VEGA PULS51K User Manual

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Operating Instructions

VEGAPULS 51K … 54K

4 … 20 mA; HART

compact sensor

Contents

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

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

1 Product description .................................................................. 4

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

1.2 Application features ............................................................. 5

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

2 Types and v ersions ................................................................... 8

2.1 Overvie w .............................................................................. 8

2.2 Antennas ............................................................................. 10

3 Mo unting and in stalla tion ..................................................... 11

3.1 General installation instructions ........................................ 11

3.2 Measurement of liquids ..................................................... 12

3.3 Measurement in standpipe (surge or bypass tube) ...... 14

3.4 False echoes ...................................................................... 21

3.5 Common installation mistakes ........................................... 23

Contents

4 Electrical connection .............................................................. 25

4.1 Connection and connection cable .................................... 25

4.2 Connecting the sensor ...................................................... 27

4.3 Connecting of the external indicating instrument

VEGADIS 50 ....................................................................... 31

4.4 Configuration of measuring systems ............................... 32

5 Set-up ........................................................................................ 40

5.1 Adjustment media .............................................................. 40

5.2 Adjustment with PC ............................................................ 40

5.3 Adjustment with adjustment module MINICOM ............... 42

5.4 Adjustment with HART® handheld ................................... 48

6 Diagnostics............................................................................... 50

6.1 Simulation ............................................................................ 50

6.2 Error codes ........................................................................ 50

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Contents

7 Technic al data .......................................................................... 51

7.1 Technical data ..................................................................... 51

7.2 Approvals ........................................................................... 58

7.3 Dimensions ......................................................................... 59

Supplement ..................................................................................... 63

Safet y Manual ................................................................................. 63

1 General ............................................................................... 63

1.1 Validity ................................................................................. 63

1.2 Area of application ............................................................... 63

1.3 Relevant standards ............................................................. 63

1.4 Determination of safety-related characteristics.................. 64

2 Planning .............................................................................. 65

2.1 Low demand mode ............................................................... 65

2.2 High demand or continuous mode ....................................... 65

2.3 General ................................................................................ 65

3 Set-up ................................................................................. 66

3.1 Mounting and installation ..................................................... 66

3.2 Adjustment instructions and parameter adjustment ........... 66

3.3 Configuration of the processing unit ................................... 66

4 Reaction during operation and in case of failure ............. 67

5 Recurring function test ....................................................... 67

6 Safety-related characteristics ........................................... 68

SIL declaration of conformity .................................................... 69

CE declaration of conformity ..................................................... 70

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

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 manual and come with the Ex

approved instruments. work on the instruments, apart from that involved in normal installation and electrical connection, must be carried out only by qualified VEGA personnel.

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1 Product description

Product description

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

Extremely small 5.8 GHz radar signals are emitted from the antenna of the radar sensor as short pulses. The radar pulses reflected by the sensor environment and the product are received by the antenna as radar echoes. The running period of the radar pulses from emission to reception is proportional to the distance and hence to the level.

Meas. distance

1 ns

278 ns

Pulse sequence

VEGAPULS radar sensors can achieve this through a special time transformation procedure which spreads out the more than 3.6 million echo images per second into a quasi slow-motion picture, then freezes and processes them.

Time transformation

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

Virtually all products can be measured

Radar signals display physical properties similar to those of visible light. According to

emission - reflection - reception

The radar pulses 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 a 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.

4 VEGAPULS 51K … 54K

the quantum theory, they propagate through empty space. Hence, they are not dependent on a conductive medium (air), and they spread out like light at the speed of light. Radar signals react to two basic electrical properties:

- the electrical conductivity of a substance

- the dielectric constant of a substance.

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Product description

All products which are electrically conductive reflect radar signals very well. Even slightly conductive products provide a sufficiently strong reflection for a reliable measurement.

All products with a dielectric constant ε greater than 2.0 reflect radar pulses sufficiently (note: air has a dielectric constant ε

1). Signal reflectivity grows stronger with

increasing conductivity or increasing dielectric constant of the product. Hence, nearly all substances can be measured.

50 40 30 20 10

5 %

25 %

4 6 8 12 14 16 18

40 %

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

With standard flanges of DN 50 to DN 250, ANSI 2“ up to ANSI 10“ or G 1½ A and 1½“ NPT, the sensor antenna systems can be adapted to various products and measuring environments.

The high-quality materials can also withstand extreme chemical and physical conditions. The sensors deliver stable, reproducible analogue or digital level signals with reliability and precision and have a long useful life.

0,03 0,02 0,01

100 500 1000 1300 ˚C

0,018 %

0,023 %

Temperature influence: Temperature error absolutely

zero (e.g. at 500°C 0.018 %)

0,29 %

20 30 40 60

1,44 %

2,8 %

70 80 90 110 120 130 140

100

Pressure influence: Error with pressure increase very

low (e.g. at 50 bar 1.44 %)

VEGAPULS 50 sensors allow radar level

measurement in plants where it was hitherto

unthinkable because of high costs.

1.2 Application features

Applications

• level measurement of any liquid, limited in solids.

• measurement also in vacuum

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

• measuring range 0 … 20 m.

Two-wire technology

• power supply and output signal on one two-wire cable (Loop powered)

• 4 … 20 mA output signal or HART® output signal.

3,89 %

bar

Continuous and accurate

Unaffected by temperature, pressure and atmosphere content, VEGAPULS radar sensors measure quickly, accurately and continuously the levels of widely varying products.

Rugged and abrasionproof

• non-contact

• high-resistance materials

Exact and reliable

• accuracy 1 mm.

• unaffected by noise, vapours, dusts, gas compositions and inert gas stratification

• unaffected by varying density and temperature of the medium

• measurement in pressures up to 40 bar and product temperatures up to 200 °C.

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Communicative

• integrated measured value display

• optional display module separate from sensor

• adjustment with detachable adjustment module, pluggable in the sensor or in the external display

• adjustment with HART® handheld

• adjustment from PLC level with the PC

Approvals

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

1.3 Adjustment

Every measurement setup 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.

The adjustment and parameter setting of radar sensors is carried out with

- the PC

- the detachable adjustment module MINICOM

- the HART® handheld

Product description

4 ...20 mA

Adjustment with the PC on the analogue 4 … 20 mA signal and supply cable or directly on the sensor (four-wire sensor)

The PC can be connected at any location in the system or directly to the signal cable. It is connected by means of the two-wire PC interface converter VEGACONNECT 3 to the sensor or the signal cable. The adjustment and parameter data can be saved with the adjustment software on the PC and can be protected by passwords. On request, the adjustments can be quickly transferred to other sensors.

Adjustment with the PC

The set-up and adjustment of the radar sensors is generally done on the PC with the adjustment software PACT

ware

TM.

The pro-

PLC

gram leads quickly through the adjustment and parameter setting by means of pictures, graphics and process visualisations.

Adjustment with the PC on the 4 … 20 mA signal and supply cable or directly on the sensor (figure: a twowire sensor)

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Product description

Adjustment with the adjustment module MINICOM

With the small (3.2 cm x 6.7 cm) 6-key adjustment module with display, the adjustment is carried out in clear text dialogue. 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

4 ... 20 mA

ESC

Adjustment with the HART® handheld

Series 50 sensors with 4 … 20 mA output signal can also be adjusted with the HART handheld. A special DDD (Data Device Description) is not necessary - the sensors can be adjusted with the HART® standard menus of the handheld.

HART Communicator

HART® handheld

To make adjustments, simply connect the HART® handheld to the 4 … 20 mA output signal cable or insert the two communication cables of the HART® handheld into the adjustment jacks on the sensor.

4 ...20 mA

ESC

Tank 1

m (d)

12.345

HART® handheld on the 4 … 20 mA signal cable Adjustment with detachable adjustment module. The adjustment module can be plugged into the radar sensor or into the external indicating instrument VEGADIS 50.

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2 Types and versions

Types and versions

2.1 Overview

VEGAPULS series 50 sensors are a newly developed generation of very compact, small radar sensors. With modest space requirements, they were developed for short measuring distances of 0 … 20 m and for standard applications such as storage tanks and buffer tanks, but also for process vessels.

Due to their small housing dimensions and process connections, the compact sensors do your level monitoring inconspicuously, and above all, at reasonable cost. With their integrated display and remarkable intelligence, they bring the advantages of radar level measurement to applications where previously, due to high cost, the advantages of non-contact measurement had to be foregone.

VEGAPULS 50 radar sensors utilise two-wire technology perfectly. The supply voltage and the output signal are transmitted via one twowire cable. They provide an analogue 4 … 20 mA output signal as output or measuring signal.

VEGAPULS 51/52

VEGAPULS 54 (pipe antenna/ standpipe)

VEGAPULS 53

VEGAPULS 54 (pipe antenna/ standpipe)

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Types and versions

Features

General features

• Application preferably for liquids in storage tanks.

• Measuring range 0 … 20 m.

• Ex approved in Zone 1 (IEC) or Zone 1 (ATEX) classification mark

EEx ia [ia] IIC T6.

• Integrated measured value display.

Survey

VEGAPULS … 51K 52K 53K 54K

Signal output

- active (4 … 20 mA) • • • •

- passive (4 … 20 mA) • • • •

Voltage output

- two-wire technology (power

supply and signal output via one two-wire cable) • • • •

- four-wire technology (power

supply separate from the signal cable) • • • •

Process fitting

- G1½ 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 • • • •

- HART® handheld • • • •

Antenna material

- PP/PVDF • – – –

- PPS/StSt • – – –

- PTFE/PVDF – • – –

- PTFE/StSt – • – –

- PTFE – – • –

- StSt/PTFE – – – •

- Hastelloy C22/PTFE – – – •

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VEGAPULS 51K … 54K 9

Types and versions

2.2 Antennas

The antenna is the eye of the radar sensor. The shape of the antenna, however, doesn’t give a casual observer the slightest clue on how carefully the antenna geometry must be adapted to the physical properties of electromagnetic waves. The geometrical form determines focal properties and sensitivity - the same way it determines the sensitivity of a unidirectional microphone.

Four antenna systems are available for different applications and process requirements. Beside having its own unique focusing characteristics, each system differs in its chemical and physical properties.

Rod antenna

Rod antennas with high chemical resistance require only the very smallest flange diameters (DN 50). The antenna rod and the wetted flange parts are made of PTFE, PP or PPS so that the rod antenna can be easily cleaned and provide resistance to condensation. The rod antenna is suitable for pressures up to 16 bar and temperatures up to 150 °C.

Horn antenna

Horn antennas are well suited for most applications. They focus the radar signals very well. Manufactured of 1.4571 (StSt) or Hastelloy C22, they are very rugged and are physically as well as chemically resistant. They are suitable for pressures up to 40 bar and for product temperatures up to 150 °C.

