VEGA FLEX67 User Manual

Operating Instructions
VEGAFLEX 67
-200 … +400 °C 4 … 20 mA/HART - two-wire
Document ID:
32311
Guided Microwave

Contents

Contents
1.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Symbolism used . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 For your safety
2.1 Authorised personnel . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Warning about misuse . . . . . . . . . . . . . . . . . . . . . . .
2.4 General safety instructions . . . . . . . . . . . . . . . . . . . .
2.5 CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Fulllment of NAMUR recommendations . . . . . . . . . .
2.7 Safety instructions for Ex areas . . . . . . . . . . . . . . . . .
2.8 Manufacturer declaration for zone 2. . . . . . . . . . . . . .
2.9 Environmental instructions. . . . . . . . . . . . . . . . . . . . .
3 Product description
3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Packaging, transport and storage . . . . . . . . . . . . . ..
4 Mounting
4.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Instructions for installation. . . . . . . . . . . . . . . . . . . . .
4 4 4
5 5 5 5 6 6 6 6 6
7
8 11 11
12 13
5 Connecting to power supply
5.1 Preparing the connection . . . . . . . . . . . . . . . . . . . . .
5.2 Connection procedure. . . . . . . . . . . . . . . . . . . . . . . .
5.3 Wiring plan, single chamber housing . . . . . . . . . . . . .
5.4 Wiring plan, double chamber housing . . . . . . . . . . . .
5.5 Wiring plan, Ex-d double chamber housing . . . . . . . .
5.6 Wiring plan - version IP 66/IP 68, 1 bar . . . . . . . . . . .
6 Set up with the indicating and adjustment module PLICSCOM
6.1 Short description . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Insert indicating and adjustment module. . . . . . . . . . .
6.3 Adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Setup steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Menu schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Saving the parameter adjustment data. . . . . . . . . . . .
7 Set up with PACTware and other adjustment programs
7.1 Connect the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Parameter adjustment with PACTware . . . . . . . . . . . .
7.3 Parameter adjustment with AMSand PDM . . . . . . .
7.4 Saving the parameter adjustment data. . . . . . . . . . . .
2 VEGAFLEX 67 • 4 … 20 mA/HART - two-wire
16 17 18 19 21 23
24 24 26 27 33 36
37 38 39 39
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8 Maintenance and fault rectication
8.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Remove interferences . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Exchanging the electronics module . . . . . . . . . . . . . .
8.4 Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Instrument repair . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Dismounting
9.1 Dismounting steps . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Supplement
10.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
10.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Industrial property rights . . . . . . . . . . . . . . . . . . . . . .
10.4 Trademark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
40 40 41 42 43
44 44
45 57 61 61
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come with the delivery. You can nd them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your VEGAFLEX 67, we oer accessories and replacement parts. The corresponding doc­umentations are:
l 27720 - VEGADIS 61 l 30207 - Electronics module VEGAFLEX series 60 l 34296 - Protective cover l 31088 - Flanges according to DIN-EN-ASME-JIS-GOST l 30391 - Spacer
Editing status: 2012-03-19
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VEGAFLEX 67 4 20 mA/HART - two-wire 3
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 rectication. Please read this information before putting the instrument into operation and kee p this manual accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained qualied personnel. The contents of this manual should be made available to these personnel and put into practice by them.

1.3 Symbolism used

Information, tip, note
This symbol indicates helpful additional information.
Caution: If this warning is ignored, faults or malfunctions can result. Warning: If this warning is ignored, injury to persons and/or serious damage to the instrument can result. Danger: If this warning is ignored, serious injury to persons and/or destruction of the instrument can result.
Ex a pplications
This symbol indicates special instructions for Ex applications.
l List
The dot set in front indicates a list with no implied sequence.
à Action
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
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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 67 is a sensor for continuous interface measurement in liquids.
You can nd detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly u sed according to the specications in the operating instructions manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbitrary conversions or modications are explicitly forbidden.

