VEGA FLEX55P User Manual

Operating Instructions

VEGAFLEX 55P (Profibus PA)

PROF I

PROCESS FIELD BUS

BUS

Level and Pressure

Contents

Safety information ........................................................................ 2

Note Ex area ................................................................................ 2

1 Product description

1.1 Function ................................................................................. 4

1.2 Application features ............................................................. 4

1.3 Types and versions ............................................................. 5

1.4 Profibus output signal .......................................................... 6

1.5 Type code ............................................................................. 9

1.6 Bus configuration ............................................................... 10

1.7 Approvals ........................................................................... 14

1.8 Data format of the output signal ........................................ 14

2 Mounting

2.1 Installation instructions ...................................................... 15

3 Electrical connection

3.1 Connection – Connection cable – Screening ................... 17

3.2 Sensor address ................................................................. 21

3.3 Connection of the sensor .................................................. 23

3.4 Connection of the external indicating instrument ............ 24

Safety information / Note Ex area

Safety information

Please read this manual carefully, and also take note of country-specific installation standards (e.g. the VDE regulations in Germany) as well as all prevailing safety regulations and accident prevention rules. For safety and warranty reasons, any internal work on the instruments, apart from that involved in normal installation and electrical connection, must be carried out only by qualified VEGA personnel.

2 VEGAFLEX 55P (Profibus PA)

Note Ex area

Please note the attached safety instructions containing important information on installation and operation in Ex areas. These safety instructions are part of the operating instructions and come with the Ex approved instruments.

Contents

4 Setup

4.1 Adjustment media .............................................................. 25

4.2 Adjustment with the adjustment module MINICOM ........ 26

4.3 Adjustment with the PC ...................................................... 32

5 Diagnosis

5.1 Simulation ............................................................................ 33

5.2 Function diagram ............................................................... 33

5.3 Failure rectification ............................................................. 38

5.4 PA parameters .................................................................... 38

6 Technical data

6.1 Technical data ..................................................................... 43

6.2 Dimensions ......................................................................... 46

VEGAFLEX 55P (Profibus PA) 3

1 Product description

Product description

1.1 Function

High frequency microwave impulses are guided along a steel rod. The microwave impulses are reflected when they reach the product surface. The impulse running time is processed by the integrated electronics and outputted as level.

The sensors detect levels in all types of liquids. Density, conductivity and dielectric value of the product do not influence the measurement. Continuously changing properties of the medium also do not influence the measured value.

In many applications, VEGAFLEX microwave sensors are the solution to difficult technical problems. Even in products with varying or fluctuating dielectric constant, the level is reliably detected. In high, narrow vessels, where non-contact measurement technologies often deliver less than optimal results, VEGAFLEX carries out problem-free measurements. The sensor part of VEGAFLEX 55 has a coaxial construction. A rod with 8 mm diameter is positioned in a tube with 21.3 mm diameter.

• Adjustment without filling or emptying the vessel.

• Two-wire sensor, power supply and measuring signal via one two-wire cable.

• Up to 32 sensors (Ex area: 8 sensors) can be connected via one two-wire cable.

• Measuring range up to 4 m, very small minimum measuring distance.

• Unaffected by application conditions such as:

- varying products

• Unaffected by the vessel material, e.g. metal, concrete, plastic etc.

• As an option, the display with adjustment functions can be mounted separate from the sensor.

• Low wiring costs through the use of twowire technology.

1.2 Application features

Applications

• Level measurement of liquids.

• Measurement also in vacuum.

• All slightly conductive substances and all

substances with a dielectric value ε can be measured.

• Measuring range 0 ... 4 m.

Two-wire technology

• Power supply, signal transmission and output signal on one two-wire cable.

• 4 … 20 mA output signal or digital output signal.

Rugged

• Highly resistant materials: PCTFE, 1.4435, Hastelloy C22.

Precise and reliable

• Resolution 1 mm.

• Unaffected by noise, steam, gas compositions and inert gas stratification.

• Unaffected by varying density.

• Measurements under pressure up to 40 bar and with product temperatures up to 150°C.

Communicative

• Integrated measured value display.

• As an option, display can be mounted separate from the sensor.

• Adjustment from the PLC level.

