VEGA PULS45 User Manual

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Operating Instructions

VEGAPULS 42, 44 and 45 – VBUS

Level and Pressure

Contents

Safety information ........................................................................ 3

Note Ex area ................................................................................ 3

1 Product description

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

1.2 Application features ............................................................. 6

1.3 Adjustment ............................................................................ 6

2 Types and versions

2.1 Overview .............................................................................. 9

2.2 Type code........................................................................... 11

2.3 Antennas............................................................................. 12

3 Mounting and installation

3.1 General installation instructions ........................................ 14

3.2 Measurement of liquids ..................................................... 16

3.3 Measurement in standpipe (surge or bypass tube) ...... 18

3.4 False echoes ...................................................................... 25

3.5 Installation mistakes ........................................................... 27

Contents

4 Electrical connection

4.1 Connection and connection cable .................................... 30

4.2 Connection of the sensor .................................................. 33

4.3 Connection of the external indicating instrument

VEGADIS 50 ....................................................................... 34

4.4 Configuration of measuring systems ............................... 35

2 VEGAPULS 42, 44 and 45 – VBUS

Contents

5Setup

5.1 Adjustment structure ......................................................... 42

5.2 Adjustment with the PC on the signal

conditioning instrument ...................................................... 43

5.3 Adjustment with VEGAMET or MINICOM ........................ 69

5.4 Adjustment with the PC on VEGALOG ............................ 76

6 Diagnosis

6.1 Simulation ............................................................................ 82

6.2 Error code .......................................................................... 82

7 Technical data

7.1 Data ..................................................................................... 83

7.2 Approvals ........................................................................... 88

7.3 Dimensions ......................................................................... 89

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.

VEGAPULS 42, 44 and 45 – VBUS 3

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.

1 Product description

Product description

VEGAPULS series 40 sensors are a newly developed generation of very compact, small radar sensors for high resolution and accuracy. They are characterised by special focusing features for level measurement in narrow space applications. With modest space requirements they were developed for measuring distances of 0 … 4 m/10 m/20 m and for standard applications such as storage vessels and buffer tanks as well as for process tanks. With small housing dimensions and process fittings, the compact sensors monitor your levels at reasonable cost. With the integrated display they enable high precision level measurements and due to their advantages, radar sensors have increasingly become the standard solution for many applications, even for those where it was previously unthinkable due to high costs.

VEGAPULS 40 radar sensors utilise two-wire technology perfectly. The supply voltage and the output signal are transmitted via one twowire cable. They provide a digital output signal (VBUS or Profibus) or an analogue 4 … 20 mA signal as output or measuring signal.

This operating instruction manual relates to VEGAPULS 42, 44 and 45 sensors with digital VBUS output signal (VEGA-Bus).

1.1 Function

Radio detecting and ranging: Radar.

VEGAPULS radar sensors are used for noncontact, continuous distance measurement. The measured distance corresponds to a filling height and is outputted as level.

Measuring principle:

emission – reflection – reception

Tiny 26 GHz radar signals are emitted from the antenna of the radar sensor as short pulses. The radar impulses reflected by the sensor environment and the product are received by the antenna as radar echoes. The running period of the radar impulses from emission to reception is proportional to the distance and hence to the level.

Meas. distance

emission - reflection - reception

The radar impulses are emitted by the antenna system as pulse packages with a pulse duration of 1 ns and pulse intervals of 278 ns; this corresponds to a pulse package frequency of 3.6 MHz. In the impulse intervals, the antenna system operates as receiver. Signal running periods of less than one billionth of a second must be processed and the echo image evaluated in a fraction of a second.

1 ns

278 ns

Pulse sequence

4 VEGAPULS 42, 44 and 45 – VBUS

Product description

VEGAPULS radar sensors can accomplish this through a special time transformation procedure which spreads out the more than

3.6 million echo images per second in a slowmotion picture, then freezes and processes them.

Time transformation

Hence, it is possible for the VEGAPULS 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 time-consuming frequency analysis (e.g. FMCW, required by other radar techniques).

Virtually all products can be measured

Radar signals are physically similar to visible light. According to the quantum theory they propagate through empty space and are therefore not dependent, like e.g. sound waves, on a conductive medium. And like all electromagnetic waves, they travel at the speed of light. The radar signals react to two primary electrical properties:

- the electrical conductivity of a substance.

- the dielectric constant of a substance.

All products which are electrically conductive or have a dielectric constant greater than ε

1.6 have sufficiently good reflection charac-

teristics for reliable radar measurement. (Note: air has a dielectric constant ε The signal reflection increases with the con-

of 1).

ductivity or with the dielectric constant of the product. Therefore virtually all products can be measured.

50 40 30 20 10

5 %

4 6 8 12 14 16 18

25 %

40 %

Reflected radar power dependent on the dielectric constant of the measured product

With standard flanges between DN 50 and DN 150, ANSI 2" to ANSI 6" or G 1½ A and 1½" NPT the sensor antenna systems are adapted to the various products and measuring environments.

High quality materials withstand also extreme chemical and physical conditions. The sensors deliver reliable, precise and long-term stable, reproducible level signals.

Continuous and reliable

Unaffected by temperature, pressure and individual gas atmospheres, VEGAPULS radar sensors are used for quick and reliable continuous level measurement of various products.

0,03 0,02 0,01

100 500 1000 1300 ˚C

0,018 %

Temperature influence: Temperature error absolutely zero (e.g. at 500°C 0.018 %)

0,29 %

1,44 %

20 30 40 60

Pressure influence: Error with pressure increase very low (e.g. at 50 bar 1.44 %)

0,023 %

2,8 %

70 80 90 110 120 130 140

100

3,89 %

bar

VEGAPULS 42, 44 and 45 – VBUS 5

Product description

1.2 Application features

Applications

• Level measurement of all liquids.

• Measurement also in vacuum.

• All slightly conductive substances and all substances with a dielectric constant > 2.0 can be measured.

• Measuring range 0 … 10 m (type 42). Measuring range 0 … 20 m (type 44). Measuring range 0 … 4 m (type 45).

Two-wire technology

• Power supply and output signal on one two-wire cable (loop powered).

• VBUS output signal (VEGA-Bus).

Rugged and wear-free

• Non-contact.

• High resistance materials.

Exact and reliable

• Accuracy 0.05 %.

• Resolution 1 mm.

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

• Unaffected by varying density and temperature of the medium.

• Measurements of pressures up to 40 bar and temperatures up to 150 °C.

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.

Adjustment and parameter setting of the radar sensors is done with

- the PC and the adjustment program VVO

- the detachable adjustment module MINICOM

- the VEGAMET signal conditioning instrument

Adjustment with the PC

Setup and adjustment of the radar sensors is generally done on the PC with the adjustment program VEGA Visual Operating (VVO) under Windows graphics and process visualisation, the program leads you quickly through adjustment and parameterisation.

®.

By means of pictures,

Communicative

• Integrated display of measured values.

• Optional display separate from the sensor.

• Adjustment with detachable adjustment module which can be plugged into the sensor or into the external display.

• Adjustment with signal conditioning instrument.

• Adjustment with PC.

Approvals

The adjustment program recognises the sensor type

• CENELEC, ATEX, PTB, FM, CSA, ABS, LRS, GL, LR, FCC, RINA.

Visualised creation of a vessel linearisation curve

6 VEGAPULS 42, 44 and 45 – VBUS

Product description

Note:

The adjustment program VVO must be available in version 2.70 or higher.

The PC can be connected to any position of the system or the signal cable. It is connected with the two-wire PC interface converter VEGACONNECT 2 to th e sensor, the signal cable or the signal conditioning instrument. The sensor is connected directly to the VEGALOG processing system with the standard cable (RS 232).

Adjustment with the PC on the digital signal and supply cable between sensors and VEGAMET signal conditioning instrument or directly on the sensor

…

1 ... 15

CPU

VEGALOG

571 CPU

571 EA

Adjustment on the digital signal and supply cable to the VEGALOG 571 processing system or directly on the sensor

The adjustment and parameter setting data can be saved on the PC with the adjustment software and protected by passwords. The adjustments can be quickly transferred to other sensors if required.

......

CPU

1...15

VEGALOG

571 CPU

571 EA

Adjustment with the PC on the VEGALOG processing system with standard cable RS 232 (up to 15 sensors can be operated on one two-wire cable with the processing system)

Adjustment with the PC on the VEGAMET signal conditioning instrument, to which one or two sensors can be connected

VEGAPULS 42, 44 and 45 – VBUS 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 carry out the adjustment in clear text dialogue. For this purpose, the adjustment module can be plugged into the radar sensor or into the optional external indicating instrument.

Tank 1 m (d)

12.345

Detachable adjustment module MINICOM

Unauthorised sensor adjustments can be prevented by removing the adjustment module.

ESC

Tank 1

m (d)

12.345

ESC

Tank 1

m (d)

12.345

ESC

100

ESC

CONNECT

513

Adjustment with the VEGAMET signal conditioning instrument

The radar sensors with digital output signal can be adjusted, besides with the PC, also with the VEGAMET signal conditioning instrument.

100

ESC

CONNECT

515V

6-key adjustment field on the instrument front of the VEGAMET signal conditioning instrument

For adjustment, the digital VEGAMET 514V and 515V signal conditioning instruments are provided with a 6-key adjustment field with display. Here you can carry out the parameter setting in clear text dialogue. Using the 6-key adjustment field, it is also possible to adjust one or two connected sensors with the signal conditioning instrument. The adjustment scheme corresponds to that of the adjustment module MINICOM.

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

8 VEGAPULS 42, 44 and 45 – VBUS

Types and versions

2 Types and versions

2.1 Overview

Series 40 sensors are manufactured in three basic versions, VEGAPULS 42, VEGAPULS 44 and VEGAPULS 45.

VEGAPULS 42 sensors are characterised by

G 1

/2 A or 11/2" NPT thread as process fitting. These sensors are equipped as standard versions with a ø 40 mm horn as antenna.

VEGAPULS 44 sensors are characterised by a DIN or ANSI flanges as process fitting. In standard version they are manufactured with DN 50, 80, 100 and 150 as well as with ANSI 2", 3", 4" and 6". The bigger flanges come equipped with respectively larger antenna horns (ø 48, 75 and 95 mm).

Generally: The bigger the antenna horn, the better the focusing characteristics, and the better the antenna gain. This ensures that even a weak product echo can be detected reliably as level echo.

VEGAPULS 45 sensors come completely equipped with a measuring tube of 4 m length. These sensors are used in applications where high accuracy is required or for liquids with very low dielectric constant such as e.g. liquid gas.

VEGAPULS 42

VEGAPULS 45 with thread G 1½ A or 1½" NPT

VEGAPULS 44

VEGAPULS 45 with flange

VEGAPULS 42, 44 and 45 – VBUS 9

Types and versions

Features

General features

• Measurement preferably of liquids in storage tanks or process vessels with increased accuracy requirement.

• Measuring range 0 … 4 m, 0 … 10 m or 0 … 20 m.

• Ex approved in Zone 1 (IEC) or Zone 1 (ATEX) classification mark EEx ia [ia] IIC T6.

• Integrated display of measured values.

Overview

PS42XXE… PS44XXE… PS45XXXE…

Signal output

- VBUS (VEGA-Bus) • • •

Antenna

- horn antenna • • –

- pipe antenna

1) 1)

•

Process fitting

- G 1½ A; 1½" NPT • – •

- DN 50; ANSI 2" – • •

- DN 80; ANSI 3" – • •

- DN 100; ANSI 4" – • •

- DN 150; ANSI 6" – • •

Adjustment

-PC •••

- adjustment module in the sensor • • •

- adjustment module in external indicating instrument • • •

- with signal conditioning instrument • • •

Measuring range 0 … 4 m

- ø 40 mm horn 0 … 10 m – (depending on the

- ø 48 mm horn 0 … 15 m 0 … 15 m tube length)

- ø 75 mm horn 0 … 20 m 0 … 20 m

- ø 95 mm horn 0 … 20 m 0 … 20 m

When mounting on a standpipe or bypass tube, a pipe antenna is created. The tube inner diameter should be between 40 mm and 80 mm.

10 VEGAPULS 42, 44 and 45 – VBUS

Types and versions

2.2 Type code

PS 42 .XX X X X XXX X X

K - Plastic housing PBT, M20 x 1.5 cable entry N - Plastic housing PBT, ½" NPT cable entry A - Aluminium housing, M20 x 1.5 cable entry D - Aluminium housing, ½" NPT cable entry in Exd connection

housing

V - Seal of the antenna system: Viton A - Seal of the antenna system: Kalrez

G - Process fitting G 1½ N - Process fitting 1½" NPT

ABC- Process fitting DN 50 PN 40 BBE- Pr ocess fitting DN 80 PN 40 CBG-Process fitting DN 100 PN 16 DBG-Process fitting DN 150 PN 16 ARC- Process fitting ANSI 2" 150 psi BRE- Pr ocess fitting ANSI 3" 150 psi CRG-Process fitting ANSI 4" 150 psi DRG-Process fitting ANSI 6" 150 psi YYY- Process fitting on request

X - without display A - with integrated display

X - without adjustment module MINICOM B - with adjustment module MINICOM (mounted)

B - 20 … 72 V DC; 20 … 250 V AC; 4 … 20 mA, HART

(four-wire)

D - Two-wire (loop powered), 4 … 20 mA, HART

E - Power supply via signal conditioning instrument G - Segment coupler for Profibus PA

XX - FTZ (standard telecommunication approval Germany) AX - Approval in Ex-Zone 1, EEx ia IIC T6 CX - Approval in Ex-Zone 0, EEx ia IIC T6 BX - Approval in Ex-Zone 1 (Exd connection housing) DX - Approval in Ex-Zone 0 (Exd connection housing)

Type 42: with screwed process fitting Type 44:Instrument series with flange connection Type 45: with measuring tube

PS: Radar sensors series 40

VEGAPULS 42, 44 and 45 – VBUS 11

Types and versions

2.3 Antennas

The antenna is the eye of the radar sensor. A casual observer would never guess how carefully the antenna geometry must be adapted to the physical properties of electromagnetic fields. The geometrical form determines focal properties and sensitivity - the same way it determines the sensitivity of a unidirectional microphone.

For various application purposes, measurement conditions and process requirements, series 40 sensors are available with three antenna forms as VEGAPULS 42, VEGAPULS 44 and VEGAPULS 45.

VEGAPULS 42 sensors are characterised by

G 1

/2 A or 11/2" NPT thread as process fitting. These sensors are equipped as standard versions with a ø 40 mm horn as antenna.

Generally: The bigger the antenna horn, the better the focusing characteristics, and the better the antenna gain. This ensures that even a weak product echo can be detected reliably as level echo.

