Four-wire technology, supply and output signal via two separate two-wire cables for operation in Ex-Zone 1 (VEGAPULS …K Ex) or Ex-Zone 0 (VEGAPULS …K 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 24 101-EN-041227 VEGAMET/VEGALOG VEGAPULS 54K enamel 29
Set-up 4.3 Adjustment with adjustment module MINICOM You can set up and operate the sensor with the small, detachable adjustment module MINICOM as well as with the PC. 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. It is generally advantageous to set the operating range slightly larger (approx. 5 %) for than for the measuring range. Key entry 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. Display indication Parameter Adjustment w.
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: Adjust ment Signal condit ioning 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 6. False echo memory 7. 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! Info Reset to de fault Language English Reset Now! OK? Reset ing! Sensor Tag Sensor Learning! Sensor type PULS54 K Serial no. 1094 0213 Softw. Vers. 2.
Set-up 4.4 Adjustment with HART® handheld With any HART ® handheld you can set up the VEGAPULS series 50K 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.
Set-up Rx VEGALOG 24 101-EN-041227 VEGAMET VEGAPULS 54K enamel 37
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 settings and will probably activate alarms or system functions.
Technical data 6 Technical data 6.1 Technical data Power supply Power supply - four-wire sensor 24 V DC (20 … 72 V DC) 230 V AC (20 … 250 V AC), 50/60 Hz fuse 0.2 A TR 24 V DC (14 … 36 V DC) 24 V DC (14 … 29 V DC) 24 V DC (20 … 36 V DC) - two-wire sensor - two-wire Ex ia sensor - two-wire Ex d ia sensor Current consumption - four-wire sensor - two-wire sensor Power consumption - four-wire sensor - two-wire sensor Load - four-wire sensors - two-wire sensors max. 60 mA max. 22.5 mA max. 200 mW, 1.
Technical data Measuring range 1) Standard 0 … 20 m Output signal 4 … 20 mA current signal Fault signal in two or four-wire technology current signal unchanged, 20.5 mA, 22 mA (adjustable) 0 … 999 seconds (adjustable) Integration time Two-wire technology 4 … 20 mA: The analogue 4 … 20 mA output signal (measuring signal) is transmitted together with the power supply via one two-wire cable. Four-wire technology 4 … 20 mA: Separate power supply.
Technical data Measurement characteristics 1) (typical values under reference conditions, all statements relate to the nominal measuring range) Min. span between full and empty Frequency Intervals - two-wire sensor (4 … 20 mA) - four-wire sensor Beam angle (at –3 dB) - VEGAPULS 54 with DN 150 - VEGAPULS 54 with DN 200 Influence of the process temperature Influence of the process pressure Ambient conditions Ambient temperature on the housing Process temperature (flange temp.
Technical data Ex-technical data Comprehensive data in the safety instructions manual (yellow binder) Connection cables Two-wire sensors Four-wire sensors Electrical connection Cable entry -ia terminal compartment - Ex d terminal compartment Ground connection power supply and signal via one two-wire cable power supply and signal separated - spring-loaded terminal connection (max. 2.5 mm2) - plug connection (secure by cable entry) 1 … 2 x M20 x 1.5 (cable-ø 5 … 9 mm) or 2 x 1/ 2“ NPT (cable-ø 3.6 … 8.
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. 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 82 38 85 118 108 135 10 48 ø5 Note: The 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 D b k d1 f outer flange diameter flange thickness diameter of hole circle seal ledge diameter seal ledge thickness 1 /16" = approx. 1.
Technical data VEGAPULS 54K enamel Aluminium PBT Aluminium with Exd terminal compartment 201 165 215 185 370 10˚ 215 185 116 25 116 25 205 182 205 322 370 101 M20x1,5 M20x1,5 91 ø 144 ø 212 242 PBT: 535 Al: 583 24 34 PBT: 53 Al: 78 196 22 30 PBT: 53 Al: 78 PBT: 483 Al : 531 ½" NPT ø 162 ø 268 ø22 ø22 45 ˚ 45 ˚ ø 240 ø 285 ø 295 ø 340 DN 200 PN 10 24 101-EN-041227 DN 150 PN 16 VEGAPULS 54K enamel 45
Supplement Supplement Safety Manual Functional safety acc. to IEC 61508 / IEC 61511 VEGAPULS series 50 radar sensors; 4 … 20 mA/HART® compact sensor 1 1.1 General Validity This safety manual applies to VEGAPULS series 50 radar sensors in two-wire version 4 … 20 mA/HART ®, called “measuring system” in the following. 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 >10-3 up to <10-2 >10-7 up to <10-6 -2 1 >10 up to <10 -1 >10-6 up to <10-5 (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 T Proof 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 settings 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 settings 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 51 52 53 54 56 SIL 2 Overfill protection Dry run protection Individual level Max Min HFT 0 SFF > 86% PFDavg 1) < 0.12 •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 24 101-EN-041227 CE declaration of conformity VEGAPULS 54K enamel 53
Supplement 24 101-EN-041227 54 VEGAPULS 54K enamel
24 101-EN-041227 Supplement VEGAPULS 54K enamel 55
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.
