SIL declaration of conformity .................................................... 52
CE declaration of conformity..................................................... 53
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 VEGA
personnel.
24 101-EN-041227
VEGAPULS 54K enamel3
1 Product description
Product description
VEGAPULS series 50 sensors are a newly
developed generation of extremely compact,
small radar sensors.
Due to their small housing dimensions and
process fittings, the compact sensors are an
unobstrusive, and most of all, very costeffective solution for your level measurement
applications. With their integrated display
and many of the features of the VEGAPULS
81 series, they bring the advantages of radar
level measurement to applications where
previously, due to high costs, the advantages of non-contact measurement had to be
forgone.
The VEGAPULS 54 radar sensor is perfectly
suitable for two-wire technology, however, it is
also available in four-wire technology where
the output signal and power supply are carried on in two separate circuits. The supply
voltage and the output signal are transmitted
via one two-wire cable. The instruments produce an analogue 4 … 20 mA output signal
as output, i.e. measuring signal.
In the enamelled version, the sensors have
exceptional chemical resistance, and represent the ideal level sensor technology for
corrosive processes.
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.
1.1 Function
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
emission - reflection - reception
The radar pulses are emitted by the antenna
system as pulse packets 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 pulse 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.
4VEGAPULS 54K enamel
24 101-EN-041227
Product description
Puls
1 ns
278 ns
Pulse
break
Pulse sequence
VEGAPULS can achieve this through a special time transformation procedure which
spreads out the more than 3.6 million echo
images per second in a slow-motion picture,
then freezes and processes them.
t
Time transformation
t
Hence, it is possible for the VEGAPULS 50
radar sensors to process the slow-motion
pictures of the sensor environment precisely
and in detail in cycles of 0.5 to 1 second
without using time-consuming frequency
analysis (e.g. FMCW, required by other radar
techniques).
Nearly all products can be measured
Radar signals display physical properties
similar to those of visible light. According to
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.
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 suffi-
ciently (note: air has a dielectric constant ε
1).
%
50
40
30
20
10
5 %
5
0
2
0
Reflected radar power dependent on the dielectric
constant of the measured product
25 %
4 6 812 14 16 18
10
40 %
20
r
r
ε
r
Signal reflectivity grows stronger with in-
creasing conductivity or increasing dielectric
constant of the product. Hence, nearly all
substances can be measured.
As process fitting, standard flanges of DN
150, DN 200, ANSI 6“ or ANSI 8“ are used.
Due to high quality enamel coating, the sen-
sors withstand even 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.
of
24 101-EN-041227
VEGAPULS 54K enamel5
Product description
Continuous and accurate
Unaffected by temperature, pressure and
atmosphere content, VEGAPULS radar sensors measure quickly and accurately the
levels of widely varying products.
%
0,03
0,02
0,01
0
10050010001300 ˚C
0
0,018 %
Temperature influence: Temperature error absolutely
zero (e.g. at 500°C 0.018 %)
%
10
5
0,29 %
0
10
0
1,44 %
20 30 4060
50
70 80 90110 120 130 140
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 they were it
was hitherto unthinkable because of high
costs.
2,8 %
100
0,023 %
3,89 %
bar
Rugged and abrasionproof
• non-contact
• high-resistance materials
Exact and reliable
• meas. resolution 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 of -1 … 16 bar
and product temperatures of
-40°C … 200°C
Communicative
• integrated measured value display
• optional display module separate from
sensor
• connection to all BUS systems: Interbus S,
Modbus, Siemens 3964R, Profibus DP,
Profibus FMS, ASCII
• adjustment from the PLC level with the PC
• adjustment with HART
®
handheld
• adjustment with detachable adjustment
module, pluggable in the sensor or in the
external display
• level measurement of any liquid, limited use
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)
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
• 4 … 20 mA output signal
6VEGAPULS 54K enamel
24 101-EN-041227
Product description
Adjustment with the PC
The set-up and adjustment of the radar sensors is generally done on the PC with the
adjustment software PACT
gram leads quickly through the adjustment
and parameter setting by means of pictures,
graphics and process visualisations.