Pipe antenna

The pipe antennas on surge or bypass tubes only form a complete antenna system in conjunction with a measuring tube (which can also be curved). Pipe antennas are especially suitable for products with strong flow or turbulence, or products with low dielectric constant. The antenna is available with or without a horn. Versions with horn are characterised by a very high antenna gain.

High measurement reliability can thus be achieved even in products with very poor reflective properties.

The measuring tube acts as a conductor for radar signals. The running period of the radar signals changes in the tube and depends on the tube diameter. The tube inner diameter must be programmed in the sensor so that it can take the altered running time into account and deliver accurate level signals.

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Mounting and installation

3 Mounting and installation

3.1 General installation instructions

Keep in mind that in measuring environments where the medium can reach the sensor

Measuring range

The reference plane for the measuring range

flange, buildup may form on the antenna and later cause measurement errors.

of the sensor is the lower edge of the flange or the seal shoulder of the thread (VEGAPULS 51, 52). The measuring range is 0 … 20 m. When measuring in a surge or

Note: The series 50 sensors are suitable for measurement of solids only under certain conditions.

bypass tube (pipe antenna), the max. measuring distance is reduced.

full

Reference plane

max. filling

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

False echoes

empty

max.

4 m

Meas. range

16 m

max. meas. distance 20 m

If flat obstructions in the range of the radar signals cannot be avoided, we recommend

Flat obstructions and struts cause strong false echoes. They reflect the radar signal with high energy density.

diverting the interfering signals with a deflector. The deflector prevents the interfering signals from taking a direct path back to the radar sensor. The signals are then so low-

Interfering surfaces with rounded profiles scatter the radar signals into the surrounding

energy and diffuse that they can be filtered out by the sensor.

space more diffusely and thus generate false echoes with a lower energy density. Hence, those reflections are less critical than those from a flat surface.

max.

Round profiles diffuse radar signals

Profiles with flat interfering surfaces cause large false signals

Cover smooth interfering surfaces with deflectors

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VEGAPULS 51K … 54K 11

Mounting and installation

Emission cone and false 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. This emission cone depends 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 that 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.

Make sure the sensor axis is perpendicular to the product surface and avoid, if possible, vessel installations (e.g. pipes and struts) within the 50 % area of the emission cone.

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

- a number of weaker beams also exists. Under difficult measuring conditions, the antenna alignment must be selected with the objective of reaching the lowest possible echo intensity. Only giving attention to the size of the useful echo is not adequate when measuring conditions are unfavourable.

In difficult measuring environments, 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 PACTwareTM 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" of the product inside the emission cone and avoid vessel installations in the first third of the emission cone. Optimum measuring conditions exist when the emission cone reaches the measured product perpendicularly and when it is free of obstructions.

3.2 Measurement of liquids

Flange antennas

Horn antenna on DIN socket piece

Radar sensors are usually mounted on short DIN socket pieces. The lower side of the instrument flange is the reference plane for the measuring range. The antenna should always protrude out of the flange pipe. If the DIN socket piece is longer, make sure that the horn antenna does not appear in the socket opening.Better results are achieved when the antenna protrudes at least 10 mm out of the socket.

Reference plane

> 10 mm

Mounting on DIN socket piece

In vessels with dished or rounded tops, the antenna length should at least correspond to the length of the longer sockets.

Vessel center or symmetric axis

> 10 mm

Mounting on a dished vessel top

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Mounting and installation

On dished tank ends, please do not mount the instrument in the centre or close to the vessel wall, but approx. ½ vessel radius from the centre or from the vessel wall.

Dished tank 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 are thereby avoided.

Vessel center or symmetric axis

Reference plane

½ vessel radius

Mounting on round vessel tops

Horn antenna directly on the vessel top

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

Rod antenna

Rod antenna on DIN socket piece

The PTFE (Teflon) rod antenna is well suited to chemically aggressive products such as lyes and acids. Applications in the food processing industry with aseptic vessel conditions require nonreactive measuring systems and very small vessel openings. The Teflon rod antenna is not only nonreactive, but can be mounted in very small vessel openings (50 mm or 1½“ thread holes).

For measurements of liquids, the Teflon rod antenna is mounted on a straight DIN socket piece. The socket however must not be longer than 150 mm (when using the longer antenna, not longer than 250 mm). The rod antenna is available in flange sizes of DN 50, DN 80 and DN 100.

≤ 50 mm, 100 mm or 250 mm

Rod antenna on DIN socket piece

Rod antenna directly on the vessel opening

Reference plane

Opening ø 50 mm

Mounting directly on the flat vessel top

Rod antenna directly on the vessel opening

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VEGAPULS 51K … 54K 13

Mounting and installation

As an alternative to socket mounting, the rod antenna can also be mounted in round vessel openings (threaded holes). Rod antennas are available for the following vessel openings: 1½“ NPT, DN 50 up to DN 150. Keep in mind that the PTFE rod antenna can only be subjected to very small mechanical loads. If it is subjected to bending forces, deformation or even breakage will occur.

Rod antenna with thread

When mounting the sensors with 1½“ screwed process connection in a socket piece, the max. socket length must be observed. The permissible socket length depends on the antenna rod and is 50 mm, 100 mm or 250 mm, see also chapter „8.3 Dimensions“.

Reference plane

≤ 50 mm or 100 mm or 250 mm

3.3 Measurement in standpipe

(surge or bypass tube)

General instructions

Measurement in a standpipe is preferred in vessels which contain many installations, e.g. heating tubes, heat exchangers or fast-running stirrers. Measurement is then possible even when the product surface is very turbulent, and vessel installations can cause no false echoes.

Due to the concentration of radar signals in the measuring tube, even products with small dielectric constants (ε reliably measured in surge or bypass tubes. Please observe the following installation directions.

Surge pipe welded to the tank

= 1.6 up to 3) can be

Surge pipe in the socket piece

Type label

max.

Rod antenna with thread on 1½“ socket

without deflector

Pipe antenna systems in the tank

Vent hole ø 5 … 10 mm

min.

with deflector

Surge pipes or bypass tubes which are open at the bottom must extend over the full measuring range (i.e. down to 0% level), as

Rod antenna with thread on 1½“ thread hole

measurement is only possible within the tube. The tube inner diameter should be max. 100 mm or correspond to the size of the antenna horn.

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Mounting and installation

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 vessel, a pipe antenna system can be installed in a bypass tube outside the vessel. With measurement in a surge or bypass tube, the max. measuring range decreases by 5 … 20 % (e.g. DN 50: 16 m instead of 20 m and with DN 100 only 19 m instead of 20 m) due to the change of running time of the radar signal.

Align the sensor so that the type label lies on the same axis as the tube holes or the tube connection openings. The polarisation of the radar signals enables a considerably stabler measurement with this alignment.

Type label

> 500 mm

100 %

75 %

0 %

Extended bypass tube on a vessel with turbulent product movement

Type label

> 500 mm

100 %

0 %

Tube flange system as bypass tube

When mounting a VEGAPULS 52 on a bypass tube (e.g. on a previous floating or

0 %

300 ... 800 mm

displacer unit), the radar sensor should be placed approx. 500 mm or more from the

Tube flange system as bypass tube

upper tube connection. If the tube has a rough inner surface, the use of an additional measuring tube (tube in tube) is recommended, as poor surface quality of the measuring tube hampers radar measurement through an excessively high „noise level“.

For products with small dielectric values (< 4), the bypass tube should extend below the lower tube connection. Products with small dielectric constants are partly penetrated by the radar signals, which could allow the tube bottom to deliver a stronger echo than the product surface (when the bypass tube is nearly empty). By extending the lower end of the bypass tube, enough liquid remains in the tube even when the vessel i.e. emptied.

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VEGAPULS 51K … 54K 15

If enough liquid (300 … 800 mm) remains 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. In cases where there is not enough liquid at the bottom of the tube, a deflector situated there will carry out the same function. It deflects signals that reach the tube bottom into the standard connection 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 must lie in the same plane as the upper and lower vessel connection (above each other or displaced by 180°).

Mounting and installation

Welding beads too large

Tube connection protrudes

Additional connection in the bypass tube in one plane

Adhesive products

With adhesive products, a surge pipe with a larger inner diameter should be used. For non-adhesive products, the best and most inexpensive solution is a measurement tube with a diameter of 50 mm. For slightly adhesive products, use a surge pipe with a nomi-

Optimum connection to the bypass tube

16 VEGAPULS 51K … 54K

nal diameter of 100 mm or 150 mm to prevent buildup from causing measurement errors. Measurement of extremely adhesive products in a standpipe is not possible.

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Mounting and installation

DN 50

ø 50

Pipe antennas with DN 50, DN 80, DN 100 and DN 150

DN 150

ø 150

Use of guide tubes

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

To increase the min. distance, the guide tube can project 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 guide tube. In both cases, a breather hole must be provided.

Seals on tube connections and tube extensions

Extended guide tube

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.

Guide tube

Observe the following points:

• The seal used should correspond to the tube inner diameter

• If possible, conductive seal made of materials such as conductive PTFE or graphite should be used

• There should be as few seal positions as possible in the guide tube.

Guide tube in existing surge or bypass tube

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VEGAPULS 51K … 54K 17

Flange connections on bypass tubes

Standpipe measurement of inhomogeneous products

Mounting and installation

If you want to measure inhomogeneous 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.

Type label

ø 5...10

homogeneous liquids

ø 5...10

slightly inhomogeneous liquids

VEGAPULS 54: Row of holes in one axis with the type label

Every wider slot causes a false echo. The slots should therefore not exceed a width of 10 mm in order to keep the signal noise level

ø 5...10

to a minimum. Round slot ends are better than rectangular ones.

inhomogeneous liquids

Openings in a surge pipe for mixing of inhomogeneous products

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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).

DN 50

Ball valve

Vent hole

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 constricted areas in its channel. The distance to the sensor flange should be at least 500 mm.

> 500 mm

Deflector

Guidelines for standpipe construction

Radar sensors for measurement on surge or bypass tubes are used with G 1½ A screwon antenna or in the flange sizes DN 50, DN 80, DN 100 and DN 150. The radar sensors with a DN 50 flange only forms a functioning measuring system when used in conjunction with a measuring tube.

The illustration on the left shows the constructional features of a measuring tube (surge or bypass tube) as exemplified by a radar sensor with DN 50 flange.

The measuring pipe must be smooth inside (average roughness Rz ≤ 30). Use stainless steel tubing (drawn or welded lengthwise) for construction of the measuring pipe. Extend the measuring pipe to the required length with weld-on 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.