VEGAPULS 45 sensors are characterised by integrated measuring tube. The measuring tube serves the radar signals as a waveguide in which no emitted energy is lost. The complete emitted energy is returned as reflection energy. Due to this, also products with very weak reflection characteristics,

such as light petrol, liquid gas with of 1.4 … 2.0 can be reliably detected.

values

Viscous or adhesive products cannot be measured with VEGAPULS 45.

Horn antennas

Horn antennas focus the radar signals very well. Manufactured from 1.4435 (StSt) or Hastelloy C22, they are very rugged, and both physically and chemically resistant. They are suitable for pressures up to 40 bar and for medium temperatures up to 150°C. The horn

VEGAPULS 42

diameters determine the focusing of the radar signals. The antenna gain increases with increasing horn diameter (40, 48, 75, 95 mm). The antenna gain represents the relation between transmitted energy and received echo energy.

VEGAPULS 44

12 VEGAPULS 42, 44 and 45 – VBUS

Types and versions

Pipe antennas

Pipe antennas composed of horn antenna and standpipe or bypass tube

Horn antennas on a standpipe or bypass tube form a complete antenna system in conjunction with a measuring pipe (which must not be perfectly straight, but can also have bends). For the radar signals, the measuring pipe acts as a conductor. The running time of the radar signal changes in the pipe and depends on the pipe diameter. The sensor must be therefore informed about the tube inner diameter so that the running time can be taken into account and precise level signals are delivered. Pipe antennas are best suited for turbulent applications and products with very low dielectric constant.

The antennas are characterised by a very high antenna gain. As a result, high reliability is achieved even with products having very poor reflection properties.

VEGAPULS 42 pipe antenna composed of horn antenna and bypass tube

VEGAPULS 44 pipe antenna composed of horn antenna and bypass tube

VEGAPULS 45 with thread, pipe antenna integrated in the sensor

VEGAPULS 45 with flange, pipe antenna integrated in the sensor

Pipe antenna integrated in the sensor

VEGAPULS 45 series originated as a further development of VEGAPULS 42 and 44 sensors combined with a surge pipe or bypass tube. This sensor is equipped with an optimised measuring tube up to 4 m long and enables high precision level measurement also in products with very small dielectric figures of ε liquid gas).

VEGAPULS 42, 44 and 45 – VBUS 13

= 1,4 … 1,8 (e.g.

3 Mounting and installation

3.1 General installation instructions

Mounting and installation

Measuring range

The reference plane for the measuring range of the sensors is the flange face or the seal shoulder of the thread. For measurements in

Keep in mind that in measuring environments where the medium can reach the sensor flange, buildup can occur on the antenna and

can cause measurement errors. surge or bypass pipes with VEGAPULS 45 the max. measuring distance depends on the tube length.

Reference plane

max. filling

Measuring range (operating range) and max. measuring distance Note: Use of the sensors for applications with solids is limited.

full

empty

Meas. range

max. measuring distance 20 m (type 45: 4 m)

Note: The use of series 40 sensors for solids

is restricted.

max.

min.

Interfering reflections

Flat obstructions and struts cause large interfering reflections. They reflect the radar signal with high energy density. Rounded profile interfering surfaces scatter the radar signals in all directions and thus cause interfering reflections of lower energy density. Hence, they ar e less critical than reflections from a flat surface.

If flat obstructions in the range of the radar

signals cannot be avoided, we recommend

diverting the interfering signals with a deflec-

tor. Through scattering, the interfering signals

will be low in amplitude and so diffuse that

they can be filtered out by the sensor.

max.

min.

Rounded profiles diffuse radar signals

Profiles with flat surfaces cause stronger interfering signals

A deflector causes signal scattering

14 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

Emission cone and interfering reflections

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. The form and intensity of the emission cone depend on the antenna used.

Any object in this beam cone causes a reflection of the radar signals. Within the first few meters of the beam cone, tubes, struts or other installations can interfere with the measurement. At a distance of 6 m, the false echo of a strut has an amplitude nine times greater than at a distance of 18 m.

At greater distances, the energy of the radar signal distributes itself over a larger area, thus causing weaker echoes from obstructing surfaces. The interfering signals are therefore less critical than those at close range.

If possible, orient the sensor axis perpendicularly to the product surface and avoid vessel installations within the 100 % area of the emission cone, e.g. tubes or struts.

The illustrations of the emission cones are simplified and represent only the main beam

- a number of weaker beams also exist. Under difficult measuring conditions, the alignment of the antenna must be such that the lowest possible false echo values appear. Only giving attention to the size of the useful echo is not always adequate when measuring conditions are unfavourable.

Optimum measuring conditions exist when the emission cone reaches the measured product perpendicularly and when the emission cone is free of obstructions.

0 m

Meas. distance

10 m

Emission cone of a VEGAPULS 42 with screw-on antenna and with ø 40 mm horn

Meas. distance

3,50 1,90 3,501,900

0 m

VEGAPULS 42

22˚

30˚

50%

18˚

25˚

25%

VEGAPULS 44 with ø 48 mm horn

In a difficult measurement environment, searching for a mounting location with the lowest possible false echo intensity will bring the best results. In most cases, the useful echo will then be present with sufficient strength. With the adjustment software VVO

25%

on the PC, you can have a look at the echo image and optimise the mounting location (see chapter "5.2 Adjustment with the PC – Sensor optimisation – Echo curve").

If possible, provide a "clear view" to the prod-

15 m

4,0 2,3 4,02,30

Emission cone of a DN 50 flange antenna

50%

uct inside the emission cone and avoid vessel installations in the first third of the emission cone.

VEGAPULS 42, 44 and 45 – VBUS 15

Mounting and installation

0 m

Meas. distance

20 m

3,0 1,7 3,01,70m

VEGAPULS 44 with ø 75 mm horn

10˚

20˚

50%

Emission cone of a DN 80 flange antenna

0 m

VEGAPULS 44 with ø 95 mm horn

25%

3.2 Measurement of liquids

Flange antennas

In most cases, 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

antenna must always protrude out of the

flange tube.

When the DIN socket piece is longer, please

make sure that the horn antenna is not cov-

ered completely by the socket. It is better if

the antenna protrudes slightly out of the

socket.

Reference plane

< 135 mm (DN 50) < 210 mm (DN 80) < 310 mm (DN 100, DN 150)

Mounting on DIN socket piece

When mounting on dished vessel tops, the

antenna length should at least correspond to

the length of the longer sockets.

Vessel center or symmetry axis

Meas. distance

8˚

14˚

25%

<135…310mm (250…425mm with antenna extension)

Mounting on a dished vessel top; max. socket length

20 m

2,5 1,3 2,51,30

50%

depending on flange size and, if applicable, on the length of the antenna extension (see "7.3 Dimensions").

Emission cone of a DN 100 and DN 150 flange antenna

16 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

On dished tank ends, please do not mount the instrument in the centre or close to the vessel wall, but approx.

/2 vessel radius from

the centre or from the vessel wall.

Dished tank ends can act as paraboloidal reflectors. If the radar sensor is placed in the focal point of the parabolic tank, the radar sensor receives amplified false echoes. The radar sensor should be mounted outside the focal point. Parabolically amplified echoes can be thereby avoided.

Vessel center or symmetry axis

Reference plane

½ vessel radius

Mounting on dished tank ends

If the stability of the vessel will allow it (sensor weight), flat mounting directly on the vessel top is a good and economical solution. The top side of the vessel is the reference plane.

Screw-on antenna

The screw-on antenna is mainly used on small vessels. The antenna fits on small vessel openings down to 1 must not be longer than 135 mm (when using the longer antenna, not longer than 250 mm).

Screw-on antenna on socket piece 11/2"

Screw-on antenna with antenna extension on socket piece 1½"

/2" socket. The socket

Reference plane

≤ 135 mm

≤ 250 mm

As an alternative to socket mounting, the screw-on antenna can be screwed into the

Reference plane

Mounting directly on the flat vessel top

VEGAPULS 42, 44 and 45 – VBUS 17

hole in the vessel.

Rod antenna directly on vessel opening

Mounting and installation

3.3 Measurement in standpipe

(surge or bypass tube)

General instructions

Pipe antennas are preferred in vessels which contain many installations, e.g. heating tubes, heat exchangers or fast-running stirrers. Measurement is then possible where the product surface is very turbulent, and vessel installations cannot cause false echoes.

Through the focusing of the radar signals within the measuring tube, even products with low dielectric constant (ε be measured reliably in the surge or bypass tube. Note the following instructions.

Surge pipe welded to the tank

Type label

= 1.6 to 3) can

Surge pipe in the socket piece

maxmax

Make sure the required upper vent hole in

the surge pipe is aligned with the sensor

type label.

As an alternative to a surge pipe in the ves-

sel, a pipe antenna system outside the ves-

sel in a bypass tube is also possible.

The surge and bypass tubes must generally

be made of metal. For plastic tubes, a

closed, conductive jacket is always required.

For metal tubes with plastic inner coating,

make sure that the thickness of the coating is

minimal (approx. 2 … 4 mm).

Align the sensor such that the type label lies

on one axis with the tube holes or the tube

connection openings. The polarisation of the

radar signal enables a considerably more

stable measurement with this alignment.

Type label

> 300 mm

100 %

Vent hole ø 5 … 10 mm

0 %

Tube flange system as bypass tube

When mounting a VEGAPULS 42 or 44 sen-

sor on a bypass tube (e.g. on a previous

min

without deflector

Pipe antenna systems in the tank

with deflector

min

floating or displacer unit), the radar sensor

should be mounted at a distance of approx.

300 mm or more from the max. level.

The surge or bypass tubes open at the bottom should reach to the requested min. level, since a reliable measurement is only possible within the pipe. The tube inner diameter should be max. 100 mm and correspond with the size of the antenna horn.

18 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

> 300 mm

100 %

75 %

0 %

Extended bypass tube on a vessel with intense product movements

For products with small dielectric constants (< 4), a bypass tube longer than that required by the lower tube connection should be used. Products with small dielectric constants are partly penetrated by the radar signals, so that the tube bottom delivers a stronger echo than the product (when the bypass tube is nearly empty). As a result of the extension of the lower tube end, sufficient liquid will remain even when the vessel is emptied.

With a liquid quantity of 300 … 800 mm in the blind lower end of the tube, the portion of the signal that penetrates the liquid and reflects from the tube bottom is sufficiently damped the sensor can then easily distinguish it from the echo of the liquid surface. If not enough liquid remains, a deflection plate located at the bottom of a vertical pipe can provide the same function. It deflects the signal reflected from the tube end sideways into the standard tube opening.

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.

• Large welding beads in the tubes should be avoided.

• Additional connections to the bypass tube are more suitable if they lie on the same plane as the upper and lower vessel connection (superimposed or displaced by 180°).

Type label

> 300 mm

100 %

Optimum connection to the bypass tube

0 %

Bypass tube with tube stub

VEGAPULS 42, 44 and 45 – VBUS 19

300 ... 800 mm

Welding beads too large

Tube connection protrudes

Mounting and installation

Conducting tube

Conducting tube in existing surge or bypass tube

To increase the min. distance, the conducting tube can protrude out of the surge or bypass tube. For this purpose, a plain flange can be welded at the required position on the outside of the extended conducting tube. In both cases, an adequate vent hole must be provided.

Additional connection to the bypass tube in one plane

Use of conducting tubes

(VEGAPULS 44)

In case of very rough inner surfaces in existing bypass tubes (e.g. due to corrosion) or in case of big connection openings as well as bypass tubes with an inner diameter of more than 100 mm, the use of a conducting tube in the existing bypass tube is recommended. This reduces the noise level and increases reliability considerably. The flange of the conducting tube can be easily mounted as a sandwich flange between vessel and sensor flange.

20 VEGAPULS 42, 44 and 45 – VBUS

Extended conducting tube

Mounting and installation

Seals on tube connections and tube extensions

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 seal used should correspond to the tube inner diameter.

• If possible, conductive seals such as conductive PTFE or graphite should be used, especially for thicker seals.

• Make sure that there are only a few seal positions on a conducting tube.

Flange connections on bypass tubes

Adhesive products

For slightly adhesive products, choose a surge pipe with e.g. a nominal width of 50 mm. VEGAPULS 42 and 44 radar sensors with 26 GHz technology are relatively insensitive to buildup in the tube. Nevertheless, buildup must not be allowed to plug up the tube completely.

For adhesive products, the use of a DN 80 to max. DN 100 stand/surge pipe can enable measurement in spite of buildup. Products that cause excessive buildup cannot be measured in a standpipe.

VEGAPULS 45 with integrated measuring tube

The sensor version VEGAPULS 45 is especially developed for measuring tube applications and is supplied complete with a 27 mm measuring tube. With a measuring tube length up to 4 m, this sensor version is suitable e.g. for the use in existing standpipes.

max

min

VEGAPULS 45 with integrated measuring tube in a free vessel or in an existing bypass pipe

Note:

VEGAPULS 45 sensors with integrated measuring tube are equipped with a threaded process fitting or a flange connection. For sensors with threaded process fitting, make sure that the complete sensor, i.e. also the sensor housing, turns when screwing in. The sensor housing is fastened with a clipped connection. This sensor housing must not be turned with respect to the measuring tube or even loosened. Otherwise the radar signal coupling would be destroyed and the sensor would not function proberly.

VEGAPULS 42, 44 and 45 – VBUS 21

Mounting and installation

If you want to measure inhomogeneous products or stratified products in a surge pipe, it must have holes, elongated holes or slots. These openings ensure that the liquid is mixed and corresponds to the liquid in the vessel.

The more inhomogeneous the measured product, the closer the openings should be spaced.

Due to radar signal polarisation, the holes or slots must be positioned in two rows offset by 180°. The radar sensor must then be mounted so that the type label of the sensor is aligned with the rows of holes.

VEGAPULS 45 with integrated measuring tube (surge pipe) measures between the heating spirals

Standpipe measurement of inhomogeneous products

ø 5...15

homogeneous liquids

slightly inhomogeneous liquids

ø 5...15

Every wider slot causes a false echo. The slots should therefore not exceed a width of 10 mm, to keep the signal-to-noise ratio at a minimum. Round slot ends are better than rectangular ones.

Type label

ø 5...15

VEGAPULS 44: Rows of holes on one axis with the type label

inhomogeneous liquids

Openings in a surge pipe for mixing of inhomogeneous products

22 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

Surge pipe with ball valve

If a ball valve is mounted in the surge pipe, maintenance and servicing can be carried out without opening the vessel (e.g. if it contains liquid gas or toxic products).

Ball valve

ø50

Tube antenna system with ball valve cutoff in measuring tube

A prerequisite for trouble-free operation is a ball valve throat that corresponds to the pipe diameter and provides a flush surface with the pipe inner wall. The valve must not have any rough edges or constrictions in its channel and should have a min. distance of 300 mm from the sensor flange.