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 measuring
site in the system or directly to the signal
cable. It is connected by means of the twowire 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.
2
2
ware
2
2
TM.
PLC
The pro-
4 ...20 mA
Adjustment with the adjustment module
MINICOM
With the small (3.2 cm x 6.7 cm) 6-key adjustment module with display, the adjustment
can be carried out in clear text dialogue. 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
OK
2
4 ... 20 mA
ESC
+
-
Tank 1
m (d)
12.345
OK
4
ESC
+
-
OK
Adjustment with detachable adjustment module. The
adjustment module can be plugged into the radar
sensor or into the external indicating instrument
VEGADIS 50.
Adjustment with the PC on the 4 … 20 mA signal and
supply cable to the PLC or directly on the sensor
(figure: a two-wire sensor)
24 101-EN-041227
VEGAPULS 54K enamel7
Product description
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 ad-
justment jacks on the sensor.
®
1.4 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.
Horn antennas
The horn antenna is the classical radar antenna in level
measurement. The antenna
focuses the radar signals very
well. Fabricated of 1.4571
(stainless steel) with enamel
coating or Hastelloy C22, the
antenna is physicaly resistant,
and is well suited for pressures up to 16 bar at product
temperatures up to 200°C.
2
4 ...20 mA
2
HART® handheld on the 4 … 20 mA signal cable
8VEGAPULS 54K enamel
24 101-EN-041227
Mounting and installation
2 Mounting and installation
2.1 General installation instructions
Measuring range
The reference plane for the measuring range
of the sensor is the enamelled sensor seal
shoulder, against which the enamelled vessel
seal is placed. The measuring range is
0 … 20 m. For measurements in surge or
bypass tubes (pipe antenna) the max. measuring distance decreases by approx. 0.5 m.
Keep in mind that in measuring environments
where the medium can reach the sensor
flange, buildup may form on the antenna and
later cause measurement errors.
empty
Reference plane
max. filling
max. meas. distance 20 m
Measuring range (operating range) and max. measuring distance
Note: Use of the sensors for applications with solids
is limited.
full
Measuring range
False echoes
Flat obstructions and struts cause strong
false echoes. They reflect the radar signal
with high energy density.
Interfering surfaces with rounded profiles
scatter the radar signals into the surrounding
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.
Profiles with flat interfering surfaces cause large
false signals
If flat obstructions in the range of the radar
signals cannot be avoided, we recommend
diverting the interfering signals with a deflector. The deflector prevents the interfering
signals from being directly received by the
radar sensor. The signals are then so lowenergy and diffuse that they can be filtered
out by the sensor.
Round profiles diffuse radar signals
Cover flat interfering surfaces with deflectors
24 101-EN-041227
VEGAPULS 54K enamel9
Mounting and installation
Emission cone and false echoes
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 will reflect the
radar signals. Within the first few meters of
the beam cone, tubes, struts or other installations can interfere with the measurement. At a
distance of 6 m, the false echo of a strut has
an amplitude nine times greater than at a
distance of 18 m.
At greater distances, the energy of the radar
signal distributes itself over a larger area,
thus causing weaker echoes from obstructing surfaces. The interfering signals are
therefore less critical than those at close
range.
If possible, orient the sensor axis perpendicularly to the product surface and avoid
vessel installations (e.g. pipes and struts)
within the 100% emission cone.
If possible, provide a "clear view“ to 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 the emission cone is free from obstructions.
2.2 Measurement of liquids
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 must
always protrude out of the flange pipe.
Reference plane
Mounting on DIN socket piece
If the DIN socket piece is longer, please
make sure that the horn antenna protrudes at
least 10 mm out of the socket.
> 10 mm
Mounting on longer DIN socket pieces
When mounting on dished or rounded vessel
tops, the antenna must also protrude at least
10 mm (longer side of socket).