The following illustration shows the constructional features of a measuring tube as exemplified by a radar 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.

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VEGAPULS 51K … 54K 19

Flange DN 100

VEGAPULS 54

Mounting and installation

In products with lower dielectric values (< 4), a part of the radar signal penetrates the medium. If the vessel is nearly empty, echoes are generated by both the product and the vessel bottom. The echo from the vessel bottom can in some cases be stronger than the echo from the product surface. If a deflector is installed below the open end of the measuring tube, the radar signals are scattered and prevented from reaching the vessel bottom. This ensures that, in nearly empty vessels or with products of low dielectric value, the product delivers a more distinct echo than the vessel bottom.

Deburr the holes

150…500

Connecting sleeve

Welding neck flanges

Deflector

0 %

Welding of the smooth welding neck flanges

Due to the deflector, the useful echo (and thus the measured value) remains clearly detectable in a nearly empty vessel, and the 0 % level can be reliably measured.

100 %

ø 95

Welding of the connecting sleeves

5…10

The standpipe or surge pipe can be equipped with a quadrant pipe at its end instead of a deflector. This quadrant pipe reflects the radar signals that penetrate the

0,0…0,4

medium diffusely to the side and diminishes strong echoes from the tube end or the vessel bottom.

3,6

Welding of the welding

ø 100,8

~45˚

3,6

neck flanges

1,5…2

0,0…0,4

Meas. pipe fastening

Vessel bottom

Quadrant pipe on the bypass tube end

0 %

Quadrant pipe on the standpipe end

20 VEGAPULS 51K … 54K

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Mounting and installation

3.4 False echoes

The radar sensor must be be installed at a location where no installations or inflowing material cross the radar pulses. The following examples and instructions show the most frequent measuring problems and how to avoid them.

Vessel protrusions

Vessel forms with flat protrusions can make measurement very difficult due to their strong false echoes. Baffles mounted above these flat protrusions scatter the false echoes and guarantee a reliable measurement.

Correct Incorrect

Vessel protrusions (ledge)

Vessel installations

Vessel installations, such as e.g. ladders, often cause false echoes. Make sure when planning your measuring location that the radar signals have free access to the measured product.

Correct Incorrect

Ladder

Vessel installations

Ladder

Struts

Struts, like other vessel installations, can cause strong false echoes that overlay the useful echoes. Small baffles effectively prevent a direct reception of false echoes. These false echoes are scattered and diffused in the surrounding space and then filtered out as "echo noise“ by the measuring electronics.

Intake pipes, i.e. for the mixing of materials with a flat surface directed towards the sensor - should be covered with an angled baffle

Correct Incorrect

that scatters false echoes.

Correct Incorrect

Shields

Struts

Vessel protrusions (intake pipe)

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VEGAPULS 51K … 54K 21

Mounting and installation

;;

Inflowing material

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

Correct

Inflowing material

Incorrect

Buildup

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

Correct

Incorrect

Strong product movements

Strong turbulence in the vessel, e.g. caused by powerful stirrers or strong chemical reactions, can seriously interfere with the measurement. A surge or bypass tube (see illustration) of sufficient size always enables reliable and problem-free measurement even if strong turbulence occurs in the vessel, provided there is no product buildup in the tube.

Correct

Strong product movements

Incorrect

100 %

75 %

0 %

Buildup

22 VEGAPULS 51K … 54K

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Mounting and installation

3.5 Common installation mistakes

Socket piece too long

If the sensor is mounted in a socket extension that is too long, strong false echoes are generated which interfere with the measurement. Make sure that the horn antenna protrudes out of the socket piece.

Correct Unfavourable

Reference plane

≥ 10 mm

Flange antenna: Correct and unfavourable socket length

Unfavourable

Parabolic effects on dished or rounded vessel tops

Round or parabolic tank tops act on the radar signals like a parabolic mirror. 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 location is generally in the range of half the vessel radius from the centre.

Correct

- 100 mm (250 mm)

~ ½ vessel radius

Incorrect

Correct

< 100 mm (250 mm)

Flange antenna: Correct and unfavourable socket length

Mounting on a vessel with parabolic tank top

Wrong orientation to the product

Weak measuring signals are generated if the

Incorrect

sensor is not directly pointed at the product surface. Orient the sensor axis perpendicularly to the product surface to achieve optimum measuring results.

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VEGAPULS 51K … 54K 23

Mounting and installation

Sensor too close to the vessel wall

Strong false echoes can also result if the radar sensor is mounted too close to the vessel wall. Buildup, rivets, screws or weld joints superimpose their echoes onto the product i.e. useful echo. Please ensure a sufficient distance from the sensor to the vessel wall.

Correct Incorrect

Ladder

Direct sensor vertically to the product surface

If there are good reflection conditions (liquid medium, no vessel installations), we recommend locating the sensor where there is no vessel wall within the inner emission cone. For products with less favourable reflection conditions, it is a good idea to also keep the outer emission cone free of interfering installations. Note chapter "3.1 General installation instructions“.

Ladder

Standpipe installation mistakes

Pipe antenna without ventilation hole

Pipe antenna systems must be provided with a ventilation hole on the upper end of the surge pipe. If this hole is absent, incorrect measurements will result.

Type label

Incorrect

Correct

Pipe antenna: The surge pipe open to the bottom must have a ventilation or equalisation hole at the upper end

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 type label always points in the polarisation direction.

Correct

Foam generation

Thick, dense and creamy foam on the product can cause incorrect measurements. Take measures to avoid foam, measure in a bypass tube or use another measurement technology, e.g. capacitive electrodes or hydrostatic pressure transmitters.

VEGAPULS 54 on the surge pipe: The sensor type plate must be aligned with the rows of holes

24 VEGAPULS 51K … 54K

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Electrical connection

4 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, especially when using sensors which do not operate with low voltage.

Qualified personnel

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

Connection cable and screening

A standard two or four-wire cable (sensors with separate supply) with max. 2.5 mm2 wire cross-section can be used for connection.

Make sure that the connection cables are specified for the expected application conditions in your systems. The cable must have an outer diameter between 5 and 9 mm (1/2 to 1/3 inch), with NPT threads, 3.6 … 8.7 mm (0.12 to 0.34 inch) and with threaded PG cable entries, 5 … 10.5 mm. Otherwise, the seal effect of the cable entry would not be ensured.

In critical systems, the signal cables are the source of the problem. The signal cables often act as antennas that pick up interfering signals. The 4 … 20 mA signal lines are affected by earth equalisation currents and especially by current peaks in the ms or µs range (more so than digital signal lines). This can be avoided with sophisticated wiring, of which screening at both ends is a major feature.

Circumspect system planning, however, will take into account possible sources of interference from electromagnetic pollution. Due to the complex interrelationships, it may be difficult to decide whether measures against such interference should be taken, and if so, which ones. And in fact, it is extremely difficult to describe in theoretical terms the actual forces at work, since the effects depend greatly on the frequency of the interfering magnetic fields: what is very effective for one frequency can have completely opposite effects for other frequencies.

Experience has shown that even some relatively simple measures can protect the signal current circuits against electromagnetic influence. As one of the more costly measures, screening usually comes at the end of any catalogue of preventive measures against interference.

Quite often, the "electromagnetic pollution" caused by electronic actuators, energy cables and transmitting stations is so considerable that measures against the effects of electrical and magnetic fields can be necessary. This so-called "electromagnetic pollution" has increased considerably in the last few years, caused e.g. by fast-cycle power supply units and mobile phones, especially in the high-frequency range. VEGAPULS radar sensors take this into account and are for the most part insensitive to electromagnetic pollution.

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VEGAPULS 51K … 54K 25

Electrical connection

Wiring instructions

The signal cables should be wired close to the ground potential. Wiring in well-grounded metal cable channels is an effective protection against interference. Obviously, signal cables should not be wired directly together with high-energy cables, but should be separated from them, e.g., with sheet metal strips in the cable channels. Twisted cable (twisted pair) is especially suitable for signal circuits, as it compensates coupled voltage vectors. The distance between the outbound and the return conductor is just as important as the distance to ground when it comes to interference signal reception. For that reason, the distance between the two conductors should be as small as possible. Twisted pair cable meets this requirement. These measures are described by specialists with the expression "wiring close to the structure". To wire the signal cable still "closer to the structure", i.e. even closer to the ground potential, the signal cable can be provided with screening.

Earthing the screen only on one end is not always effective, see the following table. The table gives a simple overview of the effectiveness of the different protective measures against electromagnetic pollution. In practice, earthing of both sides is often useful. This allows the option of earthing only one end later by simply disconnecting the other earth contact points of the screen. Why? Actual interference only appears in the operating environment. Earthing only one end of the screen prevents interference, e.g. in the 100 kHz range, better than earthing both ends, especially if there is insufficient potential equalisation. However, you must make sure that no ground equalisation currents flow through the cable screening. Ground equalisation currents can be avoided by ground potential equalisation systems. When earthing on both ends, it is possible to connect the cable screen on one earth side (e.g. in the switching cabinet) via a YC capacitor1) to the earth potential. Use a very low-resistance earth connection (foundation, plate or mains earth).

Screening magnetic low-frequency high-frequency Ground currents

fields electrical electrical and superimposed

fields fields potential currents

l < ––

l > ––

7 none – – – –

one end – ++ – –

both ends + + ++ ++ ++ good protection against electromagnetic pollution

+ protection against electromagnetic pollution – no protection against electromagnetic pollution

Note: λ (Lambda) = –––

l cable length c speed of light (300000 km/s) f interference frequency λ wave length

Example: Interference frequency approx. 100 kHz

1c 1 3 • 10

l < – • – = – • ––––––––– = 4285 m

7 f 7 100 • 10

– s

This means that with an interference frequency of 100 kHz up to a cable length of approx. 4000 m, earthing the screen on only one end provides better protection than earthing on both ends. However, with a cable length of more than 4000 m, earthing on both ends usually produces better results.

max. 10 nF, e.g. voltage resistance 1500 V, ceramic

26 VEGAPULS 51K … 54K

21750-EN-031222

Electrical connection

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).

Intrinsically safe circuits with more than one active instrument (instrument delivering electrical energy) are not allowed. Special installation regulations (DIN 0165) must be noted.

Note!

Due to the possibility of potential transfer, earthing on both ends is prohibited in Ex applications.

Ground terminals

On VEGAPULS 51 and 52 sensors with 1½“ plastic thread, the ground terminal is galvanically isolated. The sensors have a protective insulation.

On VEGAPULS 53 and 54 sensors as well as 51 and 52 sensors with metal thread, the ground terminal is galvanically connected to the flange or thread.

