ntary documents appropriate to the ordered version come
with the delivery. You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
re reliable setup and operation of your VEGAPULS 63, we
To ensu
offer accessories and replacement parts. The corresponding documentations are:
l 27835 - Indicating and adjustment module PLICSCOM
l 32628 - Interface adapter VEGACONNECT
l 27720 - External indication VEGADIS 61
l 34296 - Protective cover
l 30176 - Electronics module VEGAPULS series 60
l 31088 - Flanges according to DIN-EN-ASME-JIS
Editing status: 2012-05-25
ldbus3
1 About this document
1 About this document
1.1 Function
is operating instructions manual provides all the information you
Th
need for mounting, connection and setup as well as important
instructions for maintenance and fault rectification. Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained qualified
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbolism used
Information, tip, note
This
symbol indicates helpful additional information.
Caution: If this
result.
Warning: If this warning is ignored, injury to persons and/or serious
damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
applications
Ex
Th
symbol indicates special instructions for Ex applications.
is
lList
The dot set in front indicates a list with no implied sequence.
warning is ignored, faults or malfunctions can
àAction
This a
rrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
Battery disposal
symbol characterizes the special information for disposal of
This
batteries and accumulators.
28451-EN-120530
4VEGAPULS 63 • Foun
dation Fieldbus
2 For your safety
2 For your safety
2.1 Auth
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
orised personnel
2.2 Appropriate use
VEGAPULS 63 is a sensor for continuous level measurement.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbitrary
conversions or modifications are explicitly forbidden.
2.3 Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards, e.g. vessel overfill or damage to system
components through incorrect mounting or adjustment.
28451-EN-120530
VEGAPULS 63 • Foundation Fie
2.4 General safety instructions
This is a high-tech instrument requiring the strict observance of
standard regulations and guidelines. The user must take note of the
safety instructions in this operating instructions manual, the countryspecific installation standards as well as all prevailing safety
regulations and accident prevention rules.
Depending on the model, the emitting frequencies of all radar sensors
are either in the C or K band range. The low transmitting power lies far
below the internationally permitted limit values. When the instrument is
used correctly, it presents no danger to human health. It may be
operated without restriction outside of closed metallic vessels.
The instrument must only be operated in a technically flawless and
reliable condition. The operator is responsible for trouble-free
operation of the instrument.
ldbus5
2 For your safety
During the entire duration of use, the user
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
is obliged to determine the
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines. By attaching the CE mark, VEGA provides a confirmation
of successful testing. You can find the CE conformity declaration in the
download area of "
2.7 Fulfillment o
The device fulfills the requirements of the applicable NAMUR
recommendations.
www.vega.com".
f NAMUR recommendations
2.8 FCC/IC conformity (only for USA/Canada)
VEGAPULS sensors with all antenna versions are FCC/IC approved.
Modifications not expressly approved by VEGA will lead to expiry ofthe operating licence according to FCC/IC.
VEGAPULS 63 is in conformity with part 15 of the FCC directives and
fulfills the RSS-210 regulations. Note the corresponding regulations for
operation:
l The instrument must not cause any interfering emissions
l The device must be insensitive to interfering immissions, including
those that may cause undesirable operating conditions
According to chapter "Dimensions" of this operating instructions
manual, the instrument is designed for operation with an antenna with
a max. amplification of 33 dB. The instrument must not be operated
with antennas not listed therein or those having an amplification of
more than 33 dB. The required antenna impedance is 50 Ω.
2.9 Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas. These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
6VEGAPULS 63 • Foun
28451-EN-120530
dation Fieldbus
2 For your safety
2.10 Environmental instructions
Protection
is why we have introduced an environment management system with
the goal of continuously improving company environmental protection.