> 300 mm

Vent hole

Deflector

Guidelines for standpipe construction

Radar sensors for measurement on surge or bypass pipes are used with G 1½ A screwed-on antenna or flange sizes DN 50, DN 80, DN 100 and DN 150. The radar sensor with a DN 50 flange is only a functional measuring system in conjunction with a measuring tube.

On the left you see the constructional features of a measuring pipe (surge or bypass tube) as exemplified by a sensor with DN 50 flange.

The measuring pipe must be smooth inside (average surface quality Rz ≤ 30). Use stain- less steel tubing (drawn or welded lengthwise) for construction of the measuring pipe. Extend the measuring pipe to the required length with welding neck 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.

Avoid welding through the pipe wall. The pipe must remain smooth inside. Roughness or welding beads on the inner surfaces must be carefully removed and burnished, as they cause false echoes and encourage product adhesion.

On the following page you will see the constructional features of a measuring pipe as exemplified by a sensor with DN 100 flange.

If the vessel contains agitated products, fasten the measuring pipe to the vessel bottom. Provide additional fastenings for longer measuring pipes.

VEGAPULS 42, 44 and 45 – VBUS 23

Mounting and installation

0 %

Flange DN 100

Deburr the holes

150…500

Connecting sleeve

Welding neck flanges

VEGAPULS 44

When measuring products with lower dielectric values (< 4), a part of the radar signal penetrates the medium. If the vessel is nearly empty, an echo is generated by the medium and the vessel bottom. In some cases, the vessel bottom generates a stronger signal echo than the product surface. With a deflector on the measuring pipe end, the radar signals are scattered. In nearly empty vessels and products with low dielectric value, the medium then generates a stronger echo than the vessel bottom.

Thanks to the deflector, only the useful signal is received in a nearly empty vessel - the

Welding of the plain welded flange

100 %

ø 95

Welding of the connecting sleeves

5…10

correct measured value is thus transmitted and the 0 % level reliably detected.

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 reduces strong echoes from the tube

0,0…0,4

3,6

Welding of the welding neck flange

3,6

1,5…2

0,0…0,4

end or vessel bottom.

0 %

Quadrant pipe on the bypass tube end

Deflector

0 %

ø 100,8

~45˚

Meas. pipe fastening

Vessel bottom

Quadrant pipe on the standpipe end

24 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

3.4 False echoes

The mounting location of the radar sensor must be selected such that 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 protrusions

Vessel forms with flat protrusions can, due to their strong false echoes, greatly effect the measurement. Shields above these flat protrusions scatter the false echoes and guarantee a reliable measurement.

Correct Wrong

Vessel protrusions (slope)

Intake pipes, i.e. for the mixing of materials with a flat surface directed towards the sensor - should be covered with a sloping shield that will scatter false echoes.

Vessel installations

Vessel installations such as, for example, a ladder, often cause false echoes. Make sure when planning your measuring location that the radar signals have free access to the measured product.

Correct Wrong

Ladder

Vessel installations

Ladder

Struts

Struts, like other vessel installations, can cause strong false echoes superimposed on the useful echoes. Small shields effectively hinder a direct false echo reflection. These false echoes are scattered and diffused in the area and are then filtered out as "echo noise" by the measuring electronics.

Correct Wrong

Struts

Vessel protrusions (intake pipe)

VEGAPULS 42, 44 and 45 – VBUS 25

Shields

Mounting and installation

Inflowing material

Do not mount the instrument in or above the filling stream. Ensure that you detect the product surface and not the inflowing material.

Correct

Inflowing material

Wrong

Buildup

If the sensor is mounted too close to the vessel wall, buildup and adhesions of the measured product to the vessel wall will cause false echoes. Position the sensor at a sufficient distance from the vessel wall. Please also note chapter "3.1 General installation instructions".

Correct Wrong

Strong product movements

Strong turbulences in the vessel, e.g. caused by stirrers or strong chemical reactions, can seriously interfere with the measurement. A surge or bypass tube (figure) allows, provided the product causes no buildup in the tube, a reliable measurement even with turbulences in the vessel.

Correct Wrong

100 %

75 %

0 %

Strong product movements

Buildup

26 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

3.5 Installation mistakes

Socket piece too long

If the sensor is mounted in a socket extension that is too long, false reflections are caused and measurement is hindered. Make sure that the horn antenna protrudes out of the socket piece.

Correct Unfavourable

Reference plane

Flange antenna: Correct and unfavourable socket length

Unfavourable

Correct

Parabolic effects on dished or arched vessel tops

Round or parabolic tank tops act like a parabolic mirror on the radar signals. If the radar sensor is placed at the focal point of such a parabolic tank top, the sensor receives amplified false echoes. The optimum mounting position is generally in the range of half the vessel radius from the centre.

Correct

~ ½ vessel radius

Unfavourable

< 135 mm (250 mm)

Screw-on antenna: Correct and unfavourable socket length

VEGAPULS 42, 44 and 45 – VBUS 27

Mounting on a vessel with parabolic tank top

Mounting and installation

Wrong orientation to the product

Weak measuring signals are caused if the sensor is not directly pointed at the product surface. Orient the sensor axis perpendicularly to the product surface to achieve reliable measuring results.

Correct Wrong

Ladder

Direct sensor vertically to the product surface

Ladder

Sensor too close to the vessel wall

If the radar sensor is mounted too close to the vessel wall, strong false echoes can be caused. Buildup, rivets, screws or weld joints superimpose their echoes onto the product or useful echo. Please ensure sufficient distance from the sensor to the vessel wall.

Foam generation

Conductive foam is penetrated by the radar signals to different depths and generates a number of single (bubble) echoes. The signals in the foam are also damped, like heat radiation that tries to penetrate styrofoam. Thick, dense, creamy foam, and especially conductive foam, on the product surface can cause incorrect measurements.

conductive foam

Liquid

In case of good reflection conditions (liquids

Foam generation

without vessel installations), we recommend selecting the sensor distance so that 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".

Take measures to avoid foam, measure in a bypass tube or use a different measuring technology, e.g. capacitive electrodes or hydrostatic pressure transmitters.

In many cases, VEGAPULS 54 radar sensors with 5.8 GHz operating frequency achieve considerably better and more reliable measuring results in foam applications than type 40 sensors with 26 GHz technology.

28 VEGAPULS 42, 44 and 45 – VBUS

Mounting and installation

Installation mistakes in the standpipe

Pipe antenna without ventilation hole

Pipe antenna systems must be provided with a ventilation hole on the upper end of the surge pipe. The lack of a hole will cause false measurements.

Correct

Pipe antenna: The surge pipe open to the bottom must have a ventilation or equalisation hole on top

Wrong

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.

Correct

VEGAPULS 44 on the surge pipe: The sensor type plate must be aligned with the rows of holes.

Type label

Wrong

VEGAPULS 42, 44 and 45 – VBUS 29

4 Electrical connection

Electrical connection

4.1 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.

Qualified personnel

Instruments which are not operated with protective low voltage or DC voltage must only be connected by qualified personnel.

Connection and grounding

A standard two or four-wire cable (sensors with separate supply) with max. 2.5 mm be used for connection. The earth conductor terminal is galvanically connected with the process fitting (thread or flange).

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).

can

Note!

In Ex applications, grounding on both ends is not allowed due to potential transfer. 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).

Note the approval documents and the included safety data sheet attached to the Ex sensors.

Connection cable

Please note that the connection cables are specified for the expected operating conditions in your systems. The cable must have an outer diameter of 5 … 9 mm (1/2 to 1/3 inch). Otherwise the seal effect of the cable entry will not be ensured.

Cables for intrinsically safe circuits must be marked blue and must not be used for other circuits.

Intrinsically safe circuits with more than one active instrument (instrument delivering electrical energy) are not allowed. Please note the special installation regulations (DIN 0165).

30 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

Screening of the sensor cable

currents flow through the cable screening. Ground equalisation currents can be avoided

Very often, the "electromagnetic pollution" caused by electronic actuators, energy cables and transmitting stations is so considerable that the sensor cable must be screened.

by ground potential equalisation systems. When earthing on both ends, it is possible to connect the cable shield on one earth side (e.g. in the switching cabinet) via a capacitor (e.g. 10 nF; 1500 V) to the earth potential. Use a very low-resistance earth connection

We recommend the use of screening to avoid

(foundation, plate or mains earth).

future interferences. However, you must make sure that no ground equalisation

Screening magnetic low-frequency high-frequency ground currents

fields electrical electrical and superimposed

fields fields potential currents

l < ––

l > ––

none – – – – one side – ++ – –

two sides + + ++ ++

++ good protection against electromagnetic pollution + protection against electromagnetic pollution – no protection against electromagnetic pollution

Note: λ (Lambda) =– – –

l cable length c light velocity (300000 km/s) f interfering frequency λ wavelength

Example: Interfering frequency approx. 100 kHz

1c 13 • 10

l < – • – = – • ––––––––– = 4285 m

7 f 7 100 • 10

– s

This means that interference can be avoided by earthing on both ends (better on one end) in case of an interfering frequency of 100 kHz up to a cable length of approx. 4000 m.

Earthing on the sensor end

Earthing on both ends (on the signal conditioning instrument via the potential separation capacitor)

e.g. 10 nF, 1500 V AC

VEGAMET

515V

VEGAPULS 42, 44 and 45 – VBUS 31

VEGAMET

515V

Electrical connection

Linear (serial) arrangement of sensors

Grounding of the cable screen on both ends, at the end of each sensor arry via a ground capacitor.

CPU

VEGALOG

571 CPU

571 EV

Radial arrangement of sensors

Grounding on at least two ends, on VEGALOG and once on the sensor star, i.e. on the longest sensor line. If the individual sensor lines are longer than approx. 15 m, a grounding of each longer line should be made via a ground capacitor.

CPU

VEGALOG

571 CPU

571 EV

32 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

4.2 Connection of the sensor

After mounting the sensor at the measurement location according to the instructions in chapter "3 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 insulation). The sleeve nut of the cable entry has a self-locking ratchet that prevents it from opening on its own.

Version with plastic housing

Power supply and BUS signal

To the indicating instrument in the sensor lid or the external VEGADIS 50 indicating instrument

Terminals (max. 2.5 mm wire cross-section)

Now insert the cable through the cable entry into the sensor. Screw the sleeve nut back onto the cable entry and clamp the stripped wires of the cable into the proper terminal positions.

The spring terminals hold the wire without a screw. Press the white opening tabs with a small screwdriver and insert the copper core of the connection cable into the terminal opening. Check the hold of the individual wires in the terminals by lightly pulling on them.

Version with Aluminium housing

Power supply and BUS signal

To the indicating instrument in the

sensor lid or the external VEGADIS 50 indicating instrument

M20 x 1.5 (diameter of the connection cable 5…9 mm)

VBUS

Tank 1 m (d)

12.345

Communication

5678

Display

2.23273

ESC

+ 1

VBUS

2 -

Tank 1 m (d)

12.345

Communication

5678

Display

2.23273

ESC

VEGAPULS 42, 44 and 45 – VBUS 33

Electrical connection

4.3 Connection of the external indicating instrument VEGADIS 50

OUTPUT (to the sensor)

SENSOR

DISPLAY

(in the cover of the indicating instrument)

DISPLAY1234 56 78

Loosen the four screws of the housing cover 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.

Power supply and BUS signal

Communication

(+) L12N

Tank 1 m (d)

12.345

VEGADIS 50

Adjustment module

ESC

Tank 1 m (d)

12.345

5678

Display

2.23274

ESC

Screws

34 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

4.4 Configuration of measuring systems

A measuring system consists of one sensor and one processing unit. The processing unit (VEGAMET signal conditioning instrument or VEGALOG processing system) evaluates the level-proportional, digital measuring signals in a number of processing routines and outputs the levels as individual current, voltage or switching signals.

Two sensors can be connected via one twowire cable to VEGAMET signal conditioning instrument. Up to 255 sensors can be connected to the VEGALOG 571 processing system. 15 sensors (loop powered) can be connected on one two-wire cable.

Beside the output of the level in percent, cubic meter or other physical units, as current, voltage or switching signal (relay or transistor), the levels can also be processed by linked processing algorithms. Scaling, linearisation, calculation of linearisation curves, differential generation, addition or tendency processing are an integral part of the VEGALOG processing systems and VEGAMET and are easy to implement via the menu selection.

Series 40 sensors with VBUS signal require for operation in Ex areas the Ex separator VEGATRENN 548V Ex, providing intrinsically safe Ex circuits to the sensors. Up to nine sensors (in groups of three sensors) can be connected to the Ex separator VEGATRENN 548V Ex.

Connection cable

Sensor wiring should be looped in screened cables. Ground the cable screens on the processing system, or better, on the sensor. We recommend grounding the cable screens on both ends. However, make sure that no earth compensation currents flow via the screens. When earthing on both ends, it is possible to connect the cable shield on one earth side (e.g. in the switching cabinet) via a capacitor (e.g. 10 nF; 1500 V).

On the following page you will see the various instrument configurations (measuring systems) consisting of sensor(s) and processing unit.

VEGAPULS 42, 44 and 45 – VBUS 35

Electrical connection

1 … 2 sensors on the VEGAMET 515V signal conditioning instrument

• Two-wire technology, power supply from the signal conditioning instrument, output signals and power supply via one two-wire cable.

• Digital output signal, two sensors on one cable.

• Display of measured value in the sensor and in the signal conditioning instrument.

• Optional external indicating instrument (can be mounted up to 25 m away from the sensor in Ex area).

• Adjustment with PC, signal conditioning instrument or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable 15 Ω per wire, max. 1000 m cable length.

VEGADIS 50

Sensor wiring should be looped in screened cables.

VEGACONNECT 2

In case of high frequency interference (> 1 MHz), it is best to ground the cable screens on both ends. Please make sure that no earth compensation currents flow via the screens. You avoid earth compensation currents (when grounding at both ends) by connecting the cable screen on one end (e.g. in the switching cabinet) via a capacitor (e.g. 10 nF; 1500 V) with the ground potential.

In case of electromagnetic interferences, screened cable should be used (see following page)

Processings see also Product Information "Signal conditioning instruments series 500"

Current outputs

VEGAMET

515V

VEGAMET 515V signal conditioning instrument in housing type 505

Voltage outputs

Relays

Digital wiring

Fault signals

36 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

1 … 2 sensors in Ex environment via separator VEGATRENN

"ia"

548V Ex on the VEGAMET 515V signal conditioning instrument

• Two-wire technology, power supply via separator, output signals and power supply via one two-wire cable.

• Ex environment acc. to CENELEC and ATEX.

• Digital output signal, two sensors on one cable.

• Display of measured values in the sensor and in the signal conditioning instrument.

• Optional external indicating instrument (can be mounted up to 25 m away from the sensor also in Ex area).

• Adjustment with PC, signal conditioning instrument or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable 15 Ω per wire, max. 1000 m cable length (see also approval certificates of the separators).