4.2 Connecting 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 indicating display can then be opened. Unscrew the sleeve nut and slip it over the connection cable (after removing about 10 cm of cable mantle). The sleeve nut of the cable entry has a self-locking ratchet that prevents it from opening on its own.

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 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.

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VEGAPULS 51K … 54K 27

Version with plastic housing

Power supply 4 … 20 mA (passive)

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

Cable entry M20 x 1.5

Power supply

Electrical connection

4 … 20 mA (active)

To the display in the lid or the external indicating instrument

4-20mA

Tank 1 m (d)

12.345

Communication

5678

2.23272

Display

ESC

Two-wire technology in plastic housing

(loop powered)

4 … 20 mA passive means that the sensor consumes a level-dependent current of 4 … 20 mA (consumer).

Terminals (max. 2.5 mm wire cross-section)

Sockets for connection of the HART® handheld or the VEGACONNECT

Pluggable adjustment module MINICOM

Communication

4-+3

8765

4-20mA

Display

2.23274

Opening

ESC

tabs

(+) L1

Tank 1 m (d)

12.345

Four-wire technology in plastic housing

(separate supply)

4 … 20 mA active means that the sensor provides a level-dependent current of 4 … 20 mA (current source).

28 VEGAPULS 51K … 54K

21750-EN-031222

ESC

Electrical connection

Version with aluminium housing

Two-wire technology

(loop powered)

4 … 20 mA passive

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

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

Four-wire technology

4 … 20 mA active

Voltage supply

M20 x 1.5 (diameter of the connection cable 6…9 mm)

To the indicating

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

M20 x 1.5

12 C 567843

12 C 5 6 7 843

(+) (-)

Communication+-4...20mA

Display

ESC

L1 N

4 … 20 mA passive means that the sensor consumes a level-dependent current of 4 … 20 mA (consumer).

Sockets for connection of VEGACONNECT (communication sockets)

4 … 20 mA active means that the sensor provides a level-dependent current of 4 … 20 mA (current source).

12 C 567843

12 C 5 6 7 843

(+) (-)

Commu-

L1 N

nication+-4...20mA

Display

ESC

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VEGAPULS 51K … 54K 29

Electrical connection

ESC

ESCESC

OKOK

12 C 5678

(+) (-) L1 N

Communication

Display

12 C 5 6 7 8

Ver sion with aluminium housing and pressure-tight encapsulated terminal compartment

Two-wire EEx d terminal compartment

(opening in Ex atmosphere not allowed)

Power supply

Locking of the cover

ser.no ********

ATEX

APPROVED

Supply: 20...36V DC/4...20mA HART

GND

Exd terminal compartment

/2“ NPT EEx d diameter of the connection cable

3.1…8.7 mm (0.12…0.34 inch))

Two-wire adjustment module terminal compartment

(opening in Ex area permitted)

/2“ NPT EEx d diameter of the connection cable to the Exd terminal compartment

3.1…8.7 mm (0.12…0.34 inch)

Exd safe connection to the Exd terminal compartment

12 C 5678

12 C 5 6 7 8

(+) (-)

Communication

Display

ESC

L1 N

Four-wire EEx d terminal compartment Four-wire adjustment module terminal

compartment

(opening in Ex area permitted)

Locking of the cover

20...72V DC

20...250V AC

Power supply

-+-+

HART

IS GND

ser.no ********

4 ... 20 mA

4...20mAsupply

543

Exd terminal compartment

/2“ NPT EEx d diameter of the connection cable to the Exd terminal compartment

3.1…8.7 mm (0.12…0.34 inch)

30 VEGAPULS 51K … 54K

/2“ NPT EEx d diameter of the connection cable to the Exd terminal compartment

3.1…8.7 mm (0.12…0.34 inch)

Exd safe connection to the Exd terminal compartment

21750-EN-031222

Electrical connection

ESC

Tank 1 m (d)

12.345

ESC

4.3 Connecting the external indicating instrument VEGADIS 50

Loosen the four screws of the housing lid on VEGADIS 50. The connection procedure can be facilitated by fixing the housing cover during connection work with one or two screws on the right of the housing.

Four-wire sensor in aluminium housing

(separate supply)

OUTPUT (to the sensor)

SENSOR

Power supply

DISPLAY (in the lid of the indicating instrument)

DISPLAY1234 56 78

4 … 20 mA active

VEGADIS 50

Adjustment module

Screws

Two-wire sensor in aluminium housing

(loop powered)

4 … 20 mA passive

to VEGADIS 50 or to the display in the sensor lid

12 C 567843

12 C 5 6 7 843

(+) (-)

Communication+-4...20mA

Display

ESC

12 C 567843

12 C 5 6 7 843

(+) (-)

Communication+-4...20mA

Display

ESC

L1 N

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VEGAPULS 51K … 54K 31

M20x1.5

Electrical connection

4.4 Configuration of measuring systems

A measuring system consists of a sensor with 4 … 20 mA signal output and a unit that evaluates and further processes the levelproportional current signal.

On the following pages, you will see a number of instrument configurations, designated as "measuring systems“, some of which are shown with signal processing units.

Measuring systems in two-wire technology:

• 4 … 20 mA shown without processing unit

• 4 … 20 mA on active PLC

• 4 … 20 mA in Ex area on active PLC

• 4 … 20 mA in Ex area on passive PLC

• 4 … 20 mA in Ex area on indicating instrument VEGADIS 371 Ex

Measuring systems in four-wire technology:

• 4 … 20 mA shown without signal conditioning instrument

Measuring systems with VEGAPULS 51K … 54K connected to any 4 … 20 mA signal processing unit

• Two-wire technology (loop powered), supply and output signal via one two-wire cable.

• Output signal 4 … 20 mA (passive).

• Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).

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

VEGADIS 50

VEGACONNECT 2

If the resistance of the processing systems connected to the 4 … 20 mA signal output is less than 250 Ω, a resistor must be connected to the connection cable during adjustment to get a loop resistance of 250 Ω. The digital adjustment signal would otherwise be severely damped or short-circuited due to insufficient resistance of the connected processing system. Digital communication with the PC would not be ensured.

32 VEGAPULS 51K … 54K

4 … 20 mA

HART® handheld

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Electrical connection

Measuring system with VEGAPULS 51K … 54K on active PLC

• Two-wire technology, power supply from active PLC.

• Output signal 4 … 20 mA (passive).

• Measured value display integrated in the sensor.

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

• Adjustment with PC, HART® handheld or the adjustment module MINICOM (can be plugged into the sensor or into the external indication instrument).

VEGADIS 50

VEGACONNECT 2

4 … 20 mA

passive

PLC (active)

HART® handheld

4 … 20 mA passive means that the sensor consumes a level-dependent current of 4 … 20 mA. The sensor reacts electrically like a varying resistor (consumer) to the PLC.

Active means that the PLC powers the passive

sensor as voltage source. insufficient resistance of the connected processing system. Digital communication with the PC would not be ensured.

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VEGAPULS 51K … 54K 33

Electrical connection

Measuring system with VEGAPULS 51K … 54K in four-wire technology

• Four-wire technology, power supply and output signal via two separate two-wire cables.

• Output signal 4 … 20 mA active.

• Optional external indicating instrument with analogue and digital indication (can be mounted up to 25 m away from the sensor).

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

• max. resistance on the signal output (load) 500 Ω.

VEGADIS 50

VEGACONNECT 2

≥ 250 Ω

4 … 20mA

(active)

HART® handheld

4 … 20 mA active means that the sensor delivers a level-dependent current of 4 … 20 mA (source). The sensor reacts electrically in the processing system (e.g. indication) like a current source.

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34 VEGAPULS 51K … 54K

Electrical connection

Measuring system with VEGAPULS 51K … 54K via separator in Ex areas on active PLC (Ex ia)

• Two-wire technology (loop powered), power supply via the signal line of the PLC; output signal 4 … 20 mA (passive).

• Separator transfers the non intrinsically safe PLC circuit to the intrinsically safe circuit, so that the sensor can be used in Ex zone 1 or Ex zone 0.

• Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).

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

VEGADIS 50

Zone 0 or Zone 1

Ex area

EEx ia

Non Ex area

Separator (e.g. Stahl) (see „7.2 Approvals“)

VEGACONNECT 2

4 … 20 mA

passive

PLC (active)

HART® handheld

4 … 20 mA passive means that the sensor or the PLC consumes a level-dependent current of 4 … 20 mA. The PLC reacts electrically like a varying resistor (consumer) to the PLC. The PLC operates actively, i.e. as current or voltage

source. severely damped or short-circuited due to insufficient resistance of the connected processing system. Digital communication with the PC would not be ensured.

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VEGAPULS 51K … 54K 35

Electrical connection

Measuring system with VEGAPULS 51K … 54K via separator (Smart-Transmitter) on passive PLC (Ex ia)

• Two-wire technology (loop powered), intrinsically safe ia supply via the signal cable of the separator for operation of the sensor in Ex zone 1 or Ex zone 0.

• Output signal sensor 4 … 20 mA passive.

• Output signal separator 4 … 20 mA active

• Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).

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

VEGADIS 50

Zone 0 or Zone 1

Ex area

EEx ia

Non Ex area

Separator (e.g. VEGATRENN 149 Ex see „7.2 Approvals“)

4 … 20 mA

(active)

VEGACONNECT 2

PLC (passive)

HART® handheld

4 … 20 mA active means that the separator delivers a level-dependent current of 4 … 20 mA The separator reacts electrically to the PLC like a current source.

4 … 20 mA passive means that the PLC consumes a level-dependent current of 4 … 20 mA. The PLC reacts electrically like a varying resistor (consumer).

PC would not be ensured.

36 VEGAPULS 51K … 54K

21750-EN-031222

Electrical connection

Measuring system with VEGAPULS 51K … 54K on VEGADIS 371 Ex indicating instrument with current and relay output (Ex ia)

• Two-wire technology (loop powered), intrinsically safe ia supply via the signal cable of the VEGADIS 371 Ex indicating instrument for operation of the sensor in Ex zone 1 or Ex zone 0.

• Optional external indicating instrument with analogue and digital display (can be mounted up to 25 m away from the sensor).

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

VEGADIS 50

Zone 0 or Zone 1

Ex area

EEx ia

Non Ex area

VEGACONNECT 2

4 ... 20 mA

(passive)

VEGADIS 371 Ex

(see „7.2 Approvals“)

HART® handheld

Relay

0/4 … 20 mA (active)

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VEGAPULS 51K … 54K 37

Electrical connection

VEGAPULS 51K Ex … 54K Ex (loop powered) with pressure-tight encapsulated connection compartment on active PLC (Ex d)

• Two-wire technology, supply via the cable from active PLC to Exd connection housing for operation in Ex-Zone 1 (VEGAPULS …Ex) or Ex-Zone 0 (VEGAPULS …Ex0).

