VEGA PULS56K User Manual

Operating Instructions

VEGAPULS 56K

Contents

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

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

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

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

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

1.3 Adjustment ............................................................................ 7

1.4 Antennas ............................................................................... 9

2 Types and versions ................................................................. 10

2.1 Type survey ........................................................................ 10

3 Mounting and installation ..................................................... 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 ...................................................................... 20

3.5 Common installation mistakes ........................................... 22

Contents

4 Electrical connection .............................................................. 24

4.1 Connection and connection cable .................................... 24

4.2 Connecting the sensor ...................................................... 24

4.3 Connecting the external indicating instrument VEGADIS 50 26

4.4 Configuration of measuring systems ............................... 27

5 Set-up ........................................................................................ 34

5.1 Adjustment media .............................................................. 34

5.2 Adjustment with PC ............................................................ 34

5.3 Adjustment with adjustment module MINICOM ............... 36

5.4 Adjustment with HART® handheld ................................... 42

6 Diagnosis .................................................................................. 44

6.1 Simulation ............................................................................ 44

6.2 Error codes ........................................................................ 44

7 Technical data .......................................................................... 45

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Contents

7.1 Data ..................................................................................... 45

7.2 Dimensions ......................................................................... 52

7.3 Approvals ........................................................................... 55

Supplement ..................................................................................... 56

Safety Manual ................................................................................. 56

1 General ............................................................................... 56

1.1 Validity ................................................................................. 56

1.2 Area of application............................................................... 56

1.3 Relevant standards ............................................................. 56

1.4 Determination of safety-related characteristics.................. 57

2 Planning .............................................................................. 58

2.1 Low demand mode ..... .......................................................... 58

2.2 High demand or continuous mode ....................................... 58

2.3 General ................................................................................ 58

3 Set-up ................................................................................. 59

3.1 Mounting and installation..................................................... 59

3.2 Adjustment instructions and parameter adjustment ........... 59

3.3 Configuration of the processing unit ................................... 59

4 Reaction during operation and in case of failure ............. 60

5 Recurring function test ....................................................... 60

6 Safety-related characteristics ........................................... 61

SIL declaration of conformity .................................................... 62

CE declaration of conformity ..................................................... 63

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 56K 3

1 Product description

Level measurement in high temperature proc­esses or of products with high temperatures
was formerly very difficult or even impossi­ble. And if the measurement had to be made
under high pressure, as well, there was prac­tically no measuring system available. Not to
mention a non-contacting system with high
measurement accuracy.

In distillation and stripper columns, levels
(e.g. of sump, plate and head products)
were usually measured indirectly up to now
via pressure transmitters or differential pres­sure measurements. The installation required
for such pressure measuring systems (pres­sure lines, pressure transmitters…) is con­siderable and expensive, often amounting to
several times the value of the sensor itself.
Due to the lack of suitable alternatives, instru­mentation departments have not only had to
live with this but also accept high mainte­nance costs (cleaning of measuring pipes,
errors by condensation, buildup on the dia­phragm) as well as inadequate accuracy
(temperature errors, density fluctuations,
installation faults…).

The requirements of the petrochemical indus­try on a non-contact level sensor are the
following:

• independent of temperature and pressure

• process temperature up to 350°C

• process pressure up to 64 bar

• high resistance wetted parts, materials for
universal use

• accuracy 0.1 %

• rugged metal housing

• Ex-approved (available in EEx d and EEx
ia)

• loop-powered as well as digitally connect­able

This state of affairs defines the development
goals for a high-temperature radar level
measuring system, the VEGAPULS 56 series.
The new series represents an innovation in
high temperature radar sensors for level
measurement, in temperatures up to 350°C
and pressures up to 64 bar.

Product description

The sensors would not have been possible
without the new developments in materials
science and production technology. A spe­cially developed ceramic is used as coupling
material. It has high frequency characteristics
similar to those of plastic materials, which are
normally used. But it demonstrates incredibly
high chemical and thermal resistance.

The sensor is connected to the process only
via high-grade, expensive materials. This
refers not so much to the flange of high-alloy
stainless steel (1.4571 or better), as to the
specially developed ceramic (Al2O3) and its
connecting elements. The ceramic rod re­ceives from the high frequency module (from
the intelligent Fuzzy-Logic processing elec­tronics) the radar signals and its cone­shaped end operates as emitter and
receiver. The seal between stainless steel
flange and ceramic rod is an expensively
produced tantalum seal ring.

1.1 Function

Radio detecting and ranging: Radar.

VEGAPULS radar sensors are used for non­contact and 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.

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4 VEGAPULS 56K

Product description

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.

1 ns

Hence, it is possible for the VEGAPULS 56
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 suffi­ciently (note: air has a dielectric constant εr of

1).

r

278 ns

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.

50
40
30
20
10

5 %

5

0

2

0

25 %

4 6 8 12 14 16 18

10

40 %

20

ε

r

Reflected radar power dependent on the dielectric

t

t

constant of the measured product

Time transformation

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VEGAPULS 56K 5

Product description

Signal reflectivity grows stronger with in­creasing conductivity or increasing dielectric
constant of the product. Hence, nearly all
substances can be measured.

With standard flanges from DN 50 up to DN
250, ANSI 2“ up to ANSI 10“ the sensor an­tenna systems are adapted to the various
products and process environments. The
high-quality materials 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.

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

10

0

0,8 %

20 30 40 60

50

0,023 %

3 %

70 80 90 110 120 130 140

100

bar

1.2 Application features

Applications

• level measurement of liquids and 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

• 4 … 20 mA output signal or digital output
signal

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 64 bar
and product temperatures up to 350°C

Communicative

• individual connection, with 15 sensors on
one two-wire cable (digital output signal)

• 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

Ex approvals

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

Pressure influence: Error with pressure increase very
low (e.g. at 50 bar 0.8 %)

VEGAPULS 56 sensors now make radar level
measurement possible in plants where it was
hitherto unthinkable.