2.3 Warning about misuse

Inappropriate or incorrect use of the instrument can give rise to application-specic hazards, e.g. vessel overll or damage to system components through incorrect mounting or adjustment.

2.4 General safety instructions

This is a high-tech instrument requiring the strict observance of standard regulations and guidelines. The user must take note of the safety instructions in this operating instructions manual, the country­specic installation standards as well as all prevailing safety regulations and accident prevention rules.
The instrument must only be operated in a technically awless and reliable condition. The operator is responsible for trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine the compliance of the necessary occupational safety measures with the current valid rules and regulations and also take note of new regulations.
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VEGAFLEX 67 4 20 mA/HART - two-wire 5
2 For your safety

2.5 CE conformity

This device fullls the legal requirements of the applicable EC guidelines. By attaching the CE mark, VEGA provides a conrmation of successful testing. You can nd the CE conformity declaration in the download area of "
www.vega.com".
2.6 Fulllment of NAMUR recommendations
The device fullls the requirements of the applicable NAMUR recommendations.

2.7 Safety instructions for Ex areas

Please note the Ex-specic safety information for installation and operation in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex-approved instruments.

2.8 Manufacturer declaration for zone 2

In conformity with DIN EN 60079-15/2005 VEGAFLEX 67 is suitable for use in zone 2.
The operator must use the instrument as it was intended to be used and follow the specications of the following documents:
l this operating instructions manual l the manufacturer declaration 32905 (download under "
com")
l the applicable installation regulations
www.vega.

2.9 Environmental instructions

Protection of the environment is one of our most important duties. That is why we have introduced an environment management system with the goal of continuously improving company environmental protection.
The environment management system is certied according to DIN EN ISO 14001.
Please help us full this obligation by observing the environmental
instructions in this manual:
l Chapter "Packaging, transport and storage" l Chapter "Disposal"
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3 Product description

3.1 Structure

3 Product description
Scope of delivery
Constituent parts
The scope of delivery encompasses:
l Level sensor VEGAFLEX 67 l Documentation
- this operating instructions manual
- Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM" (optional)
- Supplementary instructions manual 31708 "Heating for in- dicating and adjustment module" (optional)
- Supplementary instructions manual "Plug connector for con- tinuously measuring sensors" (optional)
- Ex-specic "Safety instructions" (with Ex versions)
The VEGAFLEX 67 consists of the components:
l Process tting with probe l Housing with electronics l Housing cover, optionally available with indicating and adjustment
module
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VEGAFLEX 67 4 20 mA/HART - two-wire 7
1 2
3
3 Product description
Fig. 1: VEGAFLEX 67 in cable version with plastic housing 1 Housing cover with integrated indicating and adjustment module (optional)
2 Housing with electronics 3 Process tting
Type label
The type label contains the most important data for identication and use of the instrument:
l Article number l Serial number l Technical data l Article numbers, documentation
With the serial number, you can access the delivery data of the instrument via
www.vega.com, "VEGA Tools" and "serial number search". In addition to the type label outside, you can also nd the serial number on the inside of the instrument.