• Output signal 4 … 20 mA (passive).

• Measured value display integrated in the sensor.

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

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

Ex area Non Ex area

VEGADIS 50 Ex

If the resistance of the processing systems

VEGACONNECT 2

connected to the 4 … 20 mA signal output is less than 250 Ω, a resistor must be connected to the connection cable during adjustment to get a loop resistance between 250 Ω. The digital adjustment signal would otherwise be severely damped or short-circuited due to insufficient resistance of the connected processing system. Digital communication with the PC or the HART® handheld would not be ensured.

4 … 20 mA

passive

PLC (active)

HART handheld

4 … 20 mA passive means that the sensor consumes a level-dependent current of 4 … 20 mA. The sensor reacts electrically like a varying resistor (consumer) to the PLC.

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38 VEGAPULS 51K … 54K

Electrical connection

VEGAPULS 51K Ex … 54K Ex with pressure-tight encapsulated connection compartment in four-wire technology (Ex d)

• Four-wire technology, supply and output signal via two separate two-wire cables for operation in Ex-Zone 1 (VEGAPULS …Ex) or Ex-Zone 0 (VEGAPULS …Ex0).

• Output signal 4 … 20 mA (active).

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

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

• Load max. 500 Ω.

Ex area

VEGADIS 50 Ex

If the resistance of the processing systems

Non Ex area

VEGACONNECT 2

> 250 Ω

4 … 20 mA active means that the sensor delivers

4 … 20mA

active

HART® handheld

a level-dependent current of 4 … 20 mA (source). The measuring signal of the sensor reacts electrically to the processing system (e.g. display) like a current source.

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VEGAPULS 51K … 54K 39

5 Set-up

Set-up

5.1 Adjustment media

Radar sensors can be adjusted with the

- PC (adjustment software PACT

- detachable adjustment module MINICOM

- HART® handheld.

The adjustment must be carried out with only one adjustment device. If, for example, you attempt to adjust the parameters with the MINICOM and the HART® handheld at the same time, the adjustment will not work.

With the adjustment program PACT the PC, you can adjust the radar sensors quickly and conveniently. The PC communicates via the interface adapter VEGACONNECT 3 with the sensor. During the process, a digital adjustment signal is superimposed on the signal and supply cable. The adjustment can be carried out directly on the sensor or at any desired location along the signal cable.

Adjustment module MINICOM

With the adjustment module MINICOM, you adjust directly in the sensor or in the external indicating instrument VEGADIS 50. With a dialogue text display and 6 keys, the module offers the same adjustment functionality as the adjustment software VVO.

ware

)

5.2 Adjustment with PC

When using a sensor in conjunction with a VEGA signal conditioning instrument, use a communication resistor according to the following schedule:

VEGA signal conditioning instr. Rx

VEGAMET 513, 514, 515, 602 50 … 100 Ohm

VEGAMET 614 no additional VEGADIS 371 resis tor

necessary

VEGAMET 601 200 … 250 Ohm

VEGASEL 643 150 … 200 Ohm

VEGAMET 513 S4, 514 S4 515 S4, VEGALOG EA card 100 … 150 Ohm

HART® handheld

VEGAPULS series 50K radar sensors, like other HART® protocol compatible instruments, can be adjusted with the HART® handheld. A manufacturer-specific DDD (Data-DeviceDescription) is not required. The radar sensors are adjusted with the HART® standard menus. All main functions are therefore accessible. Functions that are rarely used, such as, for example, scaling of the A/D converter for signal output or adjustment with medium, are not possible, i.e. disabled, with the HART

handheld. These functions must be carried out with the PC or the MINICOM.

40 VEGAPULS 51K … 54K

21750-EN-031222

Set-up

PLC

Ri ≥ 250 Ω

250 Ω

PLC

Ri < 250 Ω

VEGAMET/VEGALOG

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VEGAPULS 51K … 54K 41

Set-up

5.3 Adjustment with adjustment module MINICOM

You can set up and operate the sensor with the small, detachable adjustment module MINICOM just as well as with the PC. The adjustment module is simply plugged into the sensor or into the external indicating instrument (optional).

ESC

Tank 1

m (d)

12.345

4 ... 20 mA

ESC

Tank 1

m (d)

12.345

The adjustment module, like the adjustment program VVO on the PC, provides adjustment options for all sensor versions. There are some differences with MINICOM, however. For one thing, it is not possible to enter your own linearisation curve.

Error codes:

E013 No valid measured value

- Sensor in the warm-up phase

- Loss of the useful echo E017 Adjustment span too small E036 Sensor program not operating

- Sensor must be reprogrammed

(service)

- Fault signal also appears during

programming

E040 Hardware failure, electronics

defective

Adjustment steps

On the following pages you will find the complete menu schematic of the adjustment module MINICOM. Set up the sensor in the numbered sequence:

1. Measuring tube adjustments (only for

measurement in a standpipe)

2. Operating range

3. Adjustment

4. Conditioning

5. Meas. conditions

6. False echo storage (only required when

errors occur during operation).

7. Indication of the useful and noise level

8. Outputs Short explanations to the setup steps 1 … 8 follow.

You carry out all adjustment steps with the 6

1. Measurement in a standpipe

keys of the adjustment module. A small display shows you, apart from the measured value, a short message on the menu item or the value entered in a menu item.

Adjustment is only necessary if the sensor is mounted in a standpipe (surge or bypass tube). When measuring in a standpipe, do a sounding of the distance and correct the

The volume of information of the small display cannot be compared with that of the adjustment program VVO, but you will quickly find your way and carry out your adjustments quickly and efficiently with the small MINICOM.

42 VEGAPULS 51K … 54K

measured value display (which can differ several percent from the sounded value) according to the sounding. From then on, the sensor corrects running time shift of the radar signal and displays the correct value of the level in the standpipe (measuring tube).

21750-EN-031222

Set-up

2. Operating range

Without special adjustment, the operating range corresponds to the measuring range. It is generally advantageous to set the operating range slightly larger (approx. 5 %) than the measuring range.

Example: Min./max. adjustment: 1.270 … 5.850 m; adjust operating range to approx.

1.000 … 6.000 m.

3. Adjustment

Max.

Min.

Under the menu item " the sensor of the measuring range it should operate in.

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

100 % (1.270 m) correspond to 1200 liters

Span (4.58 m)

0 % (5.850 m) corresponds to 45 liters

Adjustment

“ you inform

Adjustment without medium

(adjustment independent of the level)

Key entry 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 "OK“.

m(d)

0.0%

m (d)

XX.XXX

Adjustment in

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

The entered percentage value

is written in the sensor and the min. distance value corresponding to that percentage value flashes.

21750-EN-031222

VEGAPULS 51K … 54K 43

Set-up

+ –

With the "+“ or "–“ key you can assign a level distance (example 5.85 m) to the previously adjusted percentage value. If you do not know the distance, you have to do a sounding.

The adjusted product dis-

tance 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.

Note:

For level detection outside the operating range, the operating range must be corrected accordingly in the menu "

ing range“

Sensor optimisation/Operat-

100.0%

m (d)

XX.XXX

(max. adjustment)

Now you make the max. adjustment (upper product distance) (example: 100 % and

1.270 m product distance). First, enter the percentage value and then the product distance corresponding to that percentage value.

Note:

The difference between the entered 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 at 40 % (3.102 m) and upper product distance at 45 % (3.331 m), the measurement will be less accurate. A characteristic 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. If the adjustment points are too close together, small errors inflate to considerably larger ones when the 0 % or the 100 % value is outputted.

Adjustment with medium

with medium

Max.

Min.

adjust

at %

XXX.X

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.

4. Conditioning

Signal condit ioning

Scal ing

0 %

100 %

Deci-

prop.

corres

corres ponds

XXXX

mal point

888.8

Conditioning

ponds

XXXX

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

Enter in the menu window " the numerical 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 "OK“.

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

Unit

Mass

“, you

0 % corresponds

“

21750-EN-031222

44 VEGAPULS 51K … 54K

Set-up

• Confirm with "OK“.

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

prop. to

“ you choose the physical quantity (mass, volume, distance…) and in the menu "

Unit

“ the physical unit (kg, l, ft3,

gal, m3 …).

Linearisation:

Adjust ment

Signal condit ioning

Scal ing

Lin. curve

Linear

Integra tion time

0 s

A linear correlation between the percentage value of the product distance and percentage value of the filling volume has been preset. With the menu "Lin. curve“ you can choose between linear, spherical tank and cylindrical tank. The generation of a customized linearisation curve is only possible with the PC and the adjustment program VVO.

5. Meas. conditions

(see menu plan no. 5) Choose "Liquid“ or "Solid“ and the options corresponding to your application.

7. Useful level, noise level

In the menu

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

Ampl.: means amplitude of the level echo in

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

The greater the "S-N“ value (difference between the amplitudes of the useful signal 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

This means that the noise level is only 68 dB – 53 dB = 15 dB.

Ampl.:

XX dB

S-N:

dB (useful level)

level minus the level of the background noise

6. False echo memory

A 15 dB noise level and a 53 dB signal difference yield a high degree of measurement

A false echo storage is always useful when

reliability.

unavoidable false echo sources (e.g. struts) must be minimised. By creating a false echo memory, 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.

8. Outputs

Under the menu "Outputs“ you determine, for example, whether the current output should be inverted, or which unit of measurement should be shown on the sensor display.

21750-EN-031222

VEGAPULS 51K … 54K 45

Menu schematic for the adjustment module MINICOM

Sensor

m(d)

4.700

Parameter

Sensor optimize

PULS

After switching on, the sensor

type and the software version are

displayed for a few seconds.

4.00

Configuration

Set-up

Multidrop operation (HART® sensor address):

• Sensor address zero: The sensor outputs beside the 4…20 mA signal also a digital (HART®) level signal.

• Sensor address 1…15: the sensor delivers only a digital (HART®) level signal. The sensor current is frozen to 4 mA (power supply).

Adjust ment

Meas. enviro nment

Operating range

Begin

0.50

m (d)

End

m (d)

6.00

Meas. condit ions

Condit ion

liquid

Condit ion

solid

Fast change

Sensor Tag

Verdam

pfer

Agitat ed sur face No

High dust level No

Sensor addr.

Foaming prod. No

Large angle repose No

Unit

Low DK product No

Multi ple echo No

Signal condit ioning

m (d)

Measure in tube

Multi ple echo No

Measur ing in tube

Tube diamet

mm (d)

Correc tion Now!