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Product description

1.3 Adjustment

Every measurement set-up 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

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.
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.

ware

TM.

The pro-

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

PLC

Adjustment with the PC on the 4 … 20 mA signal and
supply cable to the PLC or directly on the sensor

+-

2

4 ... 20 mA

2

Adjustment with the PC on the 4 … 20 mA signal and
supply cable to the PLC or directly on the sensor

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VEGAPULS 56K 7

2

2

4 ... 20 mA

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
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

ESC

+

Tank 1

-

m (d)

12.345

OK

2

4 ... 20 mA

ESC

+

-

OK

Adjustment with the HART® handheld

VEGAPULS 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.

To make adjustments, simply connect the

HART Communicator

HART® handheld

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.

ESC

+

Tank 1

-

m (d)

12.345

OK

4

Adjustment with detachable adjustment module on the
radar sensor or on the external indicating instrument
VEGADIS 50

HART® handheld on the 4 … 20 mA signal cable

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

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Product description

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.

Various antenna configurations are available
for different applications and process condi­tions. Beside the focussing properties, each
is characterised by special chemical and
physical features.

Horn antennas

Horn antennas focus the radar signals very

well. Manufactured of

1.4571 (StSt) or Hastelloy
C22 they are very rugged
and physically as well as
chemically resistant.
Horn antennas are used for
measurement in closed or
open vessels.

Pipe antenna

Pipe antennas on surge or by­pass tubes form a complete
antenna system in conjunction
with a measuring pipe (which
can also be bent). Pipe antennas
are best suited for products with
extreme turbulence or products
with low dielectric constant.

The antenna can be configured
with or without horn. Antennas
with horn are characterized by
very high antenna gain - reliable
measurement results are
achieved even in case of prod­ucts with very bad reflection
properties.

The measuring pipe constitutes
a conductor for radar signals.
The running period of the radar

DN 50

signals changes in the pipe and
depends on the pipe diameter.
The pipe inner diameter must be
programmed into the electronics
so that the running period can
be compensated.

DN 150

DN 80

DN 250

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VEGAPULS 56K 9

2 Types and versions

VEGAPULS 56 are a newly developed gen­eration of very compact high temperature
radar sensors. For the first time it is now
possible to carry out a non-contact level
measurement under high temperatures and
pressures. They bring the benefits of radar
level measurement to applications where
previously, due to extreme process condi­tions, the special special advantages of ra­dar had to be forgone.

VEGAPULS 56 radar sensors are perfectly
adapted to two-wire technology. They trans­mit the supply voltage and the output signal
via one two-wire cable. An analogue
4 … 20 mA output signal is available as out­put or measuring signal.

VEGAPULS 56
DN 150

VEGAPULS 56
DN 50 pipe antenna

VEGAPULS 56
DN 80 pipe antenna

Types and versions

2.1 Type survey

General features

• level measurement on processes and
products under high temperatures and
high pressures

• measuring range 0 … 20 m

• Ex-approved in Zone 1 and Zone 10 (IEC)
or Zone 0 and Zone 20 (ATEX) classifica­tion mark EEx ia IIC T6 or
EEx d ia IIC T6

• integrated measured value display

• external measured value display which can
be mounted up to 25 m away in Ex-area

Survey of features

Signal output
– 4 … 20 mA active (four-wire sensor)
– 4 … 20 mA passive (two-wire sensor)

Power supply
– two-wire technology (power supply and

signal output via one two-wire cable)

– four-wire technology (power supply sepa-

rated from the signal cable)

Process fitting
– DN 50; ANSI 2“
– DN 80; ANSI 3“
– DN 100; ANSI 4“
– DN 150; ANSI 6“
– DN 200; ANSI 8“
– DN 250; ANSI 10“

Adjustment
–PC
– adjustment module in the sensor
– adjustment module in the external indicat-

ing instrument

– HART® handheld

Antennas
– horn antenna with stainless steel horn and

ceramic tip

– standpipe antenna with ceramic tip

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;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

;;

Mounting and installation

3 Mounting and installation

3.1 General installation instructions

Measuring range

The reference plane for the measuring range
of the sensors is the lower edge of the flange.
The measuring range is 0 … 20 m. With
measurements in surge or bypass tubes
(pipe antenna) the max. measuring distance
decreases (see „Technical data - Measuring
range“).

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.

Reference plane

min. meas.
distance

full

min. meas.
distance

full

empty

Measuring

range

min.

min. meas.
distance

empty

max. meas. distance 20 m

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

False echoes

If flat obstructions in the range of the radar

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 smooth interfering surfaces cause large
false signals

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VEGAPULS 56K 11

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 smooth interfering surfaces with deflectors

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.

Heat insulation

In case of process temperature of more than
200°C an insulation on the rear of the flange is
necessary to keep radiated heat away from
the sensor electronics.

The best would be to incorporate the sensor
insulation into the vessel insulation and insu­late up to approx. the first pipe segment.

40°C

60°C

350°C

Heat insulation

100°C 240°C

Vessel insulation

max. 350°C

12 VEGAPULS 56K

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Mounting and installation

3.2 Measurement of liquids

Sensor 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.

> 10 mm

Mounting on round vessel tops

Reference plane

Mounting on short 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

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

When mounting on dished or rounded vessel
tops, the antenna must also protrude at least
10 mm (long socket side).

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VEGAPULS 56K 13

Mounting on round vessel tops

Mounting and installation

Sensor 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.

Reference plane

Mounting directly on flat vessel top

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 agitators. Measurement is then possible
when the product surface is very turbulent,
and vessel installations can cause no false
echoes.

Due to the concentration of the radar signals
within the measuring tube, even products
with small dielectric constants (εr= 1.6 up to

3) can be reliably measured in surge or by-

pass tubes. Note the following instructions.

Surge pipes which are open at the bottom
must extend over the full measuring range
(i.e. down to 0% level), as measurement is
only possible within the tube.