VEGADIS 50

Zone 0 or Zone 1

Sensor wiring should be looped in screened cables.

Ex area Non-Ex area

EEx ia

In case of electromagnetic interferences, screened cable should be used (see following

VEGAMET

page)

Processings see also Product Information "Signal conditioning instruments series 500"

VEGATRENN

548V

515V

VEGACONNECT 2

VEGAMET 515V signal conditioning instrument with Ex separator VEGATRENN 548V Ex in housing type 506

Note!

In Ex systems, earthing on both ends is not allowed due to potential difference. It is allowed, however in conjunction with potential equalisation system or y

capacitors.

Current outputs

Voltage outputs

Relays

Digital wiring

Fault signals

VEGAPULS 42, 44 and 45 – VBUS 37

Electrical connection

5 sensors per two-wire cable (grouped radially) on the VEGALOG 571 processing system

• 15 sensors with power supply and digital output signals via three two-wire cables on one input card of the VEGALOG 571 processing system.

• Display of measured values 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 or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable 15 Ω per wire, max. 1000 m cable length.

CPU

VEGALOG

571 CPU

571 EV

38 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

5 sensors per two- wire cable (grouped in line) on the VEGALOG 571 processing system

• 15 sensors with power supply and digital output signals via three two-wire cables on one input card of the VEGALOG 571 processing system.

• Display of measured values integrated in the sensor.

• Optional external indicating instrument (can be mounted up to 25 m away from the sensor also in Ex area).

• Adjustment with PC or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable 15 Ω per wire, max. 1000 m cable length.

CPU

VEGALOG

571 CPU

571 EV

VEGAPULS 42, 44 and 45 – VBUS 39

Electrical connection

15 sensors via one two-wire cable on the VEGALOG 571 processing system

• 15 sensors with power supply and digital output signals via one two-wire cable on one input card of the VEGALOG 571 processing system.

• Display of measured values integrated in the sensor.

• Optional external indicating instrument (can be mounted up to 25 m away from the sensor also in Ex area).

• Adjustment with PC or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable with 15 sensors on one two-wire cable 10 Ω per wire (instead of 15 Ω), max. 1000 m cable length.

VEGADIS 50

Screened cable in case of electromagnetic interferences

Processings see also Product Information "Signal conditioning instruments series 500"

Current outputs

CPU

Voltage output

Relay outputs

Transistor output

Fault signals

Display outputs

Digital wiring Connection to all bus systems

VEGACONNECT 2

VEGALOG

571 CPU

571 EV

VEGALOG 571 processing system with input cards in 19" rack. 15 sensors on one module card and cable

Interface cable RS 232

Sensor wiring should be looped in screened cables. Please make sure that no earth compensation currents flow via the screens. You avoid earth compensation currents (when grounding at both ends) by connecting the cable screen on one end (e.g. in the switching cabinet) via a capacitor (e.g. 10 nF; 1500 V) with the ground potential.

15 sensors per two-wire cable individual grouping

40 VEGAPULS 42, 44 and 45 – VBUS

Electrical connection

5 sensors per two-wire cable via VEGATRENN 548V Ex separator

"ia"

on the VEGALOG 571 processing system

• 5 sensors with power supply and digital output signals via one two-wire cable on the separator.

• Display of measured values integrated in the sensor.

• Optional external indicating instrument (can be mounted up to 25 m away from the sensor also in Ex area).

• Adjustment with PC or adjustment module MINICOM (can be plugged into the sensor or into the external indicating instrument VEGADIS 50).

• Max. resistance of the signal cable 15 Ω per wire, max. 1000 m cable length (see also approval certificates of the separators and technical data).

VEGADIS 50

Ex area

EEx ia

Non-Ex area

EEx ia

Screened cable in case of electromagnetic interferences

CPU

2 2 2

Processings see also Product Information "Signal conditioning instruments series 500". Current outputs etc. like image on previous page

VEGALOG

VEGATRENN

571 CPU

571 EV

548

VEGALOG 571 processing system (19" module card)

VEGATRENN

VEGALOG

VEGATRENN

571 EV

548

Input card of VEGALOG 571

VEGATRENN 548V Ex separator (max. 15 sensors per card)

Input card of VEGALOG 571 (max. 15 sensors per card)

VEGACONNECT 2

Sensor wiring should be looped in screened cables. In case of high frequency

Interface cable RS 232

interference (> 1 MHz) it is best to ground the cable screens on both ends. Please make sure that no earth compensation currents flow via the screens. You avoid earth compensation currents (when grounding at both ends) by connecting the cable screen on one end (e.g. in the switching cabinet) via a capacitor (e.g. 10 nF; 1500 V) with the ground potential. Sensor cables leading to the same separator card can be looped together in one screened

5 sensors per two-wire cable individual grouping

multiwire cable. Sensor cables leading to other separator cards must be looped in separate screened cables.

VEGAPULS 42, 44 and 45 – VBUS 41

5 Setup

Setup

5.1 Adjustment structure

The radar sensors can be operated

- with the PC (adjustment program VVO,

version ≥ 2.70)

- with the adjustment module MINICOM

- with the VEGAMET signal conditioning instrument.

The adjustment is always possible with one adjustment instrument at once.

Adjustment with the PC

The PC with the adjustment program VVO (VEGA Visual Operating) in version ≥ 2.70 can be connected to:

- the sensor

- the signal cable

- the VEGAMET 514V, 515V signal conditioning instrument

- the VEGALOG 571 processing system.

With the adjustment program VVO on the PC, you can adjust the radar sensors very easily. A digital adjustment signal is herewith superimposed to the signal and supply cable. By this means, the adjustment can be made directly on the sensor, on any position of the signal cable or on the VEGAMET or VEGALOG processing system.

Note:

Make sure that for adjustment of VEGAPULS 42, 44 and 45 sensors, the adjustment program VVO in version 2.70 or higher is installed.

PC directly on the sensor

Insert VEGACONNECT into the communication sockets of an individual sensor. Only sensor-relevant adjustment options such as e.g., sensor optimisation on the affected sensor, are adjustable. Other sensors and VEGAMET are then not adjustable. This is due to an adjustment hierarchy beginning with VEGAMET or VEGALOG and ending with the sensor.

PC on the signal cable

Only the sensor-relevant adjustment options of sensors connected to the signal cable are adjustable on the signal cable. However, not available are the configuration and measured data processing functions of VEGAMET or VEGALOG.

Note:

The adjustment with the "PC on the signal cable" and with the "PC directly on the sensor" is described in chapter "5.2 Adjustment with the PC on the signal conditioning instrument". For this reason, adjustment with the PC when connected directly to the sensor or the signal cable is not shown separately.

Adjustment with the PC on the VEGAMET signal conditioning instrument or on the VEGALOG processing system

The PC communicates via the interface converter VEGACONNECT 2 with the signal conditioning instrument or via the standard RS 232 interface cable with the VEGALOG processing system and all sensors connected to VEGAMET or VEGALOG. If you connect the PC to the processing system or the signal conditioning instrument, besides the connected sensors, also the processing system or the signal conditioning instrument is adjustable.

Adjustment with the VEGAMET signal conditioning instrument

Sensor and VEGAMET signal conditioning instrument can be operated with the 6 key adjustment field of the signal conditioning instrument just like with the adjustment program VVO. The scope of the adjustment functions is the same as with VVO on the PC.

42 VEGAPULS 42, 44 and 45 – VBUS

Setup

Adjustment with the adjustment module MINICOM

With the adjustment module MINICOM you adjust the individual sensor directly in the sensor or in the external indicating instrument VEGADIS 50. The adjustment module MINICOM with the 6 key adjustment field with text display enables the parameter adjustment of the sensor with an array of functions comparable to the adjustment program VVO or the VEGAMET signal conditioning instrument, but not the configuration of the measuring system.

Adjustment of the signal conditioning instrument is only possible with the adjustment program VVO or the 6 key adjustment field on the instrument itself.

5.2 Adjustment with the PC on the signal conditioning instrument

To connect the PC to the signal conditioning instrument, the interface converter VEGACONNECT is required. The PC communicates via the interface converter with the signal conditioning instrument and the connected sensors.

In the following setup and adjustment instructions you will find information on the following topics and adjustment points:

•

Configuration

- create/modify measurement loop

- configuration info

•

Parameter adjustment 1

- adjustment

- conditioning/scaling

- meas. loop data

•

Sensor optimisation

- meas. environment/operating range

- meas. environment/meas. conditioning

- meas. environment/pulse velocity

- echo curve

- false echo storage

•

Parameter adjustment 2

- user-programmable linearisation curve

- linearisation curve

- defining the linearisation curve by incremental filling

- calculating the linearisation curve

- calculate cylindrical tank

•

Outputs

- configuration outputs

- parameter adjustment outputs

•

Display of measured value

•

Simulation

•

Backup

(optional)

Note:

Keep in mind that you first have to log in a sensor in the configuration menu before you can continue with the parameter setting and, if necessary, carry out adjustments in the menu "

Sensor optimisation

VEGAPULS 42, 44 and 45 – VBUS 43

Adjustment with the PC on the signal conditioning instrument

Beside the measured values, adjustment signals are also transmitted digitally via the signal and supply cable between sensor and VEGAMET. The adjustment program VVO can then communicate with VEGAMET and all connected sensors. In chapter "4.4 Configuration of measuring systems", connection of the PC to different sensor arrangements is shown.

Before starting setup:

Do not be confused by the many pictures, adjustment steps and menus on the following pages. Just carry out the setup with the PC step by step and you will soon no longer need the following instructions. Actions, like entering a value or making a choice, are indicated in the following by a large black dot, like this:

• Choose …

• Start …

• Click to …

• Connect the standard output of your PC by the standard RS 232 interlink cable to VEGALOG.

• Now switch on the power supply of the processing system.

By this convention, the actions to be carried out are clearly separated from supplementary information in the following adjustment instructions.

Start now:

• Connect the standard plug of VEGACONNECT 2 (9-pole) to the interface COM 1 or COM 2 of your PC.

• Insert the two small pin plugs of VEGACONNECT 2 into the CONNECT socket on the front of the signal conditioning instrument.

• Now switch on the power supply of the signal conditioning instrument.

Usually after approx. 1 … 2 minutes (selftest) the measuring system is operating and displaying the measured value.

• Now start the adjustment software VVO on your PC.

• Choose with the arrow keys or the mouse the item "

Planning

" and click to "OK".

You are asked for user identification.

• Enter under name "VEGA".

• Also enter "VEGA" under password.

You are asked for the kind of sensor connection or if you want to carry out a virtual adjustment.

• Choose "

Direct cable connection

", if your PC is directly connected to the VEGAMET via a VEGACONNECT.

44 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on the signal conditioning instrument

The adjustment program VEGA Visual Operating (VVO), called in the following VVO, gets into contact with the connected sensor or processing system …

• Click to "OK" and you are in the main menu window.

… and indicates after a few seconds if and with which system a connection exists.

Note:

If you make no connection with the sensor, check the following:

- Is the sensor being supplied with sufficient

voltage (min. 20 V)?

- Did you inadvertently use a VEGACONNECT instead of the new VEGACONNECT 2?

User identification

The preset user identification can be modified later in the menu "

User access

If the adjustment software VVO gets in contact with the signal conditioning instrument for the first time, you will be asked if you want to transfer the data from the signal conditioning instrument to the PC.

• Click to "

In the following menu window "

choice

Yes

DISBUS-group

" you can give a name to the database

or keep the proposed file name.

VEGAPULS 42, 44 and 45 – VBUS 45

Adjustment with the PC on the signal conditioning instrument

Change COM port

In the menu "

nication

Configuration/Program/Commu-

" you can set the interface parameters

of your PC or change the used COM port.

Configuration

During the setup of the measuring system you are confronted with two terms: "Configuration" and "Parameter adjustment". The meas. system is first set up with a configuration and then with a parameter adjustment.

Note:

The signal conditioning instruments are shipped with the sensor configuration you ordered with the signal conditioning instrument.

Generally, you will use a preconfigured signal conditioning instrument. In the following menu "

Configuration

ments necessary and you can continue directly with the menu " If your signal conditioning instruments are not preconfigured, start now with the section "

Configuration

adjustments in section "

ment

", there are normally no adjust-

Parameter adjustment

" and then continue with the

Parameter adjust-

No matter whether you set up a measuring system (consisting of sensor and VEGAMET signal conditioning instrument or VEGALOG processing system) with the adjustment software VVO or with the signal conditioning instrument, the adjustment procedure is always the same:

- first of all in the menu "

Configuration

", you

create a measurement loop

- then configure a measurement loop

- in the menu "

Instrument data

" you carry out

the parameter adjustment of the sensor.

Configuration

The term "Configuration" means the basic adjustments of VEGAMET. You inform VEGAMET about the application (level measurement, gauge, distance …), the measurement loop name and the input channel. The configuration represents an electronic wiring and labelling of your VEGAMET or, in other words, telling the system which sensor for what application and where.

Parameter adjustment

After the configuration, you carry out the parameter adjustment for each individual sensor. This means adjusting the sensors to the respective operating range and adapting them to the specific application. You infor m the sensor which product distance (which level) is "empty" and which "full". This is called adjustment. Here you choose which physical quantity (volume, mass) and unit of measurement (m

, gal, liters …) the adjusted measured value should be outputted in. In the submenu "Sensor optimisation", you inform the sensor electronics about the actual environment, such as e.g. quick changes of the measured value, foam generation, gas stratification, solid or liquid.

46 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on the signal conditioning instrument

Create new measurement loop

• Choose the menu "Configuration/Measure-

ment loop/New" and you are in the menu

window "

Application

Create new measurement loop -

• Choose one of the two inputs of the VEGAMET signal conditioning instrument (VEGAMET 514V has only one sensor input) and click to "OK".

• Choose the parameter (

ment"

, gauge or distance) and the sensor

type (

"Radar"

• Click to "

for radar).

Continue

"level measure-

After a few seconds, the menu window "

Create new measurement loop - Sensor configuration

" opens.

• Click in the menu window "

measurement loop - Sensor configuration

to "

Sensor coordination

• Click to "

• Then click to "

Sensor search

Input

Create new

". The menu window

" opens.

• Choose " "

• Click to " "

loop

VEGAPULS 42, 44 and 45 – VBUS 47

Standard level measurement

no options

Continue

" and the menu window

New application - Select measurement

" opens.

" and

• Choose the serial number of the sensor to which you want to allocate e.g. input 1. If two radar sensors are connected to VEGAMET, you will get here a choice of the serial numbers of the two sensors.

Adjustment with the PC on the signal conditioning instrument

• Confirm with "OK".

• Click in the menu window "

nation

" again to "OK".

You are again in the menu window "

Sensor coordi-

Create new measurement loop - Sensor configuration

• Click to "

Continue

"…

• Enter in the menu window "

Create new measurement loop - Measurement loop description

and a measurement loop description.