> 10 mm
Mounting on round vessel tops
10VEGAPULS 54K enamel
24 101-EN-041227
Mounting and installation
On dished vessel tops, please do not mount
the instrument in the centre or close to the
vessel wall, but approx.½ vessel radius from
the centre or from the vessel wall.
Dished tank tops can act as paraboloidal
reflectors. If the radar sensor is placed in the
focal point of the parabolic tank top, the radar
sensor receives amplified false echoes. The
radar sensor should be mounted outside the
focal point. Parabolically amplified echoes are
thereby avoided.
Reference plane
1
/2 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.
2.3 False echoes
The radar sensor must 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.
CorrectIncorrect
Vessel protrusions (ledge)
Intake pipes, i.e. for the mixing of materials with a flat surface directed towards the sensor - should be covered with an angled baffle
that scatters false echoes.
Reference plane
Mounting directly on flat vessel top
Vessel protrusions (intake pipe)
24 101-EN-041227
VEGAPULS 54K enamel11
CorrectIncorrect
Mounting and installation
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.
CorrectIncorrect
Ladder
Vessel installations
Ladder
Struts
Struts, like other vessel installations, can
cause strong false echoes that are superimposed on 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
are then filtered out as "echo noise“ by the
measuring electronics.
Inflowing material
Do not mount the instrument in or above the
filling stream. Ensure that you detect the
product surface and not the inflowing material.
Correct
Inflowing material
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
"4.1 General installation instructions“.
Correct
Incorrect
CorrectIncorrect
Shields
Struts
12VEGAPULS 54K enamel
Buildup
24 101-EN-041227
Mounting and installation
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.
CorrectIncorrect
> 500 mm
100 %
75 %
0 %
Strong product movements
Products tending to slight buildup can be
detected by using a measuring tube with
150 mm nominal width or more. In a measuring tube of this size, buildup does not cause
any problems.
2.4 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 at least 10 mm out of the socket piece.
CorrectIncorrect
> 10 mm
Correct and incorrect socket length
Parabolic effects on dished or arched
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
< 10 mm
1
/
2
radius
Incorrect
Incorrect
24 101-EN-041227
VEGAPULS 54K enamel13
Mounting on a vessel with parabolic tank top
Mounting and installation
Wrong orientation to the product
Weak measuring signals are generated if the
sensor is not directly pointed at the product
surface. Orient the sensor axis perpendicularly to the product surface to achieve optimum measuring results.
CorrectIncorrect
Ladder
Direct sensor vertically to the product surface
Ladder
Sensor too close to the vessel wall
If the radar sensor is mounted too close to
the vessel wall, strong false echoes can be
caused. Buildup, rivets, screws or weld joints
superimpose their echoes onto the product
i.e. useful echo. Please ensure a sufficient
distance from the sensor to the vessel wall.
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 in less favourable reflection environments, it is a good idea to also keep the
outer emission cone free of interfering installations. Note chapter "4.1 General installation
instructions“.
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 measuring technology, e.g. capacitive meas. probes or
hydrostatic pressure transmitters.
Foam generation
Sensor too close to the vessel wall
14VEGAPULS 54K enamel
24 101-EN-041227
Electrical connection
3 Electrical connection
3.1 Connection and connection
cable
Note!
In Ex applications, grounding on both ends is
not allowed due to potential transfer.
Safety information
As a rule, do all connecting work in the complete absence of line voltage. Always switch
off the power supply before you carry out
connecting work on the radar sensors. Protect yourself and the instruments, especially
when using sensors which do not operate
with low voltage.
Qualified personnel
Instruments which are not operated with
protective low voltage or DC voltage must
only be connected by qualified personnel.
Connection and screening
A standard two or four-wire cable (sensors
with separate supply) with max. 2.5 mm
cross-section can be used for connection.
Quite often, the "electromagnetic pollution"
caused by electronic actuators, energy cables and transmitting stations is so considerable that the sensor cable should be
screened.