It is advantageous to mount a deflector at the
tube end. This enables the minimum level of
the product to be reliably detected. This is
particularly important for products with a
dielectric figure < 5.

Marking
hole in the
intermedi­ate flange

Surge pipe in the socket
piece

max.

min.

Surge pipe welded to
the tank

Vent hole

Deflector

Pipe antenna system in the tank

Make sure the required upper vent hole in
the surge pipe is aligned with the marking
hole in the intermediate flange (polarisation
direction of the radar signals).

As an alternative to a surge pipe in the ves­sel, a pipe antenna system outside the ves­sel in a bypass tube is also possible.

Please note that when measuring in a surge
or bypass tube, the max. measuring range is
reduced by 5 … 20 % (e.g. DN 50: 16 m
instead of 20 m and DN 100 only 19 m in­stead of 20 m).

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

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14 VEGAPULS 56K

;;;

;;;

;

;

;

;

;

Mounting and installation

Marking hole

100 %

;

;

;

;

;

0 %

Tube flange system as bypass tube

Adhesive products

When measuring adhesive products, the the
surge pipe must have a larger diameter. For
non-adhesive products, a 50 mm measuring
tube is a good and cost-effective solution. In
slightly adhesive products, use preferably a
surge pipe with a nominal width of 100 mm or
150 mm so that buildup cannot cause meas­urement errors. The measurement of ex­tremely adhesive products in a standpipe is
not possible at all.

DN 50

DN 80

ø 50

ø 80

100 %

75 %

DN 100

ø 100

DN 150

ø 150

0 %

Extended bypass tube on a vessel with turbulent
product movements

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

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VEGAPULS 56K 15

Mounting and installation

Standpipe measurement of inhomoge­neous products

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.

Polarisation direction

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.

Marking hole

Row of holes in one axis with the marking hole

homogeneous
liquids

slightly inhomogeneous
liquids

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).

A prerequisite for trouble-free operation is a
ball valve throat that corresponds to the pipe
diameter. The valve must not have rough
edges or constructions in its channel.

inhomogeneous
liquids

Openings in a surge pipe for mixing of inhomogene­ous products

very inhomogeneous liquids

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

16 VEGAPULS 56K

Make sure that standpipe ventilation is pro­vided.

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Mounting and installation

Ball valve

DN 50

Standpipe ventilation

ø50

Deflector

Correct

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

Incorrect

Wrong polarisation direction

When measuring in a surge pipe, especially
when there are holes for mixing, it is impor­tant that the radar sensor is aligned with the
rows of holes. The rows of holes of the surge
pipe (displaced by 180°) must be in one
plane with the polarisation direction of the
radar signals. The polarisation direction is the
same plane as the marking hole.

Lockable measuring pipe on a pipe antenna system

Installation errors in standpipe

Missing ventilation hole

Marking
hole

Pipe antenna systems must be provided with
a vent hole at the upper end of the surge
pipe. A missing hole causes wrong measure­ments.

The polarisation direction is in the same plane as the
marking hole. The sensor must be aligned with the
marking hole to the rows of holes or the openings.

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VEGAPULS 56K 17

;

Guidelines for standpipe construction

Flange DN 50

100 %

Rz ≤ 30

Connecting
sleeve

150…500

Welding neck flange

2,9…6

Welding of the connect­ing sleeves

5…15

0,0...0,4

Mounting and installation

Radar sensors for measurement on surge or
bypass tubes are used in the flange sizes
DN 50, DN 80, DN 100 and DN 150.

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

The radar sensor with DN 50 flange forms a
functioning measuring system only in con­junction with a measuring pipe.

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
buildup.

Welding neck
flanges

Deburr the
holes

Deflector

0 %

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

~45˚

Welding of the welding
neck flange

2,9

1,5…2

0,0…0,4

ø 51,2

Vessel bottom

Meas. pipe fasten­ing

Min. product level
to be measured
(0 %)

18 VEGAPULS 56K

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Mounting and installation

On the left, you see the constructional fea­tures of a measuring pipe as exemplified by
a radar sensor with a DN 100 flange.

Radar sensors with flanges of DN 80,
DN 100 and DN 150 are equipped with a
horn antenna. Instead of the welding neck
flange also a smooth welding flange can be
used on the sensor side of these sensors.

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

Flange DN 100

100 %

Deburr the
holes

Connecting
sleeve

Welding neck
flanges

Rz ≤ 30

Deflector

0 %

2

150…500

ø 96

ø 100,8

~45˚

Smooth welding
neck flange

Welding of the smooth
welding neck flanges

5…15

0,0…0,4

3,6

Welding of the welding
neck flange

3,6

1,5…2

0,0…0,4

Meas. pipe
fastening

Min. product
level to be
measured
(0 %)

With the deflector on the measuring pipe end,
the radar signals are reflected away from the
vessel bottom. This assures that, in nearly
empty vessel and products with low dielec­tric constants, the medium is detected, not
the vessel bottom. Products with low dielec­tric constant are penetrated by the signals
and, when the product level is low, allow the
vessel bottom to deliver stronger echoes
than the product surface.

Due to the deflector, the useful signal, and
thus the measurement value, can be clearly
detected in a nearly empty vessel and the
0 % level can be reliably detected.

Vessel bottom

22915-EN-041227

VEGAPULS 56K 19

Mounting and installation

3.4 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

Shield

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.

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.

Correct Incorrect

Correct Incorrect

Shields

Shield

Vessel protrusions (intake pipe)

20 VEGAPULS 56K

Struts

22915-EN-041227

;;

;;

;;;

;;;

;;;

;;;

;;

;;

;;

Mounting and installation

Strong product movements

Strong turbulence in the vessel, e.g. caused
by powerful agitators 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

100 %

75 %

0 %

Strong product movements

Products with a tendency to light buildup can
be detected by using a measuring tube with
100 mm nominal width or larger. In such a
measuring tube, light buildup does not cause
any problems.