3.2 Principle of operation

Application range
8 VEGAFLEX 67 4 20 mA/HART - two-wire
VEGAFLEX 67 is a level sensor with coax, rod or cable probe for
continuous interface measurment.
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3 Product description
It is designed for industrial use in all areas of process technology and can be used in liquids.
Functional principle
Prerequisites for inter-
face measurement
High frequency microwave impulses are guided along a steel cable or rod or a rod inside a steel tube. When reaching the product surface, a part of the microwave impulses is reected. The other part passes the upper product and is reected a second time by the interface. The running times to the two product layers are processed by the instrument.
Upper medium (L2)
l The upper medium must not be conductive l The dielectric gure of the upper medium must be known (input
required). Min. dielectric gure: rod version 1.7; coax version 1.4. You can nd a list with the dielectric gures on our home page:
www.vega.com
l The composition of the upper medium must be stable, no varying
products or mixtures
l The upper medium must be homogeneous, no stratications within
the medium
l Min. thickness of the upper medium 100 mm l Clear separation from the lower medium, no emulsion phase, no
mull layer
l If possible, no foam on the surface
Lower medium (L1)
l The dielectric gure must be 10 higher than the dielectric gure of
the upper medium, preferably electrically conductive. Example: upper medium dielectric gure 2, lower medium at least dielectric
gure 12
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VEGAFLEX 67 4 20 mA/HART - two-wire 9
TS
d1
h1
h2
d2
1
L2
L1
3 Product description
Fig. 2: Interface measurement 1 Reference plane
d1 Distance to the interface (HART value 1) d2 Distance to the level (HART value 3) TS Thickness of the upper medium (d1 - d2) h1 Height - Interface h2 Height - Level
L1 Lower medium L2 Upper medium
Output signal
The interface is processed directly by the sensor.
The analogue output (4 20 mA) transmits the height of the interface (h1) in percent. This is also the value that is adjusted.
The display of PLICSCOM and PACTware outputs the distance to the
interface (d1) in m(d).
The HART protocol can transmit the distance to the interface - HART value 1 (d1) and the distance to the level (d2) - HART value 3.
The values can be processed e.g. with a HART interface module (HIM) or with a VEGAMET 625. VEGAMET 625 can also generate the dierence out of the two values.
Voltage supply
4 20 mA/HART two-wire electronics for voltage supply and measured value transmission on the same cable.
The supply voltage range can dier depending on the instrument version.
The data for power supply are specied 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 nd the exact voltage specications in chapter "Technical data".
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3 Product description
The optional heating requires its own operating voltage. You can nd details in the supplementary instructions manual "Heating for indicat-
ing and adjustment module".
This function is generally not a vailable for approved instruments.

3.3 Operation

The instrument can be adjusted with the following adjustment media:
l With indicating and adjustment module l with the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard, e.g. PACTware and PC
l with manufacturer-specic adjustment programs AMSor PDM l With a HART handheld

3.4 Packaging, transport and storage

Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
Your instrument was protected by packaging during transport. Its capacity to handle normal loads during transport is assured by a test according to DIN EN 24180.
The packaging of standard instruments consists of environment­friendly, recyclable cardboard. For special versions, PE foam or PE foil is also used. Dispose of the packaging material via specialised recycling companies.
Transport must be carried out under consideration of the notes on the transport packaging. Nonobservance of these instructions can cause damage to the device.
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.
Up to the time of installation, the packages must be left closed and stored according to the orientation and storage markings on the outside.
Unless otherwise indicated, the packages must be stored only under the following conditions:
l Not in the open l Dry and dust free l Not exposed to corrosive media l Protected against solar radiation l Avoiding mechanical shock and vibration
l Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
l Relative humidity 20 85 %
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VEGAFLEX 67 4 20 mA/HART - two-wire 11

4 Mounting

4 Mounting

4.1 General instructions

Suitability for the pro­cess conditions
Mounting position
Welding work
Handling
Moisture
Make sure that all parts of the instrument exposed to the process, in particular the sensor element, process seal and process tting, 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 nd the specications in chapter "Technical data" and on the type label.
Select an installation position you can easily reach for mounting and connecting as well as later retrotting of an indicating and adjustment module. The housing can be rotated by 330° without the use of any tools. Y ou can also install the indicating and adjustment module in four dierent positions (each displaced by 90°).
Before beginning the welding work, remove the electronics module from the sensor. By doing this, you avoid damage to the electronics through inductive coupling.
With threaded versions, the housing must not be used to screw in the instrument! Applying tightening forces on the housing can damage its internal parts.
Use the hexagon for screwing in.
Use the recommended cables (see chapter "Connecting to power
supply") and tighten the cable gland.
You can give your instrument additional protection against moisture penetration by leading the connection cable downward in front of the cable entry. Rain and condensation water can thus drain off. This applies mainly to outdoor mounting as well as installation in areas where high humidity is expected (e.g. through cleaning processes) or on cooled or heated vessels.
12 VEGAFLEX 67 • 4 … 20 mA/HART - two-wire
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Fig. 3: Measures against moisture penetration
4 Mounting
Measuring range
Pressure
Mounting position
The reference plane for the measuring range of the sensors is the sealing surface of the thread or ange.
Keep in mind that a min. distance must be maintained below the reference plane and p ossibly also at the end of the probe ­measurement in these areas is not possible (dead band). Particularly 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 dead bands are listed in chapter "Technical data". Keep in mind for the adjustment that the default setting for the measuring range refers to water.
The process tting must be sealed if there is gauge or low pressure in the vessel. Before use, check if the seal material is resistant against the measured product and the process temperature.
The max. permissible pressure is specied in chapter "Technical data" or on the type label of the sensor.