We recommend the use of screened cable.
Screening is also a good preventative measure against future sources of interference.
Ground the cable screen preferably on the
sensor.
It is a good idea to ground the cable screen
on both ends. However, you must make sure
that no ground equalisation currents flow
through the cable screening. Ground equalisation currents can be avoided by potential
equalisation systems. If ground equalisation
cables are not available, grounding on both
ends can be realised by connecting (e.g. in
the switching cabinet) one end via a capaci-
1)
tor
to the ground potential. Use a very lowresistance ground connection (foundation,
plate or mains earth).
24 101-EN-041227
VEGAPULS 54K enamel15
2
wire
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 must not be connected with more than one active instrument
(i.e. an instrument delivering electrical energy) must not be connected. Please note
the special installation regulations (DIN 0165).
Connection cable
Make sure that the connection cables are
specified for the expected conditions in your
systems. The cable must have an outer diameter between 5 and 9 mm (1/2 to 1/3 inch), or
with Ex d housing, 3.1 … 8.7 mm (0.12 to
0.34 inch). Otherwise, the seal effect of the
cable entry would not be ensured.
Cables for intrinsically safe circuits must be
marked blue and may not be used for other
circuits.
Earth conductor terminal
On VEGAPULS 54 sensors, the earth conductor terminal is galvanically connected to
the flange.
1)
max. 10 nF, e.g. voltage resistance 1500 V,
ceramic.
Electrical connection
3.2 Connecting the sensor
After mounting the sensor at the measurement location according to the instructions in
chapter "4 Mounting and installation“, loosen
the closing screw on top of the sensor. The
sensor lid with the optional indication display
can then be opened. Unscrew the sleeve nut
and slip it over the connection cable (after
removing about 10 cm of cable mantle). The
sleeve nut of the cable entry has a self-locking ratchet that prevents it from opening on
its own.
Version with plastic housing
Power supply
4 … 20 mA (passive)
+
-
1)
To the indicating instrument in the
sensor lid or to the external indicating
instrument VEGADIS 50
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 levers 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.
Power supply
4 … 20 mA (active)
-
+
+
-
2)
12C567843
12C5678
Commu-
+-
4...20 mA
Tank 1
m (d)
12.345
nication
Display
+
ESC
-
OK
Two-wire technology in
plastic housing
(loop powered)
1)
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
the VEGACONNECT
Pluggable
adjustment
module
MINICOM
2
®
handheld or
12C567843
12C567843
(+) (-)
L1 N
Tank 1
m (d)
12.345
Commu-
nication
-
+ -
4...20 mA
+
Display
ESC
OK
Opening
tabs
Four-wire technology in
plastic housing
(separate supply)
2)
4 … 20 mA active means that the sensor provides
a level-dependent current of 4 … 20 mA (current
source).
16VEGAPULS 54K enamel
24 101-EN-041227
Electrical connection
ESC
OK
ESC
OK
Ver sion with aluminium housing
Two-wire technology
(loop powered)
4 … 20 mA passive
+
-
1)
To the indicating instrument in the
sensor lid or to the external indicating
instrument VEGADIS 50
M20 x 1.5
(diameter of the
connection cable
5…9 mm)
Four-wire technology
4 … 20 mA active
+
Voltage supply
M20 x 1.5
(diameter of
the connection
cable
6…9 mm)M20 x 1.5
+
-
2)
-
To the indicating
instrument in the sensor
lid or to the external
indicating instrument
VEGADIS 50
12C 567843
12C5 6 7 843
(+) (-)
Communication+-4...20mA
-
+
Display
ESC
OK
L1 N
1)
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)
2)
4 … 20 mA active means that the sensor provides
a level-dependent current of 4 … 20 mA (current
source).
12C 567843
12C5 6 7 843
(+) (-)
Commu-
L1 N
nication+-4...20mA
-
Display
ESC
+
OK
24 101-EN-041227
VEGAPULS 54K enamel17
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