Correct Incorrect

Buildup

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

Incorrect

Buildup

If the sensor is mounted too close to the
vessel wall, product buildup and other de-

Inflowing liquid

posits 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“.

22915-EN-041227

VEGAPULS 56K 21

Mounting and installation

3.5 Common installation mistakes

Socket piece too long

If the antenna 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

Horn antenna: Correct and incorrect socket length

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.

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

>10 mm

~ 1/

2

vessel
radius

Incorrect

Correct Incorrect

Incorrect

Ladder

Ladder

Mounting on a vessel with parabolic tank top

Direct sensor vertically to the product surface

22 VEGAPULS 56K

22915-EN-041227

Mounting and installation

Standpipe (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.

Correct Incorrect

Pipe antenna: The surge pipe open to the bottom
must have a ventilation hole

Wrong polarisation direction on the
standpipe

When measuring in a surge pipe, especially if
there are holes or slots for mixing in the tube,
it is important that the radar sensor is aligned
with the rows of holes.

The two rows of holes (displaced by 180°) of
the measuring tube must be in one plane with
the polarisation direction of the radar signals.
The polarisation direction is in the same plane
as the marking hole. You direct the sensor
precisely by means of the marking hole in the
intermediate flange.

Marking hole

The polarisation direction is in one plane with the
marking hole. The sensor must be directed with the
marking hole to the row of holes.

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.

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 - Emission cone and false ech­oes“.

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.

22915-EN-041227

VEGAPULS 56K 23

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.

Electrical connection

Connection cable

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 (M20x1.5)
or 3.5 … 8.7 mm (1/2“ NPT). Otherwise, the seal
effect of the cable entry would not be ensured.

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

Qualified personnel

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

Connection cable

A standard two or four-wire cable (sensors
with separate supply) with max. 2.5 mm2 wire
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 two or four-wire cable must be
screened.

We recommend the use of screening. The
screening is also a precautionary measure
against future sources of interference. Con­nect the cable screen to earth on two ends
(on the sensor and on the processing sys­tem) only if you have determined by meas­urement that no or only low earth
compensation currents flow over the
screens. Use a very low impedance earth
connection (foundation, plate or mains earth).

Ex protection

If an instrument is used in hazardous areas,
the appropriate regulations, conformity and
type approval certificates for systems in Ex
areas must be noted (e.g. DIN 0165).

Earth conductor terminal

On all VEGAPULS 56 sensors, the earth
conductor terminal is galvanically connected
to the metal process connections.

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 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.

24 VEGAPULS 56K

22915-EN-041227

ESCESC

+

-

OKOK

12 C 567843

(+) (-)
L1 N

Commu­nication+-4...20mA

Display

12 C 5 6 7 843

ESCESC

+

-

OKOK

-

+

-

+

12 C 567843

(+) (-)
L1 N

Commu­nication+-4...20mA

Display

12 C 5 6 7 843

ESC

OK

Electrical connection

Standard versions

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

Power supply

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

2)

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

(+) (-)

Commu-

L1 N

nication+-4...20mA

Display

ESC

-

+

OK

Sockets for connec­tion of
VEGACONNECT 2
(communication
sockets)

Exd version (loop-powered with pressure-tight encapsulated terminal compart­ment

EEx d terminal compartment

(opening in Ex atmosphere not allowed)

4 … 20 mA passive

-+

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

Shield

- +
2

1

1

2

1)

22915-EN-041227

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

VEGAPULS 56K 25

1)

Locking of the cover

Exd terminal compart­ment

1

/2“ NPT EEx d
(diameter of the
connection cable

3.5…8.7 mm)

Adjustment module and indicating termi­nal compartment

(opening in Ex area permitted)

1

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

3.5…8.7 mm)

2)

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

Exd safe connection to the
Exd terminal compartment

ESC

OK

Electrical connection

ESC

OK

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 affixing the housing cover during connec­tion work with one or two screws on the right
of the housing (illustration).

Four-wire sensor

(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

-

Tank 1
m (d)

12.345

Two-wire sensor

(loop powered)

4 … 20 mA
passive

+

-

+

ESC

OK

to VEGADIS 50

Screws

M20x1.5

12 C 567843

12 C 5 6 7 843

(+) (-)

Commu­nication+-4...20mA

-

+

Display

ESC

OK

12 C 567843

12 C 5 6 7 843

(+) (-)

Commu-

L1 N

nication+-4...20mA

-

L1 N

Display

ESC

+

OK

26 VEGAPULS 56K

22915-EN-041227

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 on active PLC in Ex area (ia);

• 4 … 20 mA on passive PLC in Ex area (ia);

• 4 … 20 mA on passive PLC in Ex area (d);

• 4 … 20 mA on VEGADIS 371 Ex indicating
instrument;

Measuring systems in four-wire technol­ogy:

• 4 … 20 mA shown without signal condition­ing instrument

Measuring systems with VEGAPULS 56K

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

• 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

4

22915-EN-041227

VEGAPULS 56K 27

2

VEGA­CONNECT2

4 ... 20 mA

1)

> 250 Ω

+

-

1)

If the resistance of the processing
systems connected to the
4 … 20 mA signal output is less
than 200 Ω, a resistor must be
connected to the connection cable
during adjustment to get a loop
resistance of 250 Ω up to 350 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.

Electrical connection

Measuring system with VEGAPULS 56K 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

4

2

2

VEGA­CONNECT 2

4 ... 20 mA

2

passive

2)

1)

2

PLC

HART® handheld

1)

If the resistance of the processing
systems connected to the
4 … 20 mA signal output is less
than 200 Ω, a resistor must be
connected to the connection cable
during adjustment to get a loop
resistance of 250 Ω up to 350 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.

2)

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

22915-EN-041227

28 VEGAPULS 56K

Electrical connection

Measuring system with VEGAPULS 56K Ex, 56K Ex0 via a safety barrier in
Ex area on active PLC

• 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 (VEGAPULS 56K Ex) or in zone 0 (VEGAPULS
56K Ex0)

• max. resistance of the signal cable 15 Ω per wire

• 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).