In this menu window you can select how your level signal will be outputted, e.g. as current, voltage, relay signal, etc. This "Configuration" of outputs is described in detail in chapter "Parameter adjustment 2" under "Outputs".

• Confirm with "OK" and the previous menu window appears again. Click again to "OK" and wait a moment until the settings are transferred.

Configuration information

In the menu "

tem

" - "

configuration.

" a measurement loop number

Configuration/Measuring sys-

Sensor survey

" you can check the

• Click in the menu window "

Create new measurement loop - Measurement loop description

48 VEGAPULS 42, 44 and 45 – VBUS

" to "

Level

Adjustment with the PC on the signal conditioning instrument

Parameter adjustment 1

In the menu "

justment

adjustments.

Adjustment

• Choose the menu "

meter adjustment

want to adjust.

If you have only configured one sensor on the signal conditioning instrument, you will of course have a choice of only one sensor.

Instrument data/Parameter ad-

" you carry out all important sensor

Instrument data/Para-

" and then the sensor you

You can carry out the min./max. adjustment

"with medium"

actual level) or taking the actual level into consideration, i.e. with empty vessel).

Generally, you will carr y out the adjustment without medium, inasmuch as you need not be concerned about the actual vessel filling during adjustment. If you want to carry out the adjustment with medium, you have to carry out the min. adjustment with emptied (also partly emptied) vessel and the max. adjustment with filled (also partly filled) vessel. Carrying out the adjustment without medium is more convenient and quicker, as shown in the example.

• Choose "

• Choose if you want the carry out the adjustment in

• Enter a distance for the upper and lower level and the volume in % corresponding to each distance.

(adjustment by means of the

"without medium"

no (adjustment without medium)

meters

(m) or in

(without

feet

(ft).

In the opening menu window, you now see the previously entered measurement loop names and the measurement loop descriptions.

• First choose "Adjustment".

• Click in the menu window "

Min/Max adjustment".

VEGAPULS 42, 44 and 45 – VBUS 49

Adjustment

" to

Adjustment with the PC on the signal conditioning instrument

In the example, the 0 % filling is at a product distance of 5.85 m and the 100 % filling at a product distance of 1.27 m.

Note:

The sensor can only detect levels within the defined operating range. To enable detection of levels outside the operating range, it is necessary to correct the operating range in the menu "

ment

• Confirm your adjustments with "OK" and you are again in the menu window "

ment

• Click in the menu window " "

You are again in the menu window "

ment data parameter adjustment

Sensor optimisation/Meas. environ-

Quit

Adjust-

Adjustment

Instru-

" to

Of course, the characteristics points do not have to be at 0 % and 100 %, however the distance should be as great as possible (e.g. at 20 % and at 80 %). The difference between the characteristics points for the min./max. adjustment should be at least 50 mm product distance. This is a theoretical value, because if the characteristics points are too close together, the likelihood of measuring error increases. Ideal would be to carry out the adjustment as shown in the example, at 0 % and at 100 %.

In the menu "

justment/Conditioning/Linearisation

enter later, if necessary, a correlation between product distance and percent value of volume other than linear (see later subitem "Linearisation”).

Scaling

• Click in the menu window "

parameter adjustment

The menu window "

Instrument data/Parameter ad-

" you can

Instrument data

" to "

Conditioning

" opens.

• Click to "

In the menu " 0 % and 100 % values of the parameter and their unit. You thereby inform the sensor, e.g. that at 0 % filling there are still 45 liters and at

Now, the sensor electronics has two characteristics points, one for min. and one for max., with which a linear correlation between product distance and percentage filling of a vessel can be generated.

50 VEGAPULS 42, 44 and 45 – VBUS

100 % filling 1200 liters in the vessel. The sensor display then shows with empty vessel (0 %) 45 liters and with full vessel (100 %) 1200 liters.

Scaling

" you enter the actual

Adjustment with the PC on the signal conditioning instrument

Measurement loop data

As parameter you can choose

less

(plain numbers),

and distance"

measuring unit (e.g. l, hl). The sensor display then shows the measured value in the selected parameter and unit.

• Save the adjustments in the menu " by clicking "OK".

The adjustments are now transferred to the sensor and you are again in the menu window "

Conditioning

and assign an appropriate

volume, mass, height

"dimension-

Scaling

• Click to the menu item "

Parameter adjustment

You are then in the entrance window "

ment data parameter adjustment

• Click to the menu item "

Here you get information on the application, the sensor type and the signal conditioning instrument.

Instrument data/

Meas. loop data

Instru-

VEGAPULS 42, 44 and 45 – VBUS 51

Adjustment with the PC on the signal conditioning instrument

• Click to " " your measuring system in the information windows.

• Quit the information windows.

• Quit the menu "

Application

VEGAMET

", to "

Input no. A

", to get detailed information on

Meas. loop data

" and

Sensor optimisation

In the menu "Sensor optimisation" you can adapt the sensor to the environment. Here you carry out special optimising adjustments and optimise, e.g. by means of the echo curve, the mounting location of the sensor.

• First click to "Meas. environment".

Meas. environment/Operating range

• Choose the menu "

eter adjustment

• Choose in the menu window "

data parameter adjustment

Sensor optimisation" and click to "

52 VEGAPULS 42, 44 and 45 – VBUS

Instrument data param-

Instrument

" the menu item

Sensor

The menu window "Meas. environment” opens.

With the menu item " can define the operating range of the sensor deviating from the " default, the operating range corresponds otherwise to the min./max. adjustment (span).

Operating range

" you

Min/Max adjustment

". By

Adjustment with the PC on the signal conditioning instrument

Generally, it is better to set the operating range approx. 5 % greater than the adjusted measuring range (span) determined by the min./max. adjustment. In the example:

- Min. adjustment to 1.00 m,

- Max. adjustment to 6.00 m..

• For example, enter "

6.0m

• Save the adjustments and quit the menu window "

• Click to "Measuring conditions".

• In the menu window " you click on the options corresponding to your application.

• Confirm with "OK".

After a few seconds during which the adjustments are permanently saved in the sensor, you are again in the window "

ment

Limitation of the operating range

From 1.0m Up to

Measuring conditions

Meas. environ-

After a few seconds during which the adjustments are permanently saved in the sensor, you are again in the window "

ment

Meas. environment/Pulse velocity

In the menu item " have to make settings if you measure with a VEGAPULS 42 or 44 in a surge or bypass tube (standpipe). When measuring in a standpipe, you will have a running time shift of the radar signal which is dependent on the inner diameter of the standpipe. VEGAPULS 45 is already suitably configured. To accommodate this running time shift, it is necessary to inform the sensor in this menu on the tube diameter (inner) of the standpipe (only VEGAPULS 42 and 44).

Pulse velocity

Meas. environ-

" you only

Meas. environment/Meas. condition

• Click to "

• In the menu window "

tions

to your application.

• Confirm with "OK".

VEGAPULS 42, 44 and 45 – VBUS 53

Measuring conditions

Measuring condi-

" you click the options corresponding

Adjustment with the PC on the signal conditioning instrument

Furthermore, you can manually enter in the menu item " for the pulse velocity of the radar signal which travels at light velocity.

• Quit this menu if you do not want to make adjustment with "

• With "OK" you save the settings made.

• Click in the menu window "

ment

Pulse velocity

" to "

Quit

" a correction factor

Cancel

Meas. environ-

You are again in the menu window "

optimisation

Echo curve

With the menu item " window "Sensor optimisation" you can see the course and the strength of the detected radar echo. If, due to vessel installations, you expect strong false echoes, a correction (if possible) of the mounting location and orientation (during simultaneous monitoring of the echo curve) can help localise the false echoes and reduce their intensity. In the illustration, you can see the echo curve (before correction of the sensor orientation) with a false echo nearly as large as the product echo.

Echo curve

Sensor

" in the menu

In the next illustration you can see the echo curve after optimum directing of the sensor to the product surface (sensor axis perpendicular to the product surface). The false echo, caused e.g. by a strut, is now reduced by more than 10 dB and will no longer influence the measurement.

You see that the false echo is approx. 20 dB less than the useful echo (due to the strut) and therefore can no longer influence the measurement.

• Quit the menu window "

Quit".

Echo curve

" with

54 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on the signal conditioning instrument

False echo storage

You hereby authorise the sensor to mark all echoes before the product echo as false echoes. This prevents the sensor from erroneously detecting a false echo as level echo.

With the menu item " the menu " thorise the sensor to save false echoes. The sensor electronics then saves the false echoes in an internal database and assigns them a lower level of importance than the useful echo.

• Click in the menu window to "

Sensor optimisation

optimisation

storage".

• Now click in the opening menu window "

False echo storage

oes". A small window opens.

• Enter here the verified product distance and click to "Create new

False echo storage

" you can au-

" in

Sensor

" to the menu item "False echo

" to "Learn false ech-

• Click to "Show echo curve".

The curve and the false echo marking are shown.

• Quit the menu with "Quit".

You are again in the menu window "

optimisation

With the menu item " tions in the menu " default.

Reset

Sensor optimisation

" you reset all op-

Sensor

" to

• Quit the menu window " with "Quit".

VEGAPULS 42, 44 and 45 – VBUS 55

Sensor optimisation

Adjustment with the PC on the signal conditioning instrument

You are then in the initial menu window "

strument data parameter adjustment

• Click in the menu window "

parameter adjustment

You are again in the main menu window.

Instrument data

" to "

Quit

In-

Parameter adjustment 2

Linearisation

The correlation between level and filling volume is defined by the so-called linearisation curves. If, in your vessel, there is a correlation other than linear between level ("

age value

(linearised value of the filling volume), choose in the menu window " item "

Conditioning

" of the level) and the filling volume

Conditioning

Instrument data/Parameter adjustment/

Percent-

" the menu

The menu window " which a linear correlation between percentage value of the level and the percentage value of the filling volume is preset. Beside the two programmed linearisation curves "

Horizontal cylindrical tank

tank

" you can also enter "

curves

". Linear means there is a linear corre-

lation between level and volume.

User programmable linearisation curves

• Click to "User programmable curve" to enter your own vessel geometry or a user programmable filling curve.

Linearisation

", and "

user programmable

" opens, in

Spherical

• Click to "

• Click in the menu window " the menu item "Linearisation".

56 VEGAPULS 42, 44 and 45 – VBUS

Conditioning

" to

Edit

Adjustment with the PC on the signal conditioning instrument

The user-programmable linearisation curve is generated by index markers. Each index marker consists of one value pair. A value pair is generated from a value " and a value "

value

level. "

Percentage value"

" represents the percentage value of the

Linearised

" represents the percentage

Linearised

. "

Percentage

of vessel volume at a certain percentage value of the level.

In the field "

Transfer measured value

" the current level as percent of the adjusted span is displayed. The measuring span has already been adjusted with the min./max. adjustment. In our example, the measuring span is 4.58 m and is the range from 5.85 m (empty) up to 1.27 m (full), see the following illustration.

5.85 m meas. distance corresponds to 0 % level. 1.27 m meas. distance corresponds to 100 % level. The measuring span is therefore

4.58 m (5.85 m – 1.27 m = 4.58 m).

The percentage value of 95.79 % means that now 4.387 m of the adjusted measuring span (4.58 m) have been reached:

4.58 • 0.9579 = 4.387 m.

The distance (product distance) outputted by the sensor, in case you have chosen "

distance

" as output parameter, is then:

5.85 – (4.58 • 0.9579) = 1.463 m. If the index markers or value pairs of your vessel are not known, you have to define the linearisation curve by incremental filling or calculate it with the vessel calculation program of VVO.

Defining the linearisation curve by incremental filling

In the characteristics of the example, you see four index markers or value pairs. There is always a linear interpolation between the index markers. The example vessel consists of three cylindrical segments of different height and diameter. The middle segment has a considerably smaller diameter.

• Click the check box "Show scaled values", to have the selected measuring unit displayed on the y-axis (bottom left in the menu window).

0 m

100 % at 1.27 m

1,463 m (95,79 %)

Index marker 1 is at 0 % filling (

value [%]

), corresponding in the example to

percentage

an actual distance to the product surface of

5.850 m (empty vessel). The volume quantity

is 45 liters (fluid remaining in the vessel). Index marker 2 is at a filling level of 30 %

Span

4.58 m

(100 %)

4.387 m

(95.79 %)

0 % at 5.85 m

VEGAPULS 42, 44 and 45 – VBUS 57

(30 % of the meas. distance of

1.270 m … 5.850 m). At a filling level of 30 %,

there are 576 liters in the vessel (in our example).

Adjustment with the PC on the signal conditioning instrument

Index marker 3 is at a filling level of 60 %. At this filling level there are 646 liters in the vessel. Index marker 4 is at a filling level of 100 % (product distance 1.270 m), where 1200 liters are in the vessel.

Max.

Min.

100 % (1.270 m) correspond to 1200 liters

Span (4.58 m)

0 % (5.850 m) correspond to 45 liters

Max. 32 index markers can be entered per linearisation curve (value pairs).

Calculating the linearisation curve

(using previous tank example)

In the menu window "

programmable curve --

vessel calculation program. With the vessel calculation program you can calculate (using dimensions from the technical drawings of the vessel) the correlation of filling height to filling volume. If the curve is defined this way, gauging by incremental filling is not necessary - your sensor will output volume as a function of level.

Linearisation -- user

" you can start the

• Click to "Calculate".

The tank calculation program starts. In the top left corner you choose the vessel type (upright tank, cylindrical tank, spherical tank, individual tank form or matrix). When choosing matrix, you can enter a user-programmable linearisation curve by means of index markers. This corresponds to the input of value pairs (linearisation points), as previously described.

In the following example, the tank calculation program calculates the linearisation curve of a vessel corresponding to the vessel in the previous gauging example.

• Click to "

individual tank form

" and choose three round tank segments with the dimensions 0.88 m • 0.9 m (height by diameter),

0.66 m • 0.47 m and 0.66 m • 1.12 m (this tank form corresponds to the tank form of the gauging example).

58 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on the signal conditioning instrument

• Click to "

After a short calculation time, the levels in percentage of span and the respective volume percentage will be shown. The outputted curves show the correlation in a diagram.

• Quit the linearisation table with "OK".

Calculate

You are again in the menu window "

Linearisation -- user programmable curve --

The volume percent values with corresponding percentage values of the level are shown in scaled values (in example liters) if the check box in the bottom left corner of the menu window has been clicked.

Calculate cylindrical tank

• Click in the menu window "

user programmable curve --

and in the menu window " to the symbol for cylindrical tanks.

Linearisation --

" to "Calculate

Tank calculation

You are again in the menu window "

calculation

• Click to "OK" to save the tank calculation.

VEGAPULS 42, 44 and 45 – VBUS 59

Tank

Adjustment with the PC on the signal conditioning instrument

• Choose the "

Measuring unit

", which should be used for the input of the vessel dimensions, e.g. mm.