OK?

Correc tion factor

2,50 %

Correc tion Now!

OK?

w.out medium

Adjust ment in

m(d)

0.0 %

m (d)

XX.XXX

100.0%

m (d)

XX.XXX

with medium

Minadjust at %

XXX.X

Maxadjust at %

XXX.X

Scaling

0 % corres ponds

XXXX

Lin. curve

Linear

100 % corres ponds

XXXX

Integr ation time

Decimal point

888.8

0 s

Prop.

Unit

Mass

46 VEGAPULS 51K … 54K

21750-EN-031222

Set-up

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

ESC

6. 7.

False echo memory

Create new

Meas. dist.

m (d)

X.XX

Create new

OK?

Learning!

act. dist.

m (d)

4.700

Update

Meas. dist.

m (d)

X.XX

Update Now!

Learning!

OK?

Ampl.:

XX dB

S-N:

Delete

Delete Now!

Deleting!

OK?

Act. dist.

Softw. date

15.09. 1999

m (d)

4.700

Sensor addr.

Ampl.:

XX dB

S-N:

Act. current

8.565

Add’l functions

Serial no.

1094 0213

max. range

m (d)

20.000

Language

English

Softw. vers.

4.00

Sensor type

PULS54 K

Reset to de fault

Reset Now!

OK?

Reset ing!

Info

Sensor Tag

Sensor

Simulation:Simulation:

Simulation:

Simulation:Simulation: One hour after the last simulation adjustment, the sensor returns automatically to normal operating mode.

Outputs

Curr. output

4-20mA

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Failure mode

22mA

Sensor displ.

Prop. to

distance

Simulation

Simulation Now!

Simulation

XXX.X

OK?

Act. dist. m

X,XX

High dust level No

Fast change

Yes

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 .

VEGAPULS 51K … 54K 47

5.4 Adjustment with HART® handheld

With any HART® handheld you can set up the VEGAPULS series 50K radar sensors like all other HART® compatible sensors. A special DDD (Data Device Description) is not necessary.

Set-up

Just connect the HART® handheld to the signal cable, after having connected the sensor to power supply.

Ri > 250 Ω

Note:

If the resistance of the power supply is less than 250 Ohm, a resistor must be connected into the signal/connection loop during adjustment.

250 Ω

Connection to a VEGA signal conditioning instrument

If you operate a HART

compatible sensor on a VEGA signal conditioning instrument, you have to connect the sensor via a resistor (see following table) during HART® adjustment. This resistor, together with the internal resistance of the instruments, provides the value of 250 Ohm required for the HART

instrument. An inherent system load resistance allows a corresponding reduction of Rx.

The digital adjustment and communication signals would otherwise be short-circuited due to insufficient resistance of the supply current source or the processing system, and as a result, communication with the sensor would not be ensured.

Ri < 250 Ω

VEGA signal conditioning instr. Rx

VEGAMET 513, 514, 515, 602 50 … 100 Ohm

VEGAMET 614 no additional VEGADIS 371 resis tor

required

VEGAMET 601 200 … 250 Ohm

VEGASEL 643 150 … 200 Ohm

VEGAMET 513 S4, 514 S4 515 S4, VEGALOG EA card 100 … 150 Ohm

21750-EN-031222

48 VEGAPULS 51K … 54K

Set-up

VEGALOG VEGAMET

21750-EN-031222

VEGAPULS 51K … 54K 49

6 Diagnostics

6.1 Simulation

To simulate a certain filling level, you can call up the function “Simulation” in the adjustment module MINICOM, in the adjustment software PAC T 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. One hour after the last simulation adjustment, the sensor returns automatically to standard operating mode.

6.2 Error codes

Display Meani ng Rectifying measure

ware

or in the HART® handheld.

Diagnostics

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 carried out 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.

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

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

run software (service)

- Message appears during a software update.

E040 Hardware failure/Electronics Check all connection cables.

defective Contact our service department.

50 VEGAPULS 51K … 54K

21750-EN-031222

Technical data

7 Technical data

7.1 Technical data

Power supply

- four-wire sensor 24 V DC (20 … 72 V DC) (non-Ex and Ex d ia) 230 V AC (20 … 253 V AC), 50/60 Hz

- two-wire sensor 24 V DC (14 … 36 V DC)

- two-wire Ex ia sensor 24 V DC (14 … 29 V DC)

- two-wire Exd ia sensor 24 V DC (20 … 36 V DC)

Permissible residual ripple of the power supply with two-wire sensors

- 0 … 125 Hz 1 V

- 125 Hz … 500 Hz 1.0 … 0.01 Vss declining linearly

- 500 Hz … 10 kHz 0.01 V

Power consumption

- four-wire sensor max. 130 mA

- two-wire sensor max. 22.5 mA

Power consumption

- four-wire sensor max. 2.1 W; 7.5 VA

- two-wire sensor 55 … 810 mW

Load

- four-wire sensor max. 500 Ohm

- two-wire sensor see diagram

fuse 0.315 A TR

Ω

max. load non-Ex

19,5

max. load Ex d ia

Non-Ex and Ex ia

25,5

Exd ia

min. voltage limit when using the HART adjustment resistance:

- non-Ex and Ex ia sensors

- Ex d ia sensors

30 35

Adjustment resistance (HART® and VEGACONNECT)

21750-EN-031222

975

720 670

250

1000

900

800

700

600

500

400

300

200

100

max. load Ex ia

VEGAPULS 51K … 54K 51

max. voltage limit

non-Ex and Ex d ia sensors

max. voltage limit Ex ia sensors

Technical data

Measuring range

Standard 0 … 20 m VEGAPULS 54

- DN 50 standpipe 0 … 16 m

- DN 100 standpipe 0 … 19 m

Output signal

Signal output 4 … 20 mA current signal in two-wire or

four-wire technology; the HART® signal is modulated to the 4 … 20 mA signal

Fault signal current output unchanged, 20.5 mA, 22 mA

(adjustable)

Integration time 0 … 999 seconds (adjustable)

Two-wire technology 4 … 20 mA: The analogue 4 … 20 mA output signal (measuring signal) is transmitted together with the power supply via one two-wire cable.

Four-wire technology 4 … 20 mA: Separate power supply. The analogue 4 … 20 mA output signal (measuring signal) is transmitted in a cable separate from power supply.

Measured value display (optional)

Liquid crystal indication

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

- in the external indicating instrument

and number. The display unit can be mounted up to 25 m away from the sensor

Adjustment

- PC and adjustment software VEGA Visual Operating

- adjustment module MINICOM

- HART® handheld

Min. distance of the antenna to the medium 5 cm

52 VEGAPULS 51K … 54K

21750-EN-031222

Technical data

Accuracy

(typical values under reference conditions, all statements relate to the nominal measuring range)

Characteristics linear Resolution, general max. 1 mm Resolution of the output signal 1.6 µA or 0.01 % Accuracy see diagram

Accuracy VEGAPULS 51, 52 and 53

20 mm

10 mm

-10 mm

-20 mm

1,0 m 30 m

Accuracy VEGAPULS 54

20 mm

10 mm

-10 mm

-20 mm

1,0 m 30 m

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

21750-EN-031222

VEGAPULS 51K … 54K 53

Technical data

Characteristics

(typical values under reference conditions, all statements relate to the nominal measuring range)

Min. span between

full and empty > 10 mm (recommended > 50 mm) Frequency 5.8 GHz (USA 6.3 GHz) Intervals

- two-wire sensor (4 … 20 mA) 1 s

- four-wire sensor 0.5 s

Beam angle (at -3 dB)

- VEGAPULS 51 … 53 < 24°

- VEGAPULS 54 DN 80 38° (only suitable for standpipe measurement) DN 100 30° DN 150 20° DN 200 16° DN 250 14°

Adjustment time (response time)

> 1 s (dependent on the parameter adjustment)

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 Emitted radar power (average) 0.717 µW Received average emitted power

> 1 s (dependent on the parameter adjustment)

- distance 1 m 0.4 … 3.2 nW per cm² (0.4 … 3.2 x 10-9W/cm²)

- distance 5 m 0.02 … 0.13 nW per cm²

Connection cables

Two-wire sensors power supply and signal via one

two-wire cable Four-wire sensors power supply and signal separated Electrical connection - spring-loaded terminals (max. 2.5 mm2)

- screwed connection

Cable entry

- ia terminal compartment 1 … 2 x M20 x 1.5 (cable-ø 5 … 9 mm) or 1 … 2 x ½“ NPT EEx d (cable-ø 3.1 … 8.7 mm or 0.12 … 0.34 inch)

- Exd terminal compartment

(pressure-tight encapsulated) 1 x½“ NPT EEx d (cable-ø 3.1 … 8.7 mm or

0.12 … 0.34 inch)

Ground connection max. 4 mm²

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

The adjustment time (also 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) received by a body per cm² directly in front of the antenna. The received emitted power depends on the antenna version and the distance.

54 VEGAPULS 51K … 54K

21750-EN-031222

Technical data

Ambient conditions

Vessel pressure

VEGAPULS 51 and 52

- process fitting PVDF -100 … 300 kPa (-1 … 3 bar)

- process fitting StSt -100 … 1600 kPa (-1 … 16 bar) VEGAPULS 53 -100 … 1600 kPa (-1 … 16 bar) VEGAPULS 54

- PTFE coupling -100 … 4000 kPa (-1 … 40 bar)

- ceramic coupling -100 … 6400 kPa (-1 … 64 bar)

Ambient temperature on the housing

- 4 … 20 mA two-wire sensor -40 … +80°C

- 4 … 20 mA four-wire sensor -40 … +80°C

- 4 … 20 mA four-wire sensor Ex d ia -40 … +60°C

Process temperature (flange temperature)

VEGAPULS 51

- process fitting PVDF -20 … +80°C

- process fitting StSt -40 … +120°C VEGAPULS 52

- process fitting PVDF -20 … +120°C (short-term 130°C)

- process fitting StSt -40 … +150°C VEGAPULS 53 -40 … +150°C VEGAPULS 54

- PTFE coupling (standard) -25 … +150°C

- PTFE coupling (option) -15°C/-30°C/-40 … +150°C

- ceramic coupling -60 … +250°C Storage and transport temperature -60 … +80°C Protection IP 66 and IP 67 Protection class

- two-wire sensor II

- four-wire sensor I Overvoltage category III

Ex-technical data

Comprehensive data in the safety instructions manual (yellow binder)

WHG approvals

All VEGAPULS 51 … 54 radar sensors are approved as part of an overfill protection system for stationary vessels storing water-endangering liquids.