Ex area

VEGADIS 50 Ex

EEx ia

4

Non Ex area

Safety barrier
(see „3.3 Approvals“)

2

2

VEGA­CONNECT 2

4 ... 20 mA

passive

1)

2

2

PLC

HART® handheld

1)

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.

22915-EN-041227

VEGAPULS 56K 29

Electrical connection

Measuring system with VEGAPULS 56K Ex, 56K Ex0 via separator (Smart­Transmitter) on passive PLC

• 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 (VEGAPULS 56K Ex) or in zone 0
(VEGAPULS 56K Ex0)

• 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)

• Max. resistance of the signal cable 15 Ω per wire

Ex area

VEGADIS 50 Ex

EEx ia

4

Non Ex area

Separator
(see „3.3 Approvals“)

2

VEGA­CONNECT 2

-

+

4 ... 20 mA

1)

active

2

2

PLC

HART® handheld

1)

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

30 VEGAPULS 56K

22915-EN-041227

Electrical connection

Measuring system with VEGAPULS 56K Ex, 56K Ex 0 with pressure-tight
encapsulated connection compartment on active PLC

• Two-wire technology, supply via the cable from active PLC to Exd connection compartment
for operation in Ex-Zone 1 (VEGAPULS 56K Ex) or Ex-Zone 0 (VEGAPULS 56K Ex 0)

• 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

VEGADIS 50 Ex

EEx d ia

4

Non Ex area

EEx e

2

2

VEGA­CONNECT 2

2

4 ... 20 mA

passive

1)

2

2)

PLC

HART® handheld

1)

If the resistance of the processing
systems connected to the
4 … 20 mA signal output is less
than 200 Ω, a resistor must be
connected to the connection cable
during adjustment to get a loop
resistance of 250 Ω up to 350 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.

2)

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

22915-EN-041227

VEGAPULS 56K 31

Electrical connection

Measuring system with VEGAPULS 56K Ex, 56K Ex0 on VEGADIS 371 Ex
indicating instrument with current and relay output

• 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 (VEGAPULS
56K Ex) or in Zone 0 (VEGAPULS 56K Ex0)

• 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)

• Max. resistance of the signal cable 15 Ω per wire

Ex area

VEGADIS 50 Ex

4

EEx ia

Non Ex area

EEx ia

2

2

VEGA­CONNECT 2

4 ... 20 mA

2

passive

+

-

Relay

1)

VEGADIS
371 Ex

0/4 … 20 mA

certified,
intrinsically safe
HART® handheld

1)

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

32 VEGAPULS 56K

22915-EN-041227

Electrical connection

Measuring system with VEGAPULS 56K in f our -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. load 500 Ω

VEGADIS 50

2

+

4

2

2

VEGA­CONNECT 2

1)

2

> 250 Ω

-

4 ... 20 mA

2)

active

HART® handheld

1)

If the resistance of the processing
systems connected to the
4 … 20 mA signal output is less
than 200 Ω, a resistor must be
connected to the connection cable
during adjustment to get a loop
resistance of 250 Ω up to 350 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.

2)

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.

22915-EN-041227

VEGAPULS 56K 33

5 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.

PC

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

ware

TM

)

TM

on

Set-up

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 resistor

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.

34 VEGAPULS 56K

22915-EN-041227

Set-up

+

-

PLC

Ri ≥ 250 Ω

+

250 Ω

-

PLC

Ri < 250 Ω

Rx

VEGAMET/VEGALOG

22915-EN-041227

VEGAPULS 56K 35

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

OK

2

4 ... 20 mA

ESC

+

Tank 1

-

m (d)

12.345

OK

4

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.

You carry out all adjustment steps with the 6
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.

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.

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.

1. Measurement in a standpipe

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
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).

22915-EN-041227

36 VEGAPULS 56K

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-

OK

OK

OK

OK

+

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

meter

Adjust­ment

w.o
medium

Ad­just­ment
in

m(d)

(min. adjustment)

"m“.

OK

+ –

or

Confirm the adjustment with
"OK“.

m(d)

0.0%

at

m (d)

XX.XXX

Ad­just­ment
in

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

The entered percentage value

OK

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

22915-EN-041227

VEGAPULS 56K 37

Set-up

+ –

or

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.

OK

The adjusted product dis­tance is written in the sensor
and the display stops flash­ing.

You thereby adjusted the lower product dis­tance as well as the percentage filling value
corresponding to the lower product distance.

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%

at

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

XXX.X

Max.
adjust
at %

XXX.X

Min.
adjust
at %

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

to

Mass

Kg

“, you

0 % corresponds

“

22915-EN-041227

38 VEGAPULS 56K

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:

XX

dB

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.

22915-EN-041227

VEGAPULS 56K 39

Menu schematic for the adjustment module MINICOM

Sensor

m(d)

4.700

PULS56

After switching on, the sensor type and the

K

software version are displayed for a few

0.50
seconds.

Set-up

Para­meter

Adjust
ment

3.

Sensor
opti­mize

Sensor
Tag

Sensor

Meas.
enviro
nment

Opera­ting
range

Begin

m (d)

0.50

2.

End

m (d)

6.00

5. 1.

Meas.
condit
ions

Condit
ion

liquid

4. 8.

Signal
condit
ioning

Fast
change

No

Measur
ing in
tube

act.
dist.

m (d)

4.700

Correc
tion
Now!

OK ?

Agitat
ed sur
face
No

Foam­ing
prod.
No

High
dust
level
No

Low DK
pro­duct
No

Out­puts

Large
angle
repose
No

w.out
medium

Adjust
ment
in

m(d)

with
medium

Min­adjust
at %

XXX.X

0.0 %

at

m (d)

XX.XXX

Max­adjust
at %

XXX.X

100.0%

at

m (d)

XX.XXX

Sca­ling

0 %
corres
ponds

XXXX

Lin.
curve

Linear

100 %
corres
ponds

XXXX

Integr
ation
time

Deci­mal
point

888.8

Curr.
out-

0 s

Prop.