Approvals

• Ex Zone 0 EEx ia IIC T 6 nach ATEX II 1/2 G

• Ex Zone 0 EEx d ia IIC T 6 nach ATEX II 1/2 G

> 1.5

4 VEGAFLEX 55P (Profibus PA)

ESC

Tank 1 m (d)

12.345

Product description

Adjustment with PC

The setup and adjustment of VEGAFLEX sensors is generally done on the PC with the adjustment program VVO (VEGA Visual Operating) under Windows®. The program leads quickly through adjustment and parameter setting by means of pictures, graphics and process visualisations.

VEGA’s adjustment program VVO can access the adjustment options of VEGA sensors in their entirety and, if necessary, can update the complete sensor software. To do this, the adjustment program must be installed on a PC which is equipped with a Profibus Master Class 2 interface card (Softing) (see illustration under "1.4 Profibus output signal“).

The PC with the Profibus interface card can be connected directly to any position of the DP bus by using the standard RS 485 Profibus cable.

The adjustment and parameter data can be saved with the adjustment software on the PC and can be protected by passwords. On request, the adjustments can be quickly transferred to other sensors.

Adjustment with adjustment module MINICOM

With the small (3.2 cm x 6.7 cm) 6-key adjustment module MINICOM, the adjustment can be carried out in clear text dialogue. The adjustment module can be plugged into VEGAFLEX or the external indicating instrument VEGADIS 50. Thus, VEGAFLEX can also be adjusted from the external indicating instrument VEGADIS

50.

Pluggable adjustment module MINICOM

1.3 Types and versions

VEGAFLEX series 50P

…

CPU

can be adjusted with the pluggable adjustment module MINICOM. With the software VEGA Visual Operating (VVO), it is also

In general, all VEGAFLEX series 50P sensors

VEGALOG

1 … 32

VEGALOG

571 CPU

571 EA

possible to adjust the sensor with a PC.

Profibus PA

1 ... 15

Two-wire sensors with digital data transmission acc. to Profibus standard.

Adjustment with the PC and the standard cable RS 232 on the VEGALOG processing system

VEGAFLEX 55P (Profibus PA) 5

Product description

1.4 Profibus output signal

As a process automation bus, Profibus PA enables power supply over the bus. Up to 32 sensors can be operated on a shielded twowire cable that carries both power supply and measuring signal. In Ex areas, up to ten sensors can be connected from the PA level to one two-wire cable (EEx ia).

Bus structure

A Profibus system with DP and PA segments consists of up to 126 Master and Slave participants. Data are always exchanged from point to point, with the data traffic being exclusively controlled and checked by master devices. Communication is carried out according to the Token-Passing procedure. This means that the master holding the Token can contact the slaves, give instructions, enquire data and cause the slaves to receive and transmit data. After the work is done or after a predetermined time interval, the Token is passed on by the master to the next master.

Master-Class 1

is the actual automation system, i.e. the process control computer or the PLC that enquires and processes all measured values.

Profibus adjustment scheme

In the Profibus environment, there are different adjustment concepts and adjustment tools which often differ considerably from manufacturer to manufacturer. From the user’s point of view, a manufacturer-independent adjustment program which could be operated directly on the Profibus DP, as well as at any system node (e.g. the engineering station or the process control), would be ideal.

In the past, only the program "SIMATIC PDM“, based on the HART® adjustment scheme, could fulfil this wish (though with the limitations common to HART®). As with HART®, the availability of an instrument-specific database for a comprehensive adjustment with PDM (Process Device Managing) is a requirement. Otherwise, only the basic instrument functions, such as adjustment, are available. In the PDM environment, this instrument-specific database is called EDD (Electronic Device Description), in perfect analogy to the HART® environment which also requires, except for the VEGA HART® instruments, a DD (Device Description) for each sensor.

Master-Class 2

One or several Master-Class 2 devices can operate in a Profibus network. As a rule, Master-Class 2 devices are engineering, adjustment or visualisation stations. The VEGA adjustment software VVO (VEGA Visual Operating) operates as Master-Class 2 participant on the DP bus and can work on an engineering PC, on an adjustment PC or on the process control computer and can access any VEGA sensor on the PA level.