21750-EN-031222

VEGAPULS 51K … 54K 55

Materials

Housing PBT (Valox) or

Aluminium die casting (GD-AlSi 10 Mg) Connection compartment (with EExd version) Aluminium mould casting (GK-AlSi 7 Mg) Process fitting

- VEGAPULS 51 (thread) PVDF or StSt (1.4435)

- VEGAPULS 52 (thread) PVDF or StSt (1.4571)

- VEGAPULS 53, 54 (flange) 1.4571 or Hastelloy C4

Antenna (wetted materials)

- VEGAPULS 51 (rod antenna) PVDF/PP or StSt/PPS

- VEGAPULS 52 (rod antenna) PTFE or PVDF

- VEGAPULS 53 (rod antenna) PTFE

- VEGAPULS 54 horn antenna 1.4571, Hastelloy C22 or PTFE pipe antenna PTFE/1.4571 or PTFE/Hastelloy

Antenna seal of the

coupling cone

- standard Viton

- option Kalrez, NBR, EPDM,

FEP-Viton coated, graphite

Flange coating (type 53) PTFE

Weights

All weights are valid for sensors with PBT housing and in non-Ex version. For sensors with Aluminium housing the weights increase by 0.8 kg. For sensors in Ex version the weights increase in addition by:

- 0.3 kg with Ex ia sensors

- 1.4 kg with Ex d sensors.

VEGAPULS 51

- screwed connection G 1½ A, 1½“ NPT socket length up to 50 mm 1.3 kg (screwed connection PVDF) socket length up to 100 mm 2.0 kg (screwed connection 1.4435) socket length up to 250 mm 2.37 kg (screwed connection 1.4435)

- Tri-Clamp (DIN 32 676, ISO 2852, DN 50) 1.62 kg (socket length max. 50 mm)

- R-connection (DIN 11 851, DN 50) 2.1 kg (socket length max. 50 mm)

VEGAPULS 52

- screwed connection G 1½ A, 1½“ NPT (PVDF) socket length up to 50 mm 1.5 kg socket length up to 100 mm 1.87 kg socket length up to 250 mm 2.26 kg

- screwed connection G 1½ A, 1½“ NPT (14571) socket length up to 50 mm 2.5 kg socket length up to 100 mm 2.8 kg socket length up to 250 mm 3.15 kg

- Tri-Clamp (DIN 32 676, ISO 2852, DN 50) 1.62 kg (socket length max. 50 mm)

- R-connection (DIN 11 851, DN 50) 2.1 kg (socket length max. 50 mm)

Technical data

21750-EN-031222

56 VEGAPULS 51K … 54K

Technical data

VEGAPULS 53

- DN 50 PN 40 standpipe version 4.95 kg socket length up to 100 mm 5.15 kg socket length up to 250 mm 5.82 kg

- DN 80 PN 40 + 2.0 kg

- DN 100 PN 16 + 3.1 kg

- DN 150 PN 16 + 7.7 kg

- DN 200 PN 16 + 14.1 kg

- DN 250 PN 16 + 22.3 kg

- ANSI 2“ standpipe version 4.15 kg socket length up to 100 mm 4.35 kg socket length up to 250 mm 5.1 kg

- ANSI 3§ + 2.1 kg

- ANSI 4“ + 5.0 kg

- ANSI 6“ + 9.1 kg

- ANSI 8“ + 20.4 kg

- ANSI 10“ + 28.1 kg

VEGAPULS 54

- DN 50 PN 40 4.8 kg

- DN 80 PN 40 7.6 kg

- DN 100 PN 16 8.4 kg

- DN 150 PN 16 13.1 kg

- DN 200 PN 16 23.1 kg

- DN 250 PN 16 28.5 kg

- ANSI 2“ 4.8 kg

- ANSI 3§ 6.6 kg

- ANSI 4“ 10.2 kg

- ANSI 6“ 14.3 kg

- ANSI 8“ 29.3 kg

- ANSI 10“ 34.3 kg

CE conformity

VEGAPULS series 50 radar sensors meet the protective regulations of EMC (89/336/EWG) and NSR (73/23/EWG) and R & TTE directive (1999/5/EC).

Conformity was judged acc. to the following standards: EN 300 683-1: 1997 EN 300 440-1: 1995

I-ETS 300-440 Expert opinion No. 0043052-01/SEE, Notified Body No. 0499

EN 61 326: 1997/A1: 1998 (EMC Emission/Susceptibility) EN 61 010 - 1: 1993 (NSR)

EN 50 020: 1994 (ATEX) EN 50 018: 1994 EN 50 014: 1997

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VEGAPULS 51K … 54K 57

Technical data

7.2 Approvals

When radar sensors are used in Ex areas or on ships, the instruments must be suitable and approved for the explosion zones and applications. The suitability is checked by the approval authorities and is certified in approval documents.

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

(Physikalisch Technische Bundesanstalt Physical Technical Approval Authority)

- FM

(Factory Mutual Research)

- ABS

(American Bureau of Shipping)

- LRS

(Lloyds Register of Shipping)

- GL

(German Lloyd)

- CSA

(Canadian Standards Association)

Intrinsically safe in Ex environment

Series 50 sensors in EEx ia (intrinsically safe) version require for use in Ex areas special separators or safety barriers. The separators or safety barriers provide intrinsically safe (ia) circuits. Below, a selection of instruments with which series 40 sensors work reliably.

Separator and signal conditioning instrument:

- VEGADIS 371 Ex

- A puissance 3 PROFSI 37-24070A

- VEGAMET 614 Ex

- Apparatebau Hundsbach AH MS 271-B41EEC 010

Separator, safety barrier:

- Stahl 9001/01/280/110/10

- Stahl 9001/51/280/110/14

- MTL 787 S+

- CEAG CS 3/420-106

Separator:

- VEGATRENN 149 Ex…

- Stahl 9303/15/22/11

- CEAG GHG 124 3111 C1206

Pressure-tight encapsulated in Ex area

Series 50 sensors in EEx d ia (pressure-tight encapsulated) version can be used in Ex areas without special safety barriers due to their pressure-tight encapsulated terminal compartment (provided the appropriate installation regulations are observed).

SIL conformity and IEC 61508 / IEC 61511

VEGAPULS radar sensors meet the requirements on functional safety acc. to IEC 61508 / IEC 61511. For further information see Supplement under „Safety Manual“.

58 VEGAPULS 51K … 54K

21750-EN-031222

Technical data

7.3 Dimensions

External indicating instrument VEGADIS 50

Pg 13,5

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

118

108

135

Note:

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

would not be ensured.

Flange dimensions acc. to ANSI (RF)

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

D=outer flange diameter

b = flange thickness k = diameter of hole circle d1= seal ledge diameter f = seal ledge thickness

/16" = approx. 1.6 mm

d2= diameter of holes

Adjustment module MINICOM

ESC

Tank 1 m (d)

12.345

67,5

32,5

Adjustment module for insertion into sensors or into the external indicating instrument VEGADIS 50

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VEGAPULS 51K … 54K 59

VEGAPULS 51, 52

Technical data

PBT

Aluminium

Aluminium with Exd terminal

201

165

215

185

10˚

322

182

M20x1,5

101

SW 60

7 3

5 0 2

PBT: 577 (417)

ø60

ø85

Al: 600 (440)

ø25

190

330

PBT: 607 (757)

360 (510)

116

Al: 630 (780)

395 (545)

M20x1,5

ø36

ø35

compartment

0 7 3

PBT: 642 (792)

Al: 665 (815)

215

185

5 0 2

116

½" NPT

G 11/2 A or 11/2“ NPT

Rod length max. socket length

VEGAPULS 51 330 50 m m VEGAPULS 51 190 for standpipe __ VEGAPULS 51 360 (option 510) 100 mm (option 250 mm) VEGAPULS 52 330 50 m m VEGAPULS 52 190 for standpipe __ VEGAPULS 52 395 (option 545) 100 mm (option 250 mm) VEGAPULS 53 395 (option 545) 100 mm (option 250 mm)

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Technical data

VEGAPULS 53

PBT

Aluminium

Aluminium with Exd terminal

395 (545)

compartment

0 7 3

5 0 2

ø36

ø35

ø22

45˚

185

215

PBT: 654 (804)

Al: 702 (852)

116

½" NPT

201

165

215

185

PBT

7 3

5 0 2

3 5

PBT: 652 (802)

Al: 700 (850)

ø36

ø35

395 (545)

45˚

10˚

322

182

ø36

ø35

395 (545)

ø18

M20x1,5

101

PBT: 650 (800)

Al: 698 (848)

395 (545)

116

M20x1,5

PBT: 652 (802)

Al: 700 (850)

ø36

ø35

ø18

45˚

ø104

ø125

ø165

DN 50 PN 40 (C)

ø138

ø160

ø200

DN 80 PN 40 (C)

ø158

ø180

ø220

DN 100 PN 16 (C)

ø216

ø240

ø285

DN 150 PN 16 (C)

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VEGAPULS 54

Technical data

ø76

Aluminium

185

0 7 3

5 0 2

6 7 1

PBT: 330 (250˚C: 456)

Al: 373 (250˚C: 495)

Aluminium with Exd terminal compartment

215

200 °C

ø96

116

5 9 1

PBT: 375 (250˚C: 498)

120

M20x1,5

250 °C

Al: 418 (250˚C: 540)

ø146

0 7 3

205

5 0 2

PBT: 462 (250˚C: 585)

Al: 505 (250˚C: 627)

215

185

116

½" NPT

PBT: 617

Al: 690

380

PBT

201

165

10˚

322

182

PBT

M20x1,5

3 5

101

PBT: 276 (250˚C: 399)

Al: 319 (250˚C: 441)

3 7

ø241

ø355

ø405

ø125 ø165

ø18

ø160

ø200

45˚

ø180 ø220

45˚

DN 50 PN 40 (C) DN 80 PN 40 (C) DN 100 PN 16 (C)

ø22

ø240 ø285

DN 150 PN 16 (C)

DN 250 PN 16 (C)

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Supplement Safety Manual

Functional safety acc. to IEC 61508 / IEC 61511

VEGAPULS series 50 radar sensors; 4 … 20 mA/HART

1 General

1.1 Validity

This safety manual applies to VEGAPULS series 50 radar sensors in two-wire version 4 … 20 mA/HART®, called “measuring system” in the following.

1.2 Area of application

The measuring system can be used for the following functions which meet the specific requirements of the safety technology:

- overfill protection

- dry run protection

- detection of an individual level

The functions can be also used simultaneously.

The functions can be used in the mode of operation with low demand mode as well as in the mode of operation with high demand or continuous mode.

compact sensor

The measuring system is qualified in all modes to meet the requirement degree SIL2 acc. to IEC 61508-2 / IEC 61511-1.