Unit

to

Mass

Kg

put

Curr.
out­put

4-20mA

Fail­ure
mode

22mA

Sensor
displ.

Prop.
to

di­stance

40 VEGAPULS 56K

22915-EN-041227

Set-up

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

ESC

6. 7.

m (d)

OK ?

OK ?

act.
dist.

m (d)

4.700

Update

Meas.
dist.

m (d)

X.XX

Update
Now!

OK ?

Lear­ning!

Simulation:Simulation:

Simulation:

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

Note:

Set up the sensor in the se­quence of the numbers. The
menu items under the numbers 1
to 5 are required for set-up. The

%

menus below the numbers 7 and
8 are only necessary for difficult
measurement conditions. The
menu below number 6 is only
necessary for measurement in a
standpipe.

False
echo
memory

Create
new

Meas.
dist.

X.XX

Create
new

Lear­ning!

Simu­lation

Simu­lation
Now!

Simu­lation

XXX.X

Ampl.:

XX dB

S-N:

XX

Delete

Delete
Now!

OK ?

Delet­ing!

max.
range.

m (d)

7.000

OK

Act.
dist.

m (d)

4.700

Ampl.:

XX dB

S-N:

XX

dB

Add’l
func­tions

Info

Pass­word

dB

Off

Sensor
Tag

Sensor

Reset
to de
fault

Reset
Now!

OK ?

Reset
ing!

Sensor
type

PULS52
K

Lan­guage

Eng­lish

Serial
no.

1094
0213

High
dust
level
No

Fast
change

Yes

Act.
dist.

X,XX

Unit

Softw.
vers.

1.00

m (d)

Softw.
date

15.09.
1997

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 .

22915-EN-041227

VEGAPULS 56K 41

Set-up

5.4 Adjustment with HART

®

handheld

With any HART® handheld you can set up the
VEGAPULS series 56K radar sensors like all
other HART® compatible sensors. A special
DDD (Data Device Description) is not neces­sary.

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.

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

+

-

Ri < 250 Ω

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.

+

250 Ω

-

Ri < 250 Ω

42 VEGAPULS 56K

22915-EN-041227

Set-up

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.

VEGA signal conditioning instr. Rx

VEGAMET 513, 514, 515, 602
VEGATRENN 544
VEGATOR 521…527 50 … 100 Ohm

VEGAMET 614 no additional
VEGADIS 371 resistor

required

VEGAMET 601 200 … 250 Ohm

VEGASEL 643 150 … 200 Ohm

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

VEGALOG VEGAMET

Rx

22915-EN-041227

VEGAPULS 56K 43

6 Diagnosis

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
PACT
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 Meaning Rectifying measure

TM

ware

or in the HART® handheld.

Diagnosis

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.

44 VEGAPULS 56K

22915-EN-041227

Technical data

7 Technical data

7.1 Data

Power supply

Supply voltage

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

- four-wire sensor 24 V DC (20 … 72 V)

Load diagram (loop resistance of e.g. PLC and supply cable)

Ω

1000

680
500

250

HART
load

®

230 V AC (20 … 250 V), 50/60 Hz
fuse 0.5 A TR

Voltage limit
Ex sensor

Voltage limit
non-Ex sensor

0

20 22 24 26 28 30 32 34 36

19 V

V

Current consumption

- two-wire sensor max. 22.5 mA

- four-wire sensor max. 60 mA
Power consumption

- two-wire sensor max. 80 mW, 0.45 VA

- four-wire sensor max. 200 mW, 1.2 VA

Measuring range

1)

Standard 0 … 20 m
Measurement in a standpipe

- VEGAPULS 56 on DN 50 0 … 16 m

- VEGAPULS 56 on DN 100 0 … 19 m

Output signal (see also „Outputs and processing“)

4 … 20 mA current signal
Load

- four-wire sensor max. 500 Ω

- two-wire sensor see above diagram

1)

Min. distance from the antenna top to the medium 5 cm

22915-EN-041227

VEGAPULS 56K 45

Technical data

Accuracy

1)

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

Influence

- of the ambient temperature

- of the process temperature

- of the process pressure

1)

1)

21

0.06 %/10 K
negligible (0.004 %/10 K at 5 bar)
(0.003 %/10 K at 40 bar)
negligible (0.025 %/bar)

Resolution 1 mm
Resolution of the output signal 1.6 µA, 0,01 % or 1 mm
Accuracy see diagram

20 mm

10 mm

-10 mm

-20 mm

1,0 m 30 m

Adjustment time > 2 s (dependent on the parameter adjustment)

Characteristics

Frequency 5.8 GHz (USA 6.3 GHz)
Intervals

- two-wire sensor 0.6 s

- four-wire sensor 0.3 s
Min. span between full
and empty adjustment

- analogue output signal 10 mm (recommended 50 mm)

- digital output signal 5 mm (recommended 50 mm)
Beam angle (at –3 dB)

- with DN 80 38° (only for standpipe measurement)

- with DN 100 30° (only for standpipe measurement)

- with DN 150 20°

- with DN 200 16°

- with DN 250 14°

1)

Reference conditions acc. to IEC 770

46 VEGAPULS 56K

22915-EN-041227

Technical data

Ambient conditions

Ambient temperature on the housing -20°C … +60°C
Flange temperature (process temp.) -40°C … +350°C (pressure-dependent), see

following diagrams

Vessel installation with process temperatures > 200°C the rear of

the flange must be covered with a heat insulation

see chapter „4 Mounting and installation“
Storage and transport temperature -40°C … +80°C
Protection IP 66/IP 67
Protection class