The following example shows a cylindrical tank is inclined by 3° and has a length of 10000 mm and a diameter of 5000 mm. The cylindrical tank has a 1500 mm wide, spherical form at the right end and a dished end at the left.

In the bottom left corner in the menu window "

Tank calculation

dimensions are internal dimensions

" you find the information "

All

Entering the wall thickness is not necessary for the calculation of the dished boiler end as its mathematical calculation is based on the outer dimension.

• Click to "Calculate".

You will get the calculated linearisation table after a short calculation time. By means of 32 linearisation points, a function correlating vessel volume to filling height is outputted. The example vessel has a filling of 216561 liters at the 100 % line or 216.6 m

. It is possible to output the volume in barrels, gallons, cubic yards or cubic feet.

The calculation program calculates the vessel volume by means of the inner dimensions of the vessel. Above the information "

sions are internal dimensions

two fields with the percentage values 0 % and 100 %. Here you can shift the 100 % line or the 0 % line. In the example, the 100 % filling line was defined at a distance of 650 mm from the upper vessel edge (inner).

All dimen-

", you will find

There is a linear interpolation between the linearisation points.

• Click to "OK" and you are again in the menu

window "

• Again click in the menu window "

culation

Tank calculation

" to "OK" and you are in the

Tank cal-

linearisation menu.

60 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on the signal conditioning instrument

The sensor then outputs the actual filling volume by means of the adjusted vessel dimensions.

Here the calculated linearisation curve is again outputted. The volume information under "

Linearised

longer to the calculated volume of the tank calculation program. Why?

In the menu " tioning/Scaling) you entered that at 0 % filling there are 45 liters in the tank and at 100 % filling 1200 liters. The geometry of the calculated cylindrical tank is reduced to a size that has a volume of only 1200 liters. The linearisation curve of the calculated vessel is therefore modified to fit the volume data you entered in the menu "

If the true content of the calculated vessel should be outputted, the volume that was determined in the tank calculation program must be entered in the menu "Scaling".

" now corresponds no

Scaling

" (Instrument data/Condi-

Scaling

• Quit the menu with "OK".

• Confirm with "OK" and your individual linearisation curve is saved in the sensor.

Again in the menu window " can enter with the menu item " a measured value integration. This is recommended for agitated product surfaces, to prevent the measured value indication and output from changing constantly. As a standard feature, an integration time of 0 seconds is preset.

• Quit the menu with "OK"., you are again in the menu window "

eter adjustment

Conditioning

Integration time

Instrument data param-

", you

• Quit the menu window with "OK".

VEGAPULS 42, 44 and 45 – VBUS 61

Adjustment with the PC on the signal conditioning instrument

Outputs

Configure outputs

VEGAMET 514V/515V is provided with current, voltage and switching outputs. VEGALOG enables additional transistor outputs. Before an adjustment signal is set (parameter adjustment), it must be assigned to a particular (configurate), because inputs and outputs are independent components. For example, a sensor signal can be assigned to several current or voltage outputs (three per VEGAMET) and the parameter adjustment for each output can be different (0 … 20 mA; 20 … 0 mA etc.). Relay switching functions, after being assigned to a sensor signal, are adjusted during the parameter adjustment, for example with certain switching routines (dry run protection, overfill protection, switching points, switching hysteresis).

In the following, the configuration of outputs with the PC is described, which can be naturally carried out also with the 6 adjustment keys on the VEGAMET 514V, 515V and 614V signal conditioning instrument. See operating instructions of the signal conditioning instruments.

• Choose in the opening window "

Selection of measurement loop – Designations and outputs

" the measurement loop (sensor), to

which you want to assign an output signal.

For signal conditioning instruments, you have a choice of max. two (VEGAMET 515V) sensors or measurement loops.

When using a VEGALOG, this choice can include a number of measurement loops, as you will see in the following illustration.

• For configuration of the outputs, choose "

Configuration/Measurement loop/Modify

• Click to "

62 VEGAPULS 42, 44 and 45 – VBUS

Designations and outputs

• Choose the sensor or the measurement

loop to which you want to assign outputs.

The menu window "

– Measurement loop designation

Here you can enter a new name for the measurement loop in addition to assigning the outputs.

Modify measurement loop

" opens.

Adjustment with the PC on the signal conditioning instrument

Depending on the VEGAMET or VEGALOG version, the following outputs will be available for use:

- current output (0 … 20 mA)

- voltage output (not VEGALOG)

- switching output (relay, transistor)

- VEGADIS output (local bus)

- fault signal (relay)

- PC/DCS address (local instrument bus address)

- Switching input

• Now click e.g. to "

The window, " opens, in which you can assign one or several current outputs to one measurement loop.

In the left window the available current outputs are shown. Outputs already assigned to a measurement loop are shown in the left window with their measurement loop number in addition to the output number.

• Save the adjustment with "OK".

You are again in the menu window "

Current output

Configure current output

Modify

measurement loop – Measurement loop designation

• Click to "

Also in the menu window "

output

to a measurement loop.

If you operate a VEGALOG, there are naturally more relays available.

Switching output

Configure switching

" you can assign one or several relays

VEGAPULS 42, 44 and 45 – VBUS 63

Adjustment with the PC on the signal conditioning instrument

Parameter adjustment outputs

After having configured the outputs, you can allocate the requested properties to the outputs (parameter adjustment).

• Click in the menu window to "

data/Parameter adjustment

• Choose the measurement loop on which you want to make the parameter adjustment of the outputs.

Instrument

In the window " exact current function of the current output. Here also the parameter adjustment of a switching output is done.

Current output

" you adjust the

The menu window "

adjustment

• Click to "

• In the window " "

64 VEGAPULS 42, 44 and 45 – VBUS

" opens.

Outputs

Current output

Instrument parameter

Outputs

" you choose e.g.

Adjustment with the PC on the signal conditioning instrument

• Click "

Info

" to show the function e.g. of the switching window, if the switching condition between 20 % and 60 % should be "On".

You want to have a function "

against dry running of pumps"

Protection

, where e.g. a pump in a drop vessel starts emptying at 36 % filling and switches off at 8 %.

Switching delays are adjusted under "

Configure

• Click to "OK".

• If you want to save your settings, you have to click in the window " "

Save

Switching output

" to

The settings are permanently saved in the signal conditioning instrument (or in the processing system) - even in case of mains failure.

• Click to "

Info

" to show the diagram of the

pump control.

VEGAPULS 42, 44 and 45 – VBUS 65

• Qui the menu window " with "

Quit

Switching output

Adjustment with the PC on the signal conditioning instrument

Sensor-Display

• In the menu window " "

Display of measured value

Sensor-Display

Outputs

" you click to

" and choose

• Enter the meas. distance in m which you have set in the Min/Max-adjustment and the litre values corresponding to the min. and max. value.

• Click to "Save".

• Click in the window

"Quit" .

• Click in the window "

value

" to

"Quit"

You are again in the menu window "

• Click in the menu window " "

Quit

• Click in the menu window "

parameter adjustment

You are again in the main menu window.

"Sensor-Display

Display of measured

Outputs

Instrument data

" to "

Quit

" to

Outputs

" to

Show measured value

• Click in the main menu window to the menu "

Display/Display of measured value

choose the measurement loop (in the example, only one is available).

" and

• Choose under " "

Parameter

• Choose in the menu window "

play

" "

Scaled

the values displayed, e.g. in litres. In the example, a level of 45 … 1200 liters would have been displayed.

66 VEGAPULS 42, 44 and 45 – VBUS

Sensor no.

" "Scaled" and click to "

" "A" and under

Sensor Dis-

", "

Volume

", if you want to have

Save

Adjustment with the PC on the signal conditioning instrument

• Choose in the line " output "

Scaled

value will be displayed (in liters and volume percent), as well as the actual signal current in the 0/4 … 20 mA signal cable.

Indication value

" and e.g. the measured

" the

Simulation

• Click to the menu " and choose the measurement loop (in the example only one is available).

You are informed about the effect of the simulation on relay or current outputs.

Diagnostics/Simulation

The menu window " similar to the previous menu window, opens. In this menu window however, you can set the filling of the vessel or the signal current and the indication to any value (simulate measured value).

First of all, the actual measured value and the signal current are displayed.

• Click to "Start" in the turquoise window segment.

The grey scroll bar becomes active. With this scroll bar you can modify the measured value in the range of -10 % … 110 % and thereby simulate the filling or emptying of the vessel. In the field of the turquoise window cutout you can enter any % value for the filling percentage.

Simulation of outputs

Note:

The simulated measured value is outputted during adjustment with the PC until you terminate the simulation mode.

VEGAPULS 42, 44 and 45 – VBUS 67

Adjustment with the PC on the signal conditioning instrument

Backup

• Click to "

In the menu field " serial number is displayed. You can save the sensor individually or in groups with all relevant settings in any directory on your PC. It is also possible to add small notes to each backup.

Furthermore you can save the settings of the VEGAMET signal conditioning instrument or of VEGALOG.

Services/Backup/Sensors

Backup

" the sensor with its

Restore data

Saved sensor data can be transferred to other sensors at a later time. If e.g. you have a system with several of the same storage vessels and identical sensors, it is sufficient to configure one sensor, save the settings and then transfer them to the other sensors.

• Choose the menu "

figuration/Sensors

In the yellow window cutout, you choose a sensor (or a signal conditioning instrument) which should be overwritten with the settings of another sensor.

Services/Restore con-

Choose in the field " serial number of the sensor from which you want to transfer the settings. With "

after

" you transfer these sensor settings to the sensor you have chosen in the yellow window cutout.

Besides the data of the sensors, also the data of a VEGAMET or VEGALOG can be restored.

68 VEGAPULS 42, 44 and 45 – VBUS

Selection of backup

Restore

" the

Adjustment with MINICOM or VEGAMET

5.3 Adjustment with VEGAMET or MINICOM

Beside the PC, the VEGAPULS series 40 radar sensors with VBUS output signal can also be adjusted with

- the signal conditioning instrument

- or the detachable adjustment module

MINICOM.

The adjustment with VEGAMET signal conditioning instrument provides all the adjustment options available on the PC. Adjustment takes on a different appearance, but the scope of the adjustment functions is the same.

With the adjustment module MINICOM, only the sensor-relevant adjustments are possible, such as e.g. operating range, measuring conditions, sensor scaling or false echo memory. However, all adjustment steps relating to the configuration of the VEGAMET signal conditioning instrument and its signal processing (adjustment, configuration of the inputs and outputs, linearisation curves, simulation …) are not possible.

Indicating and adjustment panels

VEGAMET signal conditioning instrument

Branching, i.e. jump to the lower menu with [OK]

Interrupt adjustment or jump to the next higher menu

Analogue LED display (0 … 100 %)

ESC

100

CONNECT

515V

Display, indication of

- measured value

- menu item

- parameter

- value

Depending on the menu item, change values or choose out of list

Choose menu window or shift flashing cursor

Save the adjusted value or move to the menu below

The adjustment of VEGAMET and the adjustment of MINICOM are identical. Adjustment is made with six keys. A small display shows you, apart from the measured value, a short message on the menu item or on the value of a menu adjustment.

The volume of information of the small display, however, cannot be compared with that of the adjustment program VVO, but in conjunction with the following menu schematic of MINICOM, the adjustment will not be a problem. You might even be able to carry out adjustments more quickly and directly with the small adjustment field than with the PC.

Note:

You will find the menu schematic for VEGAMET in the operating instructions of the signal conditioning instruments.

Adjustment module MINICOM

Tank 1 m (d)

12.345

ESC

VEGAPULS 42, 44 and 45 – VBUS 69

Adjustment steps

In the following, you will see the menu schematic of the adjustment module MINICOM. The menu schematic of the VEGAMET signal conditioning instrument is shown in the operating instructions of the signal conditioning instrument. Set up the sensor in the numbered sequence. The respective numbers are stated in the menu schematics. Numbers 1 … 4 and 11 you will find in the menu schematic of the VEGAMET signal conditioning instrument. Numbers 5 … 10 you will find in the following MINICOM menu schematic. These numbers can be adjusted with the MINICOM MET.

1. Configuration of the measurement loop; as a rule, already preconfigured (see operating instructions VEGAMET).

2. Configuration of the input; as a rule, already preconfigured (see operating instructions VEGAMET).

3. Min/Max. adjustment (see operating instructions VEGAMET).

4. Conditioning/Scaling VEGAMET (see operating instructions VEGAMET).

5. Measurement in a standpipe.

6. Operating range.

7. Meas. conditions.

8. False echo memory (only required when errors occur during operation).

9. Indication of the useful and noise level

10. Conditioning/Scaling of the sensor display .

11. Outputs (see operating instructions VEGAMET).

and with VEGA-

Adjustment with MINICOM or VEGAMET

1. Configuration of the measurement loop

(see operating instructions VEGAMET)

First of all, you have to inform the signal conditioning instrument which application (level, distance, flow, …) you have and which sensor (radar, ultrasonic, …) is connected. Choose under mode "Standard" and under option "No option".

2. Configuration of the input

(see operating instructions VEGAMET)

First of all, you have to inform the signal conditioning instrument (only VEGAMET 515V) which input (input 1 or 2) the sensor is connected to.

3. Adjustment

(see operating instructions VEGAMET)

Under the menu item " the sensor which measuring range it should operate with.

You can carry out the adjustment without and with medium. Generally, you will carry out the adjustment without medium, as you can then adjust without a filling cycle.

Max.

Adjustment

100 % (1.270 m) correspond to 1200 liters

" you inform

Short explanations to the setup steps 1 … 11 follow.

Min.

70 VEGAPULS 42, 44 and 45 – VBUS

Span (4.58 m)

0 % (5.850 m) corresponds to 45 liters

Adjustment with MINICOM or VEGAMET

Adjustment without medium

(adjustment independent of the actual level)

Key adjustment Display indication

Sensor

m(d)

4.700

Para-

The distance indication flashes and you can choose "feet" and

meter

Adjustment

w.o medium

Adjustment in

m(d)

(min. adjustment)

"m".

+ –

Confirm the adjustment with "

Adjustment in

m(d)

0.0%

m (d)

XX.XXX

With "+" and "–" you adjust the percentage value for the min. value or the lower level (example 0.0 %).

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.

100.0%

m (d)

XX.XXX

(max. adjustment)

The max. adjustment (upper product distance) is made in the same way (example: 100 % and 1.270 m).

Note:

The difference between the adjustment values of the lower product distance and the upper product distance should be as big as possible, preferably at 0 % and 100 %. If the values are very close together, e.g. lower product distance adjustment at 40 % (3,102 m) and upper product distance adjustment at 45 % (3.331 m), the measurement will be inaccurate. A characteristics curve is generated from the two points.

