VEGA PULS54K User Manual

Operating Instructions
VEGAPULS 54K enamel
Contents
Sicherheitshinweise ..................................................................... 3
Safety information ........................................................................ 3
1 Product description .................................................................. 4
1.1 Function................................................................................. 4
1.2 Application features ............................................................. 6
1.3 Adjustment ............................................................................ 6
1.4 Antennas............................................................................... 8
2 Mounting and installation ....................................................... 9
2.1 General installation instructions .......................................... 9
2.2 Measurement of liquids ..................................................... 10
2.3 False echoes ...................................................................... 11
2.4 Common installation mistakes ........................................... 13
3 Electrical connection .............................................................. 15
3.1 Connection and connection cable .................................... 15
3.2 Connecting the sensor ...................................................... 16
3.3 Connecting the external indicating instrument
VEGADIS 50 ....................................................................... 19
3.4 Configuration of measuring systems ............................... 20
Contents
4 Set-up ........................................................................................ 28
4.1 Adjustment media .............................................................. 28
4.2 Adjustment with PC............................................................ 28
4.3 Adjustment with adjustment module MINICOM ............... 30
4.4 Adjustment with HART® handheld ................................... 36
5 Diagnostics............................................................................... 38
5.1 Simulation ............................................................................ 38
5.2 Error codes ........................................................................ 38
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Sicherheitshinweise
6 Technical data .......................................................................... 3 9
6.1 Technical data ..................................................................... 39
6.2 Approvals ........................................................................... 43
6.3 Dimensions ......................................................................... 44
Supplement..................................................................................... 46
Safety Manual ................................................................................. 46
1 General ............................................................................... 46
1.1 Validity ................................................................................. 46
1.2 Area of application............................................................... 46
1.3 Relevant standards ............................................................. 46
1.4 Determination of safety-related characteristics .................. 47
2 Planning .............................................................................. 48
2.1 Low demand mode ............................................................... 48
2.2 High demand or continuous mode ....................................... 48
2.3 General ................................................................................ 48
3 Set-up ................................................................................. 49
3.1 Mounting and installation..................................................... 49
3.2 Adjustment instructions and parameter settings ................ 49
3.3 Configuration of the processing unit ................................... 49
4 Reaction during operation and in case of failure ............. 50
5 Recurring function test ....................................................... 50
6 Safety-related characteristics ........................................... 51
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.
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VEGAPULS 54K enamel 3
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.
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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 8 12 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
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VEGAPULS 54K enamel 5
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
100 500 1000 1300 ˚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 40 60
50
70 80 90 110 120 130 140
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
Approvals
• CENELEC, ATEX, PTB, FM, CSA, ABS, LRS, GL, LR, FCC
1.3 Adjustment
Every measurement set-up is unique. For
1.2 Application features
Applications
• 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
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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)
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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
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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
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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
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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.
Correct Incorrect
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)
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Correct Incorrect
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.
Correct Incorrect
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
Correct Incorrect
Shields
Struts
12 VEGAPULS 54K enamel
Buildup
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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.
Correct Incorrect
> 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.
Correct Incorrect
> 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
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VEGAPULS 54K enamel 13
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.
Correct Incorrect
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
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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).
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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)
12 C 567843
12 C 5678
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
12 C 567843
12 C 567843
(+) (-)
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).
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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
12 C 567843
12 C 5 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).
12 C 567843
12 C 5 6 7 843
(+) (-)
Commu-
L1 N
nication+-4...20mA
-
Display
ESC
+
OK
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