4.2 Instructions for installation

When mounting the cable and rod versions of VEGAFLEX 67 keep at least a distance of 300 mm (11.81 in) to other vessel installations or to the vessel wall.
During operation, the probe must not touch any installations or the vessel wall. If necessary, fasten the probe end.
In vessels with conical bottom it can be advantageous to mount the sensor in the center of the vessel, as measurement is then possible down to the lowest point of the bottom. When using the cable version,
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VEGAFLEX 67 4 20 mA/HART - two-wire 13
4 Mounting
keep in mind that measurement down to the tip of the probe is not possible. The exact value of the min. distance (lower dead band) is stated in chapter "Technical data".
Fig. 4: Vessel with conical bottom
Inowing medium
Make sure that the probe is not subjected to strong lateral forces. Mount VEGAFLEX 67 at a position in the vessel where no
disturbances, e.g. from lling openings, agitators, etc., can occur.
Fig. 5: Lateral load
Extreme vibration caused by the system, e.g. due to agitators or turbulence in the vessel from inowing medium, can cause the coax probe of VEGAFLEX 67 to vibrate in resonance. With coax probes of
14 VEGAFLEX 67 • 4 … 20 mA/HART - two-wire
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1
2
4 Mounting
more than 1 m (3.281 in) length, you must secure the probe by fastening a suitable insulated brace or guy directly above the end of the rod.
Fixing
Temperature insulation
If there is a danger of the probe touching the vessel wall during operation due to product movements or agitators etc., the measuring probe should be securely xed.
In the gravity weight there is a thread (M12), e.g. for a ring bolt (optional) - (article no. 2.27424).
Make sure that the probe cable is not completely taut. Avoid tensile loads on the cable.
Avoid undened cable-vessel connections, i.e. the connection must be either grounded reliably or isolated reliably. Any deviation from this requirement can lead to measurement errors.
VEGAFLEX 67 should be integrated in the vessel insulation. This prevents the electronics from strong heating or cooling by temperature radiation.
Make sure that with heated or cooled vessels the permissible ambient temperature on the housing is not exceeded. The permissible ambient temperature is stated in chapter "Technical data" under "Ambient
conditions".
Fig. 6: Vessel with temperature insulation 1 Temperature insulation
2 Ambient temperature on the housing
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VEGAFLEX 67 4 20 mA/HART - two-wire 15