The environment management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
l Chapter "Packaging, transport and storage"
l Chapter "Disposal"
of the environment is one of our most important duties. That
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus7
3 Product description
3 Product description
3.1 Structure
Vers
ions
Scope of delivery
Constituent parts
e VEGAPULS 63 radar sensor is available in two electronics
Th
versions:
l Standard electronics type PS60KF
l Electronics with increased sensitivity type PS60KL
The respective version can be determined by means of the type label
on the electronics.
The electronics version influences the CE conformity, the factory
setting for the medium selection and vessel form, the accuracy as well
as the approvals of VEGAP ULS 63. The differences are listed in the
respective sections of this operating instructions manual.
The scope of delivery encompasses:
l VEGAPULS 63 radar sensor
l Documentation
- this operating instructions manual
- Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM" (optional)
- Supplementary instructions manual 31708 "Heating for in-
- Ex-specific "Safety instructions" (with Ex versions)
- if necessary, further certificates
The VEGAPULS 63 consists of the components:
l Process fitting with flange
l Housing with electronics, optionally available with plug connector,
optionally available with connection cable
l Housing cover, optionally available with indicating and adjustment
module PLICSCOM
The components are available in different versions.
8VEGAPULS 63 • Foun
28451-EN-120530
dation Fieldbus
3
2
1
3 Product description
cation area
Appli
Functional principle
Power supply and bus
communicatio
n
DD/CFF
Fig. 1: VEGAPULS 63 - flange version with
1Housing cover with integrated PLICSCOM (optional)
2Housing with electronics
3Process fitting with encapsulated antenna system
plastic housing
3.2 Principle of operation
VEGAPULS 63 is a radar sensor in K-band technology (emitting
frequency approx. 26 GHz) for continuous level measurement. It is
particularly suitable for small vessels that contain aggressive liquids
under easy process conditions.
The electronics version "Increased sensitivity" enables the use of
VEGAPULS 63 also in applications with very poor reflective properties
or products with low e
The antenna of the radar sensor emits short radar pulses with a
duration of approx. 1 ns. These pulses are reflected by the product
and received by the antenna as echoes. The transit time of the radar
pulses from emission to reception is proportional to the distance and
hence to the level. The determined level is converted into an
appropriate output signal and outputted as measured value.
Power is supplied via the H1 Fieldbus. A two-wire cable according to
Fieldbus specification serves as carrier of both power and digital datafor multiple sensors. This cable can be operated in two versions:
l via an H1 interface card in the control system and additional power
supply
l via a Linking device with HSE (High speed Ethernet) and
additional power supply according to IEC 61158-2
The DD (Device Descriptions) and CFF (capability files) necessary for
planning and configuration of your FF (Foundation Fieldbus) communication network are available in the download area of the VEGA
homepage
www.vega.com un
value.
r
der "Services - Downloads - Software -
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus9
3 Product description
Packag
ing
Foundation Fieldbus". T
there. A CD with the appropriate files and certificates can be ordered
via e-mail under info@de.vega.com or by phone from one of the VEGA
agencies under the order number "DRIVER.S".
The backlight of the indicating and adjustment module is powered by
the sensor. Prer equisite is a certain level of operating voltage.
The data for power supply are specified in chapter "Technical data".
The optional heating requires its own operating voltage. You can find
detailed information in the supplementary instructions manual "Heating
for indicating and adjustment module". This function is generally not
available for approved instruments.
he appropriate certificates are also available
3.3 Operation
The instrument can be adjusted with the following adjustment media:
l With indicating and adjustment module
l with the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard, e.g. PACTware and
PC
l a configuration tool
3.4 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environmentfriendly, recyclable cardboard. For special versions, PE foam or PE foil
is also used. Dispose of the packaging material via specialised
recycling companies.
Transport
Transport inspection
Storage
10VEGAPULS 63 • Foun
Transport must be carried out under consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or
concealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
l Not in the open
28451-EN-120530
dation Fieldbus
3 Product description
Stora
ge and transport
temperature
l Dry and dust free
l Not expose
l Protected against solar radiation
l Avoiding mechanical shock and vibration
l Storage and transport temperature see chapter "Supplement -
d to corrosive media
Technical data - Ambient conditions"
l Relative humidity 20 … 85 %
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus11
4 Mounting
4 Mounting
Mountin
Moisture
g position
4.1 General ins
Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module. The housing can be rotated by 330° without the use of any
tools. You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).