Even the smallest deviations between actual product distance and entered product distance will considerably influence the slope of the characteristic curve. When the adjustment points are too close together, small errors multiply to considerably larger errors at the output of the 0 % or the 100 % value.

The adjusted percentage value is written in the sensor and the distance corresponding to the percentage

Adjustment with medium

(dependent on the actual level)

with medium

value flashes.

+ –

With the "

" or "–" key you can assign a level distance (example 5.85 m) to the previously adjusted percentage

Min. adjust at %

XXX.X

Max. adjust at %

XXX.X

value. If you do not know the distance, you have to do a sounding.

VEGAPULS 42, 44 and 45 – VBUS 71

Adjustment with MINICOM or VEGAMET

Fill the vessel e.g. to 10 % and enter 10 % in the menu "

Min. adjust

" with the "+" and "–" keys. Then fill the vessel, e.g. to 80 % or 100 % and enter 80 % or 100 % in the menu "

Max. adjust

" with the "+" and "–" keys. If you do not know the distance, you have to calculate it by incremental filling.

The indication stops flashing and the adjustment will be saved.

You have entered the min. value.

100.0%

m (d)

XX.XXX

(max. adjustment)

Enter the max. adjustment like the min. adjustment with "+", "–" or "OK" (example: 1.270 m).

4. Conditioning/Scaling VEGAMET

(see operating instructions VEGAMET)

Under the menu item " you choose the product distance at 0 % and at 100 % filling. Then you enter the parameter and the physical unit as well as the decimal point, e.g. distance.

Signal condit ioning

Scal ing

Conditioning/Scaling

Enter in the menu window "

0 % corresponds

the value of the 0 % filling. In the example of the adjustment with the PC and the adjustment software VVO this would be 45 for 45 liters.

• Confirm with "

With the "—>" key you change to the 100 % menu. Enter here the value of your parameter corresponding to a 100 % filling. In the example 1200 for 1200 liters.

• Confirm with "

If necessary, choose a decimal point. However, note that only max. 4 digits can be displayed. In the menu "

prop. to

" you choose the parameter (mass, volume, distance…) and in the menu "

Unit

" the physical unit (kg, l,

ft3, gal, m3 …).

Linearisation:

Adjust ment

Signal condit ioning

Scal ing

Lin. curve

Linear

Integr ation time

0 s

A linear correlation between the percentage value of the product distance and percentage value of the filling volume is preadjusted. With the menu "Lin. curve" you can choose between linear, spherical tank and cylindrical tank. The creation of one’s own linearisation curve is only possible with the PC and the adjustment program VVO.

0 %

100 %

Deci-

prop.

corres

corres ponds

XXXX

mal point

888.8

ponds

XXXX

72 VEGAPULS 42, 44 and 45 – VBUS

Unit

Mass

Adjustment with MINICOM or VEGAMET

5. Measurement in a standpipe

This adjustment is only necessary if the sensor is mounted on a standpipe (surge or bypass tube). When measuring in a standpipe, the distance must be sounded and the measured value display (can deviate a few percentages from the sounded value) must be corrected according to the sounding. Then the sensor corrects future running time shifts of the radar signal in the standpipe and displays the correct level in the standpipe (meas. tube).

6. Operating range

Without special adjustment, the operating range corresponds to the measuring range. The measuring range has already been adjusted with the min./max. adjustment. Generally it is useful to choose a slightly bigger (approx. 5 %) operating range than measuring range.

Example: Min./max. adjustment: 0.500 … 3.500 m; adjust operating range to approx.

0.400 … 3.600 m.

7. Meas. conditions

(see MINCOM menu schematic)

9. Useful and noise level

In the menu

you get important information on the signal quality of the product echo. The higher the "S-N" value, the more reliable the measurement (menu schematic MINICOM).

Ampl.: means amplitude of the level echo in

S-N: means Signal-Noise, i.e. the useful

The bigger the "S-N" value (difference between the amplitude useful level and the noise level), the better the measurement: > 50 dB Measurement excellent 40 … 50 dB Measurement very good 20 … 40 dB Measurement good 10 … 20 dB Measurement satisfactory 5 … 10 dB Measurement sufficient < 5 dB Measurement poor

Example:

Ampl. = 68 dB S-N = 53 dB

68 dB – 53 dB = 15 dB noise level

Ampl.:

XX dB

S-N:

dB (useful level)

level minus the level of the background noise

53 dB signal level difference indicates very

8. False echo storage

A false echo storage is always useful when unavoidable false echo sources (e.g. struts) must be minimised. By creating a false echo

high measurement reliability.

10. Conditioning/Scaling of the sensor display

storage, you authorise the sensor electronics to record the false echoes and save them in an internal database. The sensor electronics treats these (false) echoes differently from the useful echoes and filters them out.

The menu item "Signal conditioning" in the MINICOM menu relates only to the sensor display and will be overwritten by adjustments in the signal conditioning instrument.

11. Outputs

(see operating instructions VEGAMET)

VEGAPULS 42, 44 and 45 – VBUS 73

MINICOM menu schematic

Sensor

m(d)

4,700

PULS52 V

1.00

When switching on, the sensor type and the software version are displayed for a few seconds.

Adjustment with MINICOM or VEGAMET

Parameter

Sensor optimisation

Meas. environment

Operating range

Begin

m (d)

0.50

Sensor Tag

Sensor

End

m (d)

6.00

Only visible with VEGAMET

Meas. conditions

Condit ion

Liquid

Sensor optimisation

see menu schematic

Configuration/Inputs…"

of the VEGAMET signal

conditioning instrument

Measuring in tube

Meas. dist.

m (d)

4.700

Correction Now !

OK ?

Agitat

Fast

ed sur

change

face No

Only with VEGAPULS 42 and 44

Foam-

Low

ing

prod.

product

False echo memory

Create new Now ! OK ?

Meas. in tube

Create new

Meas. dist.

m (d)

X.XX

Learning !

Multiple echos No

Configuration

Sensor Tag

Sensor

Update

Meas. dist.

m (d)

X.XX

Update Now! OK ?

Learning !

Meas. unit

m (d)

Delete

Delete now! OK ?

Deleting !

Fast change

XXXX

High dust level No

100 % corres ponds

XXXX

Decimal point

Large angle repose No

888.8

Prop. to

Mass

Multiple echos No

Unit

Outputs

Sensor displ.

Prop. to

Distance

Displ. adjust ment

Adjustment in

m (d)

10.

0.0%

m (d)

XX.XXX

100.0%

m (d)

XX.XXX

Condit ion

Solid

Signal conditioning

Scaling

0 % corres ponds

74 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with MINICOM or VEGAMET

With these keys you move in the menu field to the left, right, top and bottom

ESC

Reset to default

Reset Now!

OK ?

Resetting

actual dist.

m (d)

4.700

see menu schematic "Add'l

funct./Info…" of the

VEGAMET signal condi-

tioning instrument

Ampl.:

XX dB

S-N:

max. range

m (d)

7.000

actual dist.

m (d)

4.700

Ampl.:

XX dB

S-N:

Add´l functions

Info Lan-

Reset

Sensor Tag

Sensor

to default

Reset Now!

Sensor type

PULS 52 V

Input 1

OK ?

Resetting!

guage

English

Serial number

1094 0218

Softw. vers.

3.00

Softw. date

10.09. 1999

Simulation:

The sensor returns to standard operating mode after one hour (after the last simulation setting).

Error code:

E013 No valid measured value

- Sensor in the warm-up phase

actual dist. m

X,XX

- Loss of the useful echo E017 Adjustment span too small E036 Sensor software does not run

- Sensor must be programmed with

new software (service).

- message appears during a soft-

ware update.

E040 Hardware failure

VEGAPULS 42, 44 and 45 – VBUS 75

High dust level No

Fast change

Menu items in bolt print provide sensor and measured value information and cannot be modified in this position.

Light grey menu fields are only displayed if required (dependent on the adjustments in other menus).

White menu items can be modified with the "+" or "–" key and saved with the "OK" key.

Adjustment with the PC on VEGALOG

5.4 Adjustment with the PC on VEGALOG

For connection of the PC to the VEGALOG processing system, a standard RS 232 DTEDTE (Data Terminal Equipment) interface cable is required. Connect the PC with the cable to the processing system.

DTE DTE

DCD 1 1 DCD RxD 2 2 RxD TxD 3 3 TxD DTR 4 4 DTR GND 5 5 GND

--- 6 6 ---

--- 7 7 ---

--- 8 8 ---

--- 9 9 ---

Beside the measured values, adjustment signals are also transmitted digitally between sensor and processing system via the signal and supply cable. The adjustment program VVO can then communicate with the processing system and all connected sensors. In chapter "4.4 Configuration of measuring systems" the connection of the PC to the different configurations is shown.

The individual adjustment steps are marked in the following with a dot. Example:

• Choose …

• Start …

• Click to …

The first steps of the setup with the PC in conjunction with the VEGALOG processing system correspond to the adjustment in chapter "5.3 Adjustment with VEGAMET or MINICOM".

• Connect the standard interface of your PC

with the standard RS 232 interlink cable (9pole) to the VEGALOG processing system.

• Now switch on the power supply of the

processing system.

After approx. 1 … 2 minutes (self-test) the measuring system, consisting of processing system and sensors, is in operating condition and the sensors display measured values.

• Now start the adjustment software VVO on your PC.

• Choose with the arrow keys or the mouse the item "

Planning

" on the entrance screen

and click to "OK".

In the next window, you are asked for the user identification.

• Enter under name "VEGA".

• Also enter "VEGA" under password.

The adjustment program VEGA Visual Operating (VVO), called in the following VVO, gets into contact with the connected sensor and indicates after a few seconds if and with which sensor a connection exists.

Note:

If you make no connection with the sensor, check the following:

- Is the processing system being supplied with supply voltage?

- Did you inadvertently use a wrong RS 232 cable instead of the VEGA RS 232 connection cable?

76 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on VEGALOG

If VVO (adjustment software) gets in contact with the processing system for the first time, you will be asked if you want to transfer the data from the processing system to the PC.

• Click to "

If you have connected the VVO to a VEGALOG from which data has already been saved, you are asked if the saved data should be transferred from the PC to VEGALOG or the data from VEGALOG to the PC.

The preadjusted user identification can be modified at a later time in the menu "

ration/Program/User access

Yes

Configu-

Configuration

The adjustment of a radar sensor with the PC on a VEGALOG generally corresponds to the adjustment of a radar sensor on the signal conditioning instrument, as in chapter "5.2 Adjustment with the PC on VEGAMET".

The only difference are the increased configuration requirements of VEGALOG. A number of possible sensor inputs and signal outputs as well as different processing routines must be assigned. First of all, you must define where and what processing which sensor (input) does.

Configuration info

• Choose the menu "

ing system

Configuration/Measur-

No matter whether you set up a measuring system (unit consisting of sensor and VEGAMET signal conditioning instrument or VEGALOG processing system) with the adjustment software VVO or with the signal conditioning instrument, the adjustment procedure is always the same:

- first of all, create a measurement loop and configure a measuring system in the menu "

Configuration

- carry out the parameter adjustment of the sensor in the menu "

VEGAPULS 42, 44 and 45 – VBUS 77

" and then

Instrument data

You now reach the menu "

Measuring system

representation of the VEGALOG connected to the PC is displayed.

• Click to an individual card number and you will get a "Card info" in the window

Configuration

", in which a graphical

Adjustment with the PC on VEGALOG

Create new measurement loop

• Click in the card info window of your EV card (input card VBUS) to "

Sensor survey"

You get an overview of the sensors connected to the card.

• Choose the menu "

ment loop/New

Configuration/Measure-

You are in the menu window "

measurement loop - Application

Create new

". Choose the parameter (level measurement, gauge or distance) and the sensor type (Pulse Radar for radar).

• Choose "

Radar

• Click to "

78 VEGAPULS 42, 44 and 45 – VBUS

Level measurement

Continue

" and "

Pulse

Adjustment with the PC on VEGALOG

• Choose in the next menu window "

ard level measurement

• Click to "

After a few seconds, the menu window "

Continue

" and "

Stand-

no options

Cre-

ate new measurement loop - Sensor configuration

" opens.

• Click to "

The small menu window " opens.

Sensor coordination

• Choose the serial number of the sensor you want to coordinate and confirm with "OK".

• Click in the menu window "

Create new

measurement loop - Sensor configuration

to "

Continue

• Click in the menu window "

Create new measurement loop - Measurement loop designation

" to "

Level

VEGAPULS 42, 44 and 45 – VBUS 79

Adjustment with the PC on VEGALOG

The menu window "

loop - Measurement loop designation

Enter:

- a measurement loop number

- a measurement loop description

- allocate one or several output signals to your sensor.

• For example, configure a current output by clicking to "

In the menu window "

put

", you choose a current output card in your VEGALOG and allocate one or several current outputs to the sensor.

Create new measurement

Current output

Configure current out-

" opens.

• Confirm your adjustments with "OK".

• Click to " initial menu.

Quit

" and you are again in the

You have carried out the special additional configuration settings in conjunction with a VEGALOG.

• Confirm your adjustment with "OK" and you are again in the window "

Create new meas-

In the menu "

tem"

you now see that one sensor is

configured.

Configuration/Measuring sys-

urement loop - Measurement loop designation

80 VEGAPULS 42, 44 and 45 – VBUS

Adjustment with the PC on VEGALOG

Parameter adjustment 1

Now you have to carry out the parameter adjustment for the sensor. The parameter adjustment is nearly identical to the parameter adjustment in chapter "5.2 Adjustment with the PC on VEGAMET".

In the menu "

justment

settings. The settings correspond to those under parameter adjustment 1 in chapter "5.2 Adjustment with the PC on the signal conditioning instrument".

The same is valid for the following menu items corresponding to the adjustment steps in chapter "5.2 Adjustment with the PC on the signal conditioning instrument". For this reason, they are not described again in this paragraph.

•

Sensor optimisation

- Meas. environment/Operating range

- Meas. environment/Meas. conditions

- Meas. environment/Pulse velocity

- Echo curve

- False echo storage

•

Parameter adjustment 2

- Linearisation

- User-programmable linearisation curves

- Defining the linearisation curve by incremental filling

- Calculating the linearisation curve

- Calculate cylindrical tank

•

Outputs

- Configuration outputs

- Parameter adjustment outputs

•

Display of measured value

•

Simulation

•

Backup

Instrument data/Parameter ad-

" you carry out all important sensor

VEGAPULS 42, 44 and 45 – VBUS 81

6 Diagnosis

Diagnosis

6.1 Simulation

To simulate a certain filling, you can call up the function "Simulation" on the adjustment module MINICOM, in the software program VVO or on the signal conditioning instrument.

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.

Simulation with VVO

If you start the simulation mode with the adjustment program VVO on the PC, the simulated level is outputted until you quit the simulation mode.

Simulation with VEGAMET

If you call up the simulation mode with the adjustment keys on the signal conditioning instrument, 15 minutes after the last adjustment the signal conditioning instrument returns to standard operating condition.