- two-wire sensor II

- four-wire sensor I
Overvoltage category III
Vessel pressure max. 64 bar (temperature-dependent), see

following diagrams

Flange DIN DN 50
Material: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

Flange DIN DN 50
Material: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

Flange DIN DN 80
Material: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

bar

40

25
16

-40 0 50 100 150 200 250 300 350

bar

64

40

25
16

-40 0 50 100 150 200 250 300 350

bar

40

25
16

PN 40

PN 25

PN 16

PN 64

PN 40

PN 25

PN 16

PN 40

PN 25

PN 16

˚C

˚C

-40 0 50 100 150 200 250 300 350

22915-EN-041227

VEGAPULS 56K 47

˚C

PN 16

PN 25

PN 40

PN 64

bar

40

25
16

-40 0 50 100 150 200 250 300 350

˚C

64

Flange DIN DN 80
Materials: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

Technical data

Flange DIN DN 100
Material: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

Flange DIN DN 100
Materials: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

Flange DIN DN 150
Materials: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

bar

40

25
16

-40 0 50 100 150 200 250 300 350

bar

64

40

25
16

-40 0 50 100 150 200 250 300 350

bar

40

25
16

PN 40

PN 25

PN 16

PN 64

PN 40

PN 25

PN 16

PN 40

PN 25

PN 16

˚C

˚C

-40 0 50 100 150 200 250 300 350

48 VEGAPULS 56K

˚C

22915-EN-041227

Technical data

Flange DIN DN 150
Material: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

Flange DIN DN 200
Material: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

Flange DIN DN 200
Materials: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

bar

64

40

25
16

-40 0 50 100 150 200 250 300 350

PN 16

bar

40

25
16

-40 0 50 100 150 200 250 300 350

bar

64

40
25

16

PN 16

PN 25

PN 16

PN 64

PN 40

PN 25

PN 40

PN 25

PN 64

PN 40

˚C

˚C

-40 0 50 100 150 200 250 300 350

Flange DIN DN 250
Material: 1.4571
Seal surface acc. to DIN
2526 Form B, C, D, E

22915-EN-041227

bar

40

25
16

-40 0 50 100 150 200 250 300 350

PN 16

PN 40

PN 25

VEGAPULS 56K 49

˚C

˚C

Technical data

Flange DIN DN 250
Materials: 1.4571
Groove and tongue acc.
to DIN 2512 Form F, N

bar

64

PN 64

40

25
16

-40 0 50 100 150 200 250 300 350

PN 40

PN 25

PN 16

Flanges acc. to ANSI (ASA) B16.5 seal surface RF, materials 1.4571 in sizes 2“ up to 10“
can be used over the complete temperature range of -40°C … 350°C with the respective
nominal pressures of 150 lbs, 300 lbs, 600 lbs and 900 lbs.

Further flanges and process data on request.

Ex-technical data

Comprehensive data in the safety instructions manual (yellow binder)

Materials

Housing Aluminium die casting (GD-AlSi10Mg)
Flange 1.4571 or Hastelloy C22
Antenna ceramic (Al2O3), 1.4571 or Hastelloy C22
Seal Tantalum
Exd terminal compartment
(only EExd version) Aluminium chill casting (GK-Alsi7Mg)

Weights in kg (1 psi = 0.0689 bar)

DIN 16 bar 25 bar 40 bar 64 bar

- DN 50 6.9 -- 7.7 8.5

- DN 80 8.8 -- 10.0 10.9

- DN 100 9.8 -- 11.7 14.1

- DN 150 14.6 -- 18.7 27.5

- DN 200 21.0 -- 26 48

- DN 250 29.6 38.2 38.5 61.4

˚C

ANSI 150 psi 300 psi 600 psi 900 psi

- 2“ 6.3 7.6 8.5 15.3

- 3“ 8.1 11.3 13.1 17.2

- 4“ 11.7 16.2 22.6 28.5

- 6“ 15.8 26.7 44.0 56.2

- 8“ 27.0 50.0 85.0 100.0

- 10“ 35.8 60.7 108.0 136.0

50 VEGAPULS 56K

22915-EN-041227

Technical data

Connection cables

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

cable

Four-wire sensor power supply and signal separately, line

resistance of the 4 … 20 mA signal cable

Wire cross section generally 2.5 mm

max. 500 Ω

Ground connection max. 4 mm

2

2

Cable entry

- Ex ia terminal compartment
(adjustment module) 2 x M20 x 1.5 (cable diameter 5 … 9 mm)

- Exd terminal compartment 2 x 1/2“ NPT EEx d (cable diameter of

3.5 … 8.7 mm)

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

22915-EN-041227

VEGAPULS 56K 51

Technical data

Outputs and processing

Display

Indication - optionally mounted, scalable analogue and

Signal output

Signal output

- two-wire technology 4 … 20 mA

- four-wire technology 4 … 20 mA
Resolution of the 20 mA signal 1.6 µA (0.01 % of operating range)
Load

- four-wire 0 … 500 Ω

- two-wire see load diagram under „Power supply“
Integration time 0 … 999 seconds

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.

digital measured value display.

- optional external measured value display
which can be mounted up to 25 m away from
the sensor, measured value display powered
by the sensor

52 VEGAPULS 56K

22915-EN-041227

Technical data

22915-EN-041227

VEGAPULS 56K 53

7.2 Dimensions

Aluminium housing

Technical data

Aluminium housing with Exd
terminal compartment

370

205

320

ø165

213
185

25

116

370

205

320

18

23

ø200

ø76

20

75

185

213

ø220

25

116

20

120

ø96

ø18

ø125

DN 50

Pipe antenna

ø18

ø160

DN 80

Pipe antenna

ø18

ø180

DN 100

54 VEGAPULS 56K

22915-EN-041227

Technical data

ø285

ø22

22915-EN-041227

ø146

ø240

DN 150

22

205

ø340

ø197

ø22

ø295

DN 200

24

ø405

296

ø241

ø26

ø355

DN 250

26

380

VEGAPULS 56K 55

Technical data

External indicating instrument VEGADIS 50

38

ù5

48

10

Pg 13,5

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

135

118

108

82

Flange dimensions acc. to ANSI

d

2

b

d

f

1

k

D

85

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.