6 VEGAFLEX 55P (Profibus PA)

Product description

Adr. 21

SPS

Adr. 22

VVO

PA-

Adr. 23

Master-Class 1

Adr. 1

DP-Bus

Adr. 24

DP interface card as MasterClass 2 (e.g. Softing)

Adr. 10

Adr. 57

Segment coupler

Adr. 25 … 56

(max. 32 participants)

Adr. 58

Adr. 60

Adr. 59

Adjustment of the VEGAFLEX sensors from process control via a Profibus interface card in the process control computer or in an additional PC. The adjustment software VEGA Visual Operating (VVO) accesses the sensors bidirectionally via the interface (interface card).

VEGAFLEX 55P (Profibus PA) 7

Product description

Adjustment with adjustment module MINICOM

With the small (3.2 cm x 6.7 cm) 6-key adjustment module with display, you can carry out the sensor-relevant adjustments directly in the sensor.

Tank 1 m (d)

12.345

Detachable adjustment module MINICOM

The adjustment module can be plugged into the sensor or into the optional, external indicating instrument.

ESC

Tank 1 m (d)

12.345

4 ... 20 mA

ESC

Adjustment with the SIMA TIC PDM adjustment program

To adjust all essential functions of the VEGA sensor with the adjustment station SIMATIC PDM from Siemens, a so-called EDD is required. Without this EDD, only the basic functions such as min./max. wet adjustment or integration time can be adjusted with the PDM adjustment program. Further important adjustment functions, such as the input of the "

Meas. environment

are not available without EDD. After integration of the EDD files in the Simatic PDM adjustment software, all important adjustment functions are accessible. If it is not at hand, the obligatory GSD (instrument master file) as well as the EDD (Electronic Device Description) necessary for PDM can be downloaded from the VEGA Homepage (http://www.vega.com).

“ or a false echo storage,

ESC

Tank 1 m (d)

12.345

max. 25 m

Adjustment with detachable adjustment module. The adjustment module can be plugged into the sensor or into the external indicating instrument VEGADIS 50.

With the adjustment module MINICOM, you can adjust the sensor and set the basic functions. Beside setting the measurement conditions and the simulation mode, it is also possible to assign the Profibus address and carry out a false echo storage, see "4.2 Adjustment with the adjustment module MINICOM“.

8 VEGAFLEX 55P (Profibus PA)

Product description

1.5 Type code

The second digit of the type name, e.g. VEGAFLEX 5[5]… distinguishes the instruments according to the type and version of the sensor component.

The letter, e.g. VEGAFLEX 55[P] characterises the output signal: K stands for an analogue 4 … 20 mA output signal (compact instrument) P stands for a digital signal transmission for connection to Profibus PA

VEGAFLEX 55 P .CX D

D - Two-wire loop-powered / 4 … 20 mA output, HART

G - Profibus PA

CX - Ex Zone 0 EEx ia IIC T 6 nach ATEX II 1/2 G DX - Ex Zone 0 EEx d ia IIC T 6 nach ATEX II 1/2 G

P - Profibus PA K - Analogue 0 … 20 mA output signal (two-wire technology)

Instrument series with 8 mm rod and 21.3 mm tube

Measuring principle (FLEX for guided microwave)

VEGAFLEX 55P (Profibus PA) 9

Product description

1.6 Bus configuration

The type of sensor you use depends on your process requirements and mounting conditions, as well as the requirements of your control, regulative, or process control system.

VEGAFLEX 55P Profibus sensors are sensors for use in Profibus PA environment. Profile 3 has been implemented in the sensors. A measuring system consists of one or several sensors, one or several segment couplers and one DP master computer, such as e.g. a S7 PLC with Profibus interface or a process control system with Profibus DPMaster-Slot. The processing unit, e.g. the PLC, evaluates the level-proportional, digital measuring signals in a number of evaluation routines and puts them to use process-specifically.

On the following two pages, you will see schematic illustrations of the bus configuration.

The automation system as Master-Class 1 takes over bus control completely. It reads out all signals cyclically and, if necessary, gives instructions to the participants (e.g. sensors). Besides this, additional master systems (e.g. visualisation systems or adjustment tools) can be connected to the DP bus. These systems operate as so-called Master-Class 2 participants. Like the MasterClass 1 system, they can read out signals, give instructions and operate in the acyclical mode.

Each participant on the bus must have an unambiguous address. The addressing covers both bus levels. A Profibus DP network can have max. 126 participants, including all participants on the PA level. In practice, each Master-Class 1 computer gets address 1 and the Master-Class 2 computers address 10 … 20. As a rule, the slaves or participants get the addresses 21 … 126. On the Profibus PA level, max. 32 sensors can be connected on one PA segment coupler.