The measuring system is designed for 15 years of use in safety-related applications.

In safety-related systems with an architecture 1oo2D and the requirement SIL3, the measuring system must be combined with a second, different measuring system (diversely redundant). The safety-related characteristics must be calculated separately.

1.3 Relevant standards

• IEC 61508 part 1, 2, 4 Functional safety of electrical/electronic/programmable electronic systems

• IEC 61511-1 Functional safety – safety instrumented systems for the process industry sector – Part 1: Framework, definitions, system, hardware and software requirements

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1.4 Determination of safety-related characteristics

The failure limit values for a safety function, depending on the SIL class.

Safety integritySafety integrity

Safety integrity Low demand mode High demand or continuous

Safety integritySafety integrity

level mode

SIL PFD

4 >10-5 up to <10

3 >10-4 up to <10

2 >10-3 up to <10

1 >10-2 up to <10

avg

-4

-3

-2

-1

(from IEC 61508, part 1/7.6.2)

Safety integrity of the hardware: Limitations due to the architecture for safety-related subsystems of type B

PFH

>10-9 up to <10

>10-8 up to <10

>10-7 up to <10

>10-6 up to <10

-8

-7

-6

-5

Safe failure fraction SFF Hardware fault tolerance HFT

0 1 (0)

< 60 % not allowed SIL 1 SIL 2

60 % up to < 90 % SIL 1 SIL 2 SIL 3

90 % up to < 99 % SIL 2 SIL 3 (SIL 4)

> 99 % SIL 3 (SIL 4) (SIL 4)

(from IEC 61508, part 2/7.4.3)

Acc. to IEC 61511-1, paragraph 11.4.4 the fault tolerance specified acc. to the above chart can be reduced by one for all subsystems if the following conditions are met:

- instrument has proven during operation

- only process-relevant parameters can be modified on the instrument (e.g. measuring range, …)

- the adjustment of this process-relevant parameters is protected (e.g. password, …)

- the safety function needs less than SIL 4

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2 Planning

2.1 Low demand mode

If the demand rate is only once a year, then the measuring system can be used as safetyrelevant subsystem in „low demand mode“ (see IEC 61508-4, 3.5.12).

Corresponding characteristics : PFD It is dependent on the test interval T

(average probability of dangerous failure on demand).

avg

between the function tests of the protective function.

Proof

2.2 High demand or continuous mode

If the demand rate is more than once a year, the measuring system must be used as safetyrelevant subsystem in „high demand or continuous mode“ (see IEC 61508-4, 3.5.12).

The fault reaction time of the measuring system must be set to less than or at the most, equal to the fault tolerance time of the total system. The smallest fault reaction time of the measuring system is 60 sec.

Corresponding characteristics: PFH (probability of a dangerous failure per hour)

2.3 General

The safe condition of the measuring system in case of failure is defined for both modes of operation at an output current > 21 mA. An output current < 3.6 mA and > 21 mA must be configured as alarm in the processing unit.

Definition of a dangerous undetected failure:

- the instrument does not react to the demand of the process

- the output current deviates by more than 2 % from the actual value.

Otherwise the tolerance data in the operating instructions manual are applicable. Make sure that the measuring system is used as it was intended for the application (see operating instructions manual). The application-specific limits must be complied with and the specifications must not be exceeded (see operating instructions manual). Use only in products against which the materials of the antenna system are sufficiently chemically resistant.

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3 Set-up

3.1 Mounting and installation

The prevailing plant conditions influence the safety of the measuring system. Therefore note the mounting and installation instructions of the appropriate operating instructions manual.

3.2 Adjustment instructions and parameter adjustment

Adjustment instructions

The activation of the measuring system as safety-relevant subsystem is only possible via PC adjustment programs. Not all safety-relevant parameters can be adjusted with the adjustment module MINICOM. The set parameters must be checked and protected against unauthorised access (password, screwed housing cover, …).

General instructions, see operating instructions manual

Parameter adjustment

The following software versions are required:

- Sensor software: from 4.50.00

- DTM-Collection: from 10/2003

With the adjustment program PACT the Device Type Manager (DTM).

Note

If a reset is triggered on the sensor after the SIL parameter adjustment or if the failure mode = 22 mA is changed, the sensor will loose its SIL qualification.

ware

™, the SIL parameter adjustment must be activated in

3.3 Configuration of the processing unit

If the measuring system delivers output currents > 21 mA or < 3.6 mA, it must be assumed that a failure has occurred.

The processing unit must therefore interpret such current values as a failure and trigger a suitable fault signal.

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4 Reaction during operation and in case of failure

In case of modifications during operation, you have to take note of the safety functions. It must be ensured that the safety-relevant parameter adjustments remain activated.

Occurring fault signals are described in the appropriate operating instructions manual.

In case of detected failures or fault signals, the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures.

5 Recurring function test

The recurring function test serves to reveal potential dangerous errors that are otherwise not discernible.

The function of the measuring system must be checked at adequate intervals. The operator is responsible for choosing the type of test and the intervals in the stated time frame.

The time intervals depend upon the applied PFD paragraph „Safety-related characteristics“.

value acc. to the chart and diagram in the

avg

The test must be carried out in a way that verifies the flawless operation of the safety functions in conjunction with all system components. This is ensured by a controlled reaching of the response height during a filling.

If filling up to the response height is not possible, then a response of the measuring system must be triggered by a suitable simulation of the level or the physical measuring effect. If the proper functioning of the measuring system is otherwise discernible (exclusion of functionrestraining errors), it is also possible to carry out the test by simulating the appropriate output signal.

If the function test proves negative, the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures.

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6 Safety-related characteristics

The failure rate of the electronics and the antenna system was determined by an FMEDA (Failure Mode, Effects and Diagnostics Analysis) acc. to IEC 61508. The number values are based on an output current tolerance of max. 2 %.

Architecture 1oo1D SIL 2

VEGAPULS 51 Overfill protection Dry run protection Individual level VEGAPULS 52 VEGAPULS 53 VEGAPULS 54 VEGAPULS 56

HFT 0

SFF > 86%

avg

PFD

PFH [1/h]

Max

< 0.12 •10 < 0.60 •10

< 0.28 •10

Min

-2

-6

with T with T

= 1 year

Proof

= 5 years

Proof

Failure reaction time T

PFD

avg

0,60·10

0,48·10

0,36·10

0,24·10

0,12·10

0,00·10

0 1 2 3 4 5 T

T T

PFD

this value correlates almost linearly to the operating time. It is only valid for the corresponding

avg

selection circuit.

is the interval after which a periodically recurring complete function test (to check the safety function)

Proof

must be carried out.

PFH is valid for the stated Failure reaction time T tolerance time of the complete system must be higher than T

= 1 year

proof

= 3 years

proof

= 5 years

proof

Reaction

= 60 sec

Reaction

years

of the measuring system. This means that the failure

Reaction

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SIL declaration of conformity

Safety related characteristics:

SIL Safety Integrity Level SIL 2 SIL 2

HFT Hardware Fault Tolerance

SFF Safe Failure Fraction > 88 % > 86 % PFD

average Probability of dangerous

avg

(for low demand mode) PFH Probability of a dangerous Failure per

[1/h] (for high demand or continuous mode)

The failure rates were determined by a FMEDA ( Failure Modes, Effects and Diagnostics Analysis )

MTTF Mean Time To Failure 60 years 56 years MTTR = 8h

Safety Manual see supplement of the operating instructions

HFT is reduced by one according to IEC 61511-1, section 11.4.4

PFD

is valid only for the T

avg

PFH is constant over the time. According to the standard, a recurring function test is not necessary.

The failure tolerance time of the overall system must be higher than the error response time of the sensor.

FIT = failure in time [10

The assessment of the modification management was part of the proof for

Schiltach, 28.10.03 VEGA Grieshaber KG

i.V. Frühauf i.A. Blessing Head of Certification department Commissioner for functional safety

S I L d e c l a r a t i o n of c o n f o r m i t y

Functional safety according to IEC 61508 / IEC 61511

VEGA Grieshaber KG, Am Hohenstein 113, D-77761 Schiltach

declares as manufacturer, that for the radar sensors of the product families

VEGAPULS series 40 and 50 ( 4 ... 20 mA HART® )

the reliability (“proven in use”) was verified according to IEC 61508 / IEC 61511.

Therefore the devices are suitable for safety-related applications

e.g. overfill protection, dry run protection or recording of an arbitrary fill level.

The corresponding instructions of the safety manual must be considered.

Failure on Demand

Hour

safe detected failure

safe undetected failure

dangerous detected failure

dangerous undetected failure

interval according to which a recurring function test must be carried out

Proof

-9

Füllstand - Grenzstand - Druck

VEGAPULS 40 VEGAPULS 50

0 0

< 0,10 x 10-2 < 0,12 x 10-2 T

< 0,50 x 10

< 0,22 x 10

-2

< 0,60 x 10-2 T

-6

< 0,28 x 10-6

VEGAPULS 40 VEGAPULS 50

107 FIT 111 FIT

1 year

Proof

5 years

Proof

Error response time

494 FIT 518 FIT

1090 FIT 1140 FIT

221 FIT 277 FIT

reliability (“proven in use”).

60sec

SIL-KE_PULS40+50_EN_031028

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CE declaration of conformity

Supplement

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VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone (07836) 50-0 Fax (07836) 50-201 E-Mail info@de.vega.com

www.vega.com

ISO 9001

All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing.

Technical data subject to alterations

21750-EN-031222

VEGA PULS51K 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 Antennas

3 Mounting and installation

3.1 General installation instructions

3.2 Measurement of liquids

3.4 False echoes

3.5 Common installation mistakes

4 Electrical connection

4.1 Connection and connection cable

4.2 Connecting the sensor

4.4 Configuration of measuring systems

5 Set-up

5.1 Adjustment media

5.2 Adjustment with PC

5.3 Adjustment with adjustment module MINICOM

5.4 Adjustment with HART® handheld

6 Diagnostics

6.1 Simulation

6.2 Error codes

7 Technical data

7.1 Technical data

7.2 Approvals

7.3 Dimensions

Supplement

1 General

1.1 Validity

1.2 Area of application

1.3 Relevant standards

1.4 Determination of safety-related characteristics

2 Planning

2.1 Low demand mode

2.2 High demand or continuous mode

2.3 General

3 Set-up

3.1 Mounting and installation

3.2 Adjustment instructions and parameter adjustment

3.3 Configuration of the processing unit

4 Reaction during operation and in case of failure

5 Recurring function test

6 Safety-related characteristics

SIL declaration of conformity

CE declaration of conformity