5 Connecting to power supply

5 Connecting to power supply

5.1 Preparing the connection

Safety instructions
Voltage supply
Connection cable
Cable gland ½ NPT
Always keep in mind the following safety instructions:
l Connect only in the complete absence of line voltage l If overvoltage surges are expected, overvoltage arresters should
be installed
Tip:
We recommend using VEGA overvoltage arresters B63-48 and ÜSB 62-36G.X.
In hazardous areas you must take note of the respective regulations, conformity and type approval certicates of the sensors and power supply units.
Power supply and current signal are carried on the same two-wire cable. The voltage supply range can dier depending on the instrument version.
The data for power supply are specied in chapter "Technical data".
Provide a reliable separation between the supply circuit and the mains
circuits according to DIN VDE 0106 part 101. The VEGA power supply units VEGATRENN 149A Ex, VEGASTAB 690 as well as all
VEGAMETs and VEGASCANs meet this requirement.
Keep in mind the following additional factors that inuence the
operating voltage:
l Output voltage of the power supply unit can be lower under
nominal load (with a sensor current of 20.5 mA or 22 mA in case of fault message)
l Inuence of additional instruments in the circuit (see load values in
chapter "Technical data")
The instrument is connected with standard two-wire cable without screen. If electromagnetic interference is expected which is above the test values of EN 61326 for industrial areas, screened cable should be used.
Use cable with round cross-section. A cable outer diameter of 5 … 9 mm (0.2 0.35 in) ensures the seal eect of the cable gland. If you are
using cable with a dierent diameter or cross-section, exchange the seal or use a suitable cable gland.
We generally recommend the use of screened cable for HART multidrop mode.
On the instrument with cable entry ½ NPT and plastic housing there is a metallic ½" threaded insert moulded into the plastic housing.
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16 VEGAFLEX 67 • 4 … 20 mA/HART - two-wire
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 inuence 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. In the sensor, the screen must be connected directly to the internal ground terminal. The ground terminal on the outside of the housing must be connected to the potential equalisation (low impedance).
If potential equalisation currents are expected, the connection on the processing side must be made via a ceramic capacitor (e. g. 1 nF, 1500 V). The low frequency potential equalisation currents are thus suppressed, but the protective eect against high frequency interfer­ence signals remains.
Warning:
Within galvanic plants as well as vessels with cathodic corrosion protection there are considerable potential dierences. Considerably equalisation currents can be caused via the cable scrren when the screen is earthed on both ends. To avoid this, the cable screen must only connected to ground potential on one side of the switching cabinet in such applications. The cable screen must not be connected to the internal ground terminal in the sensor and the outer ground terminal on the housing not to the potential equalisation!
Information:
The metallic parts of the instrument (transmitter, process tting, etc.) are conductively connected with the inner and outer ground terminal on the housing. This connection exists either as a direct metallic contact or via the shielding of the special connection cable on instruments with external electronics. You can nd specications on the potential connections within the instrument in chapter "Technical
data".
Take note of the corresponding installation regulations for Ex applications. In particular, make sure that no potential equalisation currents ow over the cable screen. In case of grounding on both sides this can be achieved by the use of a capacitor or a separate potential equalisation.

5.2 Connection procedure

Proceed as follows:
1 Unscrew the housing cover
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VEGAFLEX 67 4 20 mA/HART - two-wire 17
5 Connecting to power supply
2 If an indicating and adjustment module is installed, remove it by
turning it to the left.
3 Loosen compression nut of the cable entry 4 Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires 5 Insert the cable into the sensor through the cable entry 6 Lift the opening levers of the terminals with a screwdriver (see
following illustration) 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. The seal ring must
completely encircle the cable
12 Screw the housing cover back on The electrical connection is nished.

5.3 Wiring plan, single chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-ia version.
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I²C
Display
1 2 5 6 7 8
3
4
1
2
I2C
Display
1
1 2 5
6 7 8
Electronics and connec­tion compartment
Wiring plan
5 Connecting to power supply
Fig. 8: Electronics and connection compartment, single chamber housing
1 Plug connector for VEGACONNECT (I²C interface)
2 Spring-loaded terminals for connection of the external indication VEGADIS
61 3 Ground terminal for connection of the cable screen 4 Spring-loaded terminals for voltage supply
Fig. 9: Wiring plan, single chamber housing 1 Voltage supply, signal output

5.4 Wiring plan, double chamber housing

The following illustration apply to non-Ex as well as Ex ia versions. The Exd version is described in the next subchapter.
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1
3
2
Display
1 2 5 6 7 8
I2C
1
2
3
Display
1 2
I2C
5 Connecting to power supply
Electronics compart­ment
Connection compart­ment
Fig. 10: Electronics compartment, double chamber housing 1 Plug connector for VEGACONNECT (I²C interface)
2 Internal connection cable to the connection compartment 3 Terminals for VEGADIS 61
Fig. 11: Connection compartment double chamber housing 1 Spring-loaded terminals for voltage supply
2 Plug connector for VEGACONNECT (I²C interface) 3 Ground terminal for connection of the cable screen
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