Simulation with MINICOM

If you start the simulation mode on the adjustment module MINICOM, the sensor returns to standard operating mode after one hour.

6.2 Error code

Error code Rectification

E013 No valid measured value Message is displayed during warm-up phase

- Sensor in the warm-up phase

- Loss of the useful echo If the message remains, a false echo storage must be made with the adjustment module MINICOM in the menu "sensor optimisation” or better, with the PC and VVO. If the message still remains, carry out a new adjustment.

E017 Adjustment span too small Carry out a readjustment.

E036 Sensor software does not run Sensor must be programmed with new software

E040 Hardware failure/Electronics defec- Check all connection cables.

tive Transducer defective.

82 VEGAPULS 42, 44 and 45 – VBUS

Make sure that the difference between min. and max. adjustment is at least 10 mm.

(service). Message appears during a software update.

Contact our service department.

Technical data

7 Technical data

7.1 Data

Power supply

Supply voltage The sensor is powered by the VEGAMET signal

Number of sensors per two-wire cable VEGAMET max. 2 sensors

Sensor voltage min. 12 V, max. 36 V DC (Ex: max. 29 V DC) Current consumption max. 6 mA Power consumption max. 81 mW Resistance of the signal cable max. 15 Ω per wire Cable length

-1.5 mm

-1 mm

- 0.75 mm

Measuring range

and 2.5 mm

VEGAPULS 42

- standard ø 40 mm horn 0 … 10 m

- optional ø 48 mm horn 0 … 15 m ø 75, 95 mm horn 0 … 20 m

VEGAPULS 44

- DN 50, ANSI 2" 0 … 15 m

- DN 80, 100, ANSI 3", 4", 6" 0 … 20 m

VEGAPULS 45 0 … 4 m

conditioning instrument, the VEGALOG processing system or the VEGATRENN 548V Ex separator

VEGALOG max. 15 sensors (recommended 5) VEGATRENN (Ex) max. 5 sensors

max. 1000 m max. 840 m max. 630 m

Output signal

Signal output digital VBUS output signal in two-wire technology

(VEGA-Bus). the digital output signal (meas. signal) is modulated to the power supply and further processed in the signal conditioning instrument or in the processing system.

Integration time (adjustable)

- in the sensor 0 … 999 seconds

- in the signal conditioning instrument 0 … 600 seconds

Load resistance of the signal cable max. 15 Ohm per

wire and max. 1000 m cable length (with 15 sensors on one two-wire cable max. 10 Ohm per wire)

Min. distance of the antenna to the medium 5 cm

VEGAPULS 42, 44 and 45 – VBUS 83

Technical data

Measured value display (optional)

Liquid-crystal indication

- in the sensor scalable output of measured values as graph and as number

- in the external indicating instrument scalable output of measured values as graph

mounted up to 25 m away from the sensor

Adjustment

- PC and adjustment software VEGA Visual Operating

- adjustment module MINICOM

- VEGA signal conditioning instrument

Accuracy

(typical value under reference conditions, all statements relate to the nominal

measuring range, for type 45 relating to a measuring range of 4 m)

Characteristics linear Accuracy (deviation in characteristics

incl. linearity, repeatability and hysteresis determined by the limit point method) < 0.05 %

Average temperature coefficient

of the zero signal 0.06 %/10 °K Resolution generally max. 1 mm Resolution of the output signal 0.005 % or 1 mm

Characteristics

(typical values under reference conditions, all statements refer to the nomi-

nal measuring range)

Min. span between

full and empty > 10 mm (recommended > 50 mm) Frequency 26 GHz technology Meas. intervals 0.6 s Beam angle (at -3 dB)

- VEGAPULS 42 22° optional 18°, 10° and 8° bigger coupling horns, deviating

from standard dimensions

- VEGAPULS 44 DN 50, ANSI 2" 18° DN 80, ANSI 3" 10° DN 100, ANSI 4" 8° DN 150, ANSI 6" 8°

Adjustment time (response time) > 1 s (dependent on the parameter setting) Influence of the process temperature cannot be measured at 0 bar;

at 5 bar 0.004 %/10 °K;

at 40 bar 0.03 %/10 °K Influence of the process pressure 0.0265 %/bar Adjustment time Radar emitted power (average) 0.717 µW Received average emitted power

> 1 s (dependent on the parameter setting)

- distance 1 m 0.5 … 1.5 nW per cm² (0.5 … 1.5 x 10-9W/cm²)

- distance 5 m 0.02 … 0.6 nW per cm²

1) 2) 3)

See footnotes on next page

84 VEGAPULS 42, 44 and 45 – VBUS

Technical data

Ambient conditions

Vessel pressure -1 … 16 bar (-100 … 1600 kPa)

-1 … 40 bar (-100 … 4000 kPa) Ambient temperature on the housing -30 °C … +80 °C Process temperature (flange temp.) -20 °C … +150 °C (option -40 °C … +150 °C) Storage and transport temperature -60 °C … +80 °C Protection IP 66 and IP 67 Protection class II Overvoltage category III

Ex technical data

Comprehensive data in the attached approval documents (yellow binder) Intrinsically safe version

- classification ia intrinsically safe in conjunction with a separator or safety barrier

- classification mark II 2G EEx ia II T6

- Ex approved Zone 1 (ATEX) Zone 1 (CENELEC, PTB, IEC)

- classification mark II 1G EEx ia IIC T6

- Ex approved Zone 0, Zone 1 (ATEX) Zone 0, Zone 1 (CENELEC, PTB, IEC)

Permissible ambient temperature on the housing

- T6 -40 °C … +55 °C

- T5 -40 °C … +70 °C

- T4, T3 -40 °C … +85 °C

- T2, T1 -40 °C … +70 °C

Permissible ambient temperature on the antenna system if used in Ex areas

- T6 -40 °C … +85 °C

- T5 -40 °C … +100 °C

- T4 -40 °C … +135 °C

- T3 -40 °C … +150 °C

Similar to DIN 16 086, reference conditions acc. to IEC 770, e.g. temperature 15 °C … 35 °C; humidity 45 % … 75 %; air pressure 860 mbar … 1060 mbar

The adjustment time (also called actuating time, response time or adjustment period) is the time required by the sensor to output the correct level (with max. 10% deviation) after a sudden level change.

Average emitted power (electromagnetic energy) per cm² received on an object directly in front of the antenna. The received emitted power depends on the antenna version and the distance.

VEGAPULS 42, 44 and 45 – VBUS 85

Technical data

Process fittings

VEGAPULS 42 thread G 1½ A, 1½" NPT

antenna as horn with ø 40 mm antenna horns from ø 48 … 95 mm (can be retrofitted optionally)

VEGAPULS 44 flanges with DN 50, DN 80, DN 100, DN 150

as well as ANSI 2", 3", 4" and 6" antenna as horn (antenna horns from ø 48 … 95 mm dependent on the flange size)

VEGAPULS 45 flanges with DN 50, DN 80, DN 100, DN 150

as well as ANSI 2", 3", 4" and 6" or thread G 1½ A, 1½" NPT

Materials

Housing PBT (Valox) or

Aluminium die-casting (GD-AlSi 10 Mg) Process fitting 1.4435 Antenna (wetted parts) 1.4435 and PTFE Antenna seal with horn and pipe antenna

- standard Viton (-20 °C)

- option Kalrez, NBR, Viton for low temperature (-40 °C)

Connection cables

Two-wire sensors Vpower supply and signal via one two-wire

cable Electrical connection

- cable entry one cable entry and spring terminal connection up to max. 2.5 mm

wire cross-section

- plug connection optional for plastic housing: four-pole reverse battery screw connection (four-wire: two plug connections)

Cable entry

- non-Ex and Ex ia sensors 1 … 2 x M20 x 1.5 (cable ø 5 … 9 mm) or 1 … 2 x ½" NPT cable ø 3.6 … 8.7 mm or

Ground connection max. 4 mm

0.12 … 0.34 inch)

86 VEGAPULS 42, 44 and 45 – VBUS

Technical data

Weights

VEGAPULS 42 2.0 … 3.1 kg VEGAPULS 44

- DN 50 4.2 … 5.0 kg

- DN 80 6.8 … 7.6 kg

- DN 100 8.0 … 9.1 kg

- DN 150 13.2 … 14.3 kg

- ANSI 2" 5.2 … 5.7 kg

- ANSI 3" 6.9 … 7.5 kg

- ANSI 4" 10.5 … 11.1 kg

- ANSI 6" 14.6 … 15.4 kg

VEGAPULS 45 (plus meas. tube weight)

- G 1½ A or 1½" NPT 2.0 … 3.8 kg

- DN 50 4.2 … 6.0 kg

- DN 80 5.9 … 7.7 kg

- DN 100 7.0 … 8.8 kg

- DN 150 11.8 … 13.7 kg

- ANSI 2" 3.7 … 5.6 kg

- ANSI 3" 6.2 … 8.0 kg

- ANSI 4" 8.3 … 10.1 kg

- ANSI 6" 12.8 … 14.6 kg Meas. tube weight 1.6 kg per m

CE conformity

VEGAPULS series 40 radar sensors meet the protective regulations of EMC (89/336/EWG) and NSR (73/23/EWG). Conformity has been judged acc. to the following standards: EMC Emission EN 61 326: 1997/A1: 1998 (class B)

Susceptibility EN 61 326: 1997/A1: 1998

ATEX EN 50 020: 1994

EN 50 018: 1994 EN 50 014: 1997

NSR EN 61 010 - 1: 1993

VEGAPULS 42, 44 and 45 – VBUS 87

Technical data

7.2 Approvals

When using radar sensors in Ex areas or in marine applications, the instruments must be suitable and approved for the explosion zones and application areas. The suitability is tested by approval authorities and is certified in approval documents.

Intrinsically safe in Ex environment

For application in Ex environment, VEGAPULS 42.CX to 45.CX sensors must be powered from an intrinsically safe circuit. This is ensured by VEGATRENN 548V Ex separators. The separator provides intrinsically safe (ia) circuits. The resistance of the signal cable must not exceed 15 Ohm per wire.

VEGAPULS 42.AX to 45.AC sensors are approved for Ex Zone 1. VEGAPULS 42.CX to 45.CX sensors are approved for Ex Zone

Please note the attached approval documents when using a sensor in Ex area.

Test and approval authorities

VEGAPULS radar sensors are tested and approved by the following monitoring, test and approval authorities:

- PTB

(Physical Technical Test Authority Physikalisch Technische Bundesanstalt)

- FM

(Factory Mutual Research)

- ABS

(American Bureau of Shipping)

- LRS

(Lloyds Register of Shipping)

- GL

(German Lloyd)

- CSA

(Canadian Standards Association)

88 VEGAPULS 42, 44 and 45 – VBUS

Technical data

7.3 Dimensions

External indicating instrument VEGADIS 50

85 38

ø5

Pg 13,5

Mounting on carrier rail 35 x 7.5 acc. to EN 50 022 or flat screwed

118

108

135

Flange dimensions acc. to ANSI (RF)

k D

Note:

Cable diameter of the connection cable min. 5 mm and max. 9 mm. Otherwise the seal effect of the cable entry

will not be ensured.

D = outer flange diameter b = flange thickness k = diameter of hole circle d

= seal ledge diameter

f = seal ledge thickness

/16" = approx. 1.6 mm

= diameter of holes

Size Flange Seal ledge Holes

Db k d1No. d

2" 150 psi 152.4 20.7 120.7 91.9 4 19.1 3" 150 psi 190.5 25.5 152.4 127.0 4 19.1 4" 150 psi 228.6 25.5 190.5 157.2 8 19.1 6" 150 psi 279.4 27.0 241.3 215.9 8 22.4

Adjustment module MINICOM

ESC

Tank 1 m (d)

12.345

67,5

VEGAPULS 42, 44 and 45 – VBUS 89

32,5

Adjustment module to plugped into sensors or into the external indicating instrument VEGADIS 50

Sensor dimensions

Technical data

PBT Aluminium

201

165

101

199

ø 40

307

253

G1½ A

1½" NPT

322

SW 60

G½A 1½NPT

182

ø 40

G1½ A

1½" NPT

ø 40

125

100

M20x1,5

145

0 7 3

PBT: 53 Al: 78

Aluminium with Exd terminal compartment

215

185

5 0 2

135

ø 40

ø 48

116

0 7 3

5 0

M20x1,5

139

ø 75

215

185

219

ø 95

116

½" NPT

319

ø18

45˚

VEGAPULS 42

ø 125

ø 165

DN 50 PN 40 (C)

ANSI 2" (RF)

ø 160

ø 200

DN 80 PN 40 (C)

ANSI 3" (RF)

ø 180

ø 220

DN 100 PN 16 (C)

ANSI 4" (RF)

VEGAPULS 44

90 VEGAPULS 42, 44 and 45 – VBUS

45˚

Technical data

Recommended max. socket length for VEGAPULS 42 and 44 dependent on the antenna version:

Sensor type Version Socket length Socket length

with antenna extension

VEGAPULS 42 Standard 135 mm 250 mm VEGAPULS 44 DN50/ANSI 2" 135 mm 245 mm

DN 80/ANSI 3" 210 mm 325 mm DN 100/ANSI 4" 310 mm 425 mm DN 150/ANSI 6" 310 mm 425 mm

ø 95

ø 40

108

319

ø 165…285

18…22

ø 27

125 65

ø 27

ø22

ø 240

ø 285

DN 150 PN 16 (C)

DN 50…DN 150 PN 16/40 (C)

ANSI 2"…ANSI 6" (RF)

L max. 4000

G1½ A

1½" NPT

ANSI 6" (RF)

VEGAPULS 45VEGAPULS 44

VEGAPULS 42, 44 and 45 – VBUS 91

VEGA Grieshaber KG Am Hohenstein 113 D-77761 Schiltach 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 latest information at the time of printing.

Technical data to subject to alterations

2.24 903 / April 2001

VEGA PULS45 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety information

Note Ex area

1 Product description

1.1 Function

1.2 Application features

1.3 Adjustment

2 Types and versions

2.1 Overview

2.2 Type code

2.3 Antennas

3 Mounting and installation

3.1 General installation instructions

3.2 Measurement of liquids

3.4 False echoes

3.5 Installation mistakes

4 Electrical connection

4.1 Connection and connection cable

4.2 Connection of the sensor

4.3 Connection of the external indicating instrument VEGADIS 50

4.4 Configuration of measuring systems

5 Setup

5.1 Adjustment structure

5.2 Adjustment with the PC on the signal conditioning instrument

5.3 Adjustment with VEGAMET or MINICOM

5.4 Adjustment with the PC on VEGALOG

6 Diagnosis

6.1 Simulation

6.2 Error code

7 Technical data

7.1 Data

7.2 Approvals

7.3 Dimensions