D = outer flange diameter

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

1

/16" = approx. 1.6 mm

d2= diameter of holes

Size Flange Seal ledge Holes

Db k d1No. d

2

2" 150 psi 152.4 19.0 120.7 91.9 4 19.1
3" 150 psi 190.5 23.8 152.4 127.0 4 19.1
4" 150 psi 228.6 23.8 190.5 157.2 8 19.1
6" 150 psi 279.4 25.4 241.3 215.9 8 22.4

Adjustment module MINICOM

Tank 1
m (d)

12.345

67,5

56 VEGAPULS 56K

ESC

+

-

32,5

OK

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

74

22915-EN-041227

Technical data

7.3 Approvals

When radar sensors are used in Ex and
dust-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.

VEGAPULS 56 radar sensors are approved
for Ex-Zone 1 and Zone 0.

Please note the attached approval docu­ments (yellow binder) 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)

Ex area Zone 0/Zone 1 without Exd con­nection housing:
Separator and signal conditioning instru­ment:

• VEGADIS 371 Ex

Separator:

• VEGATRENN 149 Ex

• Stahl 9303/15/22/11

• Knick WG 21 A 7 (opt. 470, 336)

• CEAG GHG 124 3111 C1206

Safety barrier:

• Stahl 9001/01/280/085/10

• Stahl 9001/01/280/110/10

• Stahl 9001/01/280/165/10

• CEAG GHG 11 1 9140 V0728

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“.

Ex area Zone 0/Zone 1

Series 50 sensors require for operation in Ex
area special safety barriers or separators
providing intrinsically safe (ia) circuits.

The following shows a selection of instru­ments with which VEGAPULS 56 sensors
work reliably. In conjunction with separators,
the resistance of the signal cable and the
separator resistance (voltage loss of the
separator) must not exceed the max. load
(see load diagram in chapter „3.1 Data“).

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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)

1)

2

< 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)

1)

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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2

2

2

2

2

2

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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

1)

3)

PFD

PFH [1/h]

Max

< 0.12 •10
< 0.60 •10

< 0.28 •10

Min

-2

-2

-6

with T
with T

= 1 year

Proof

= 5 years

Proof

2)

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

1)

PFD

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

avg

selection circuit.

2)

T

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

Proof

must be carried out.

3)

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

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= 1 Jahr

proof

= 3 Jahre

proof

= 5 Jahre

proof

Reaction

= 60 sec

Reaction

Jahre

of the measuring system. This means that the failure

.

Reaction

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SIL declaration of conformity

die Betriebsbewährtheit entsprechend der IEC 61508 / IEC 61511 nachgewiesen wurde.

z.B. für Überlaufschutz, Trockenlaufschutz oder Erfassung eines beliebigen Füllstandes geeignet.

Die entsprechenden Sicherheitshinweise im Safety Manual sind zu beachten.

Sicherheitstechnische Kenndaten:

SIL Safety Integrity Level SIL 2 SIL 2
HFT Hardware Fault Tolerance
SFF Safe Failure Fraction > 88 % > 86 %
PFD

average Probability of dangerous

avg

Failure on Demand
(für niedrige Anforderungsrate)
PFH Probability of a dangerous Failure per

Hour
[1/h] (für hohe Anforderungsrate oder

kontinuierliche Anforderung)

Die Ausfallraten wurden über eine FMEDA ( Failure Modes, Effects and Diagnostics Analysis ) ermittelt:

safe detected failure

λ

sd

safe undetected failure

λ

su

dangerous detected failure

λ

dd

dangerous undetected failure

λ

du

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

1)

Safety Manual siehe Anhang der Betriebsanleitung

2)

HFT ist gemäß IEC 61511-1, Abschnitt 11.4.4 um eins reduziert

3)

PFD

gilt nur für das T

avg

4)

PFH ist über die Zeit konstant. Nach der Norm ist kein wiederkehrender Funktionstest notwendig.

Die Fehlertoleranzzeit des Gesamtsystems muss größer sein als die Fehlerreaktionszeit des Standaufnehmers

5)

Fehlerrate: 1 FIT = 1 Ausfall /109 h

Die Beurteilung des Änderungswesens war Bestandteil des Nachweises der Betriebsbewährtheit.

Schiltach, 28.10.03
VEGA Grieshaber KG

i.V. Frühauf i.A. Blessing
Leiter Zertifizierung Beauftragter für Funktionale Sicherheit

SIL-KE_PULS40+50_DE_031028

S I L - K o n f o r m i t ä t s e r k l ä r u n g

Funktionale Sicherheit nach IEC 61508 / IEC 61511

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

erklärt als Hersteller, dass für die Füllstandaufnehmer der Produktfamilien

VEGAPULS Serie 40 und 50 ( 4 ... 20 mA HART® )

Die Geräte sind deshalb für den Einsatz in sicherheitsrelevanten Einrichtungen

– Intervall, nach dem ein wiederkehrender Funktionstest durchgeführt werden muss

Proof

Füllstand - Grenzstand - Druck

VEGAPULS 40 VEGAPULS 50

2)

0 0

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

3)

4)

< 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

Proof

Proof

Fehlerreaktionszeit

5)

494 FIT 518 FIT
1090 FIT 1140 FIT
221 FIT 277 FIT

1)

1 Jahr

5 Jahre

60sec

Supplement

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CE declaration of conformity

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VEGA Grieshaber KG
Am Hohenstein 113
77761 Schiltach
Germany
Phone [phone]
Fax [phone]
E-Mail [e-mail]

www.vega.com

ISO 9001

All statements concerning scope of delivery, application, practical

use and operating conditions of the sensors and processing sys-

tems correspond to the information available at the time of printing.

Technical data subject to alterations

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