A DP bus does not allow power supply via signal cable, whereas the PA bus does. Both, DP and PA, require at a minimum a screened two-wire cable. The DP bus can additionally have up to 8 cores (screened), of which some can be supply cables.

10 VEGAFLEX 55P (Profibus PA)

Product description

Ex environment

In Ex environment, intrinsically safe (EEx ia) PA sensors are used with Ex segment couplers. Generally, the number of PA sensors on a segment coupler (Ex or non Ex) depends on the current requirement of the sensors and on the current supplied by the segment coupler. Segment couplers for EEx ia environment provide 90 … 110 mA. The number of sensors results from the sum of:

- the basic current intake of all sensors

- plus 9 mA communication signal

- plus the leakage currents of all sensors

- plus a recommended current reserve (approx. 10 mA)

The min. basic current has been set at 10 mA according to the Profibus specification. VEGA Profibus sensors constantly consume a basic current of 10 mA and operate without leakage current requirement, so that in Ex environment, up to max. ten VEGA sensors can be operated on one segment coupler.

VEGAFLEX 55P (Profibus PA) 11

Adresse 1

Product description

2…8

Segment coupler

PLC/DCS

Adresse

21...52

Profibus PA

21 22 52

1 … 32 Sensoren (Ex: 1 … 10)

Master-Class 2 interface card

12 VEGAFLEX 55P (Profibus PA)

Adresse 10

Product description

Profibus DP

Segment coupler

Adresse

53...84

Adresse

3~M

Adresse

Profibus PA

53 54 84

Adresse

1 … 32 sensors

VEGAFLEX 55P (Profibus PA) 13

Product description

1.7 Approvals

VEGAFLEX sensors are approved for StEx Zone 10.

Observe the attached approval documents when using a sensor in Ex environment.

1.8 Data format of the output signal

Byte4 Byte3 Byte2 Byte1 Byte0

Status Measured value (IEEE-754 Format, see below)

Status byte:

The status byte corresponds to profile 3,0 "Profibus PA Profile for Process Control Devices“ coded. The status "Measured value OK“ is coded as 80 (hex) (Bit7 = 1, Bit 6 … 0 = 0).

Measured value:

The measured value is transmitted as a 32 Bit floating point number in IEEE-754 format.

Byte n Byte n+1

Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit

7654321076543210

VZ 27262524232221202-12-22-32-42-52-62

Sign Exponent Mantissa

-7

Byte n+2 Byte n+3

Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit

7654321076543210

2-82-92

-102-112-122-132-142-152-162-172-182-192-202-212-222-23

Mantissa Mantissa

Formula: Measured value = (-1)VZ • 2

Examples: 41 70 00 00 (hex) = 0100 0001 0111 0000 0000 0000 0000 0000 (bin)

Meas. value = (-1)0 • 2

(Exponent - 127)

(130 - 127)

• (1 + 2-1 + 2-2 + 2-3)

• (1 + Mantissa)

= 1 • 23 • (1 + 0.5 + 0.25 + 0.125) = 1 • 8 • 1.875 = 15.0

14 VEGAFLEX 55P (Profibus PA)

Mounting

2 Mounting

2.1 Installation instructions

Lateral load

Make sure that the measuring rod is not subjected to strong lateral forces. Mount VEGAFLEX at a location where no interference caused by, e.g., stirrers, filling inlets, etc. can occur.

Lateral load

Pressure

In case of gauge or low pressure in the vessel, the mounting boss must be sealed on the thread. Make sure that the seal ring is resistant to the medium.

Moisture from outside

To avoid moisture ingress, the connection cable leading to the housing should be looped downward (directly in front of the cable entry), so that rain and condensation water can drain off. This mainly applies to outdoor mounting, to areas where moisture is expected (e.g. by cleaning processes) or to cooled or heated vessels.

Moisture

Cable entries

When mounting outdoors, on cooled vessels or in humid areas where cleaning is done, e.g. with steam or high pressure, the seal of the electrical cable entry is very important.

Use electrical cable with round cross-section and tighten the cable entry firmly. The cable entry is suitable for cable diameters of 5 mm to 9 mm.

VEGAFLEX 55P (Profibus PA) 15

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