Use the recommended cables (see chapter "Connecting to power
supply") and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry. Rain and condensation water can thus drain off. This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g. through cleaning processes) or
on cooled or heated vessels.
tructions
Fig. 2: Measures against moisture
Measu
ring range
12VEGAPULS 63 • Foun
The reference plane for the measuring range of the sensors is the
lower edge of the flange.
Information:
medium reaches the antenna, buildup can form on it and cause
If the
faulty measurements later on.
penetration
28451-EN-120530
dation Fieldbus
132
100%
0%
4
1
4 Mounting
Polarisation plane
Suitability for the pro-
cess condition
s
Fig. 3: Measuring range (operating range) and
1full
2empty (max. measuring distance)
3Measuring range
4Reference plane
max. measuring distance
The emitted radar impulses of VEGAPULS 63 are electromagnetic
waves. The polarisation plane is the direction of the electrical share.
Their position is marked on the instrument.
Fig. 4: Position of the
1Marking hole
Make sure that all parts of the instrument exposed to the process, in
polarisation plane of VEGAPULS 63
particular the sensor element, process seal and process fitting, are
suitable for the existing process conditions. These include above all
the process pressure, process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data" and on the
type label.
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus13
> 200 mm
(7.87
")
4 Mounting
Mounting of instruments
with PTFE-coated flanges
Mountin
g position
4.2 Instruction
s for installation
The flange screws of VEGAPULS 63 must be always screwed with the
torque stated in the technical data so that the PTFE washer of the
encapsulated antenna system seals.
You can counteract the material-induced tension loss with PTFE by
doing the following:
1 Make sure the number of flange screws corresponds to the
number of flange holes
2 Use disc springs in addition to the flange screws for fastening the
flange
3 Tighten the screws steadily with the torque specified in the
technical data
When mounting the VEGAPULS 63, keep a distance of at least
200 mm (7.874 in) to the vessel wall. If the sensor is installed in the
center of dished or round vessel tops, multiple echoes can arise.
These can, however, be suppressed by an appropriate adjustment
(see chapter "Setup").
If you cannot keep this distance you should carry out a false echo
storage before setup. This applies mainly if buildup on the vessel wall
is expected. In this case, we recommend repeating a false echo
storage later with existing buildup.
Fig. 5: Mounting on round
1Reference plane
2Vessel center or symmetry axis
vessel tops
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel, as measurement is then possible
down to the lowest point of the vessel bottom.
14VEGAPULS 63 • Foun
28451-EN-120530
dation Fieldbus
4 Mounting
Inflowing medium
Soc
ket
Fig. 6: Vessel with conical
bottom
Do not mount the instruments in or above the filling stream. Make sure
that you detect the product surface, not the inflowing product.
Fig. 7: Inflowing liquid
mounting
Flush
The best way to mount the sensor, also with respect to cleanability, is
flush on a block flange (flange without socket piece) or with hygienic
fittings, e.g. Neumo Biocontrol.
Mounting on socket
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus15
d
h
max.
d
50 mm/2"
80 mm/3"
100 mm/4"
150 mm/6"
100 mm
150 mm
250 mm
400 mm
h
max.
4 Mounting
sor orientation
Sen
If the reflective
properties of the medium are good, you can mount
VEGAPULS 63 on a socket piece. You will find recommended values
for socket heights in the following illustration. The socket end should
be smooth and burr-free, if possible also rounded. Then carry out a
false echo storage.
Fig. 8: Deviating socket dimensions
Align
the sensor in liquids as vertical as possible to the product surface
to achieve optimum measurement.
Fig. 9: Alignment in liquids
Vessel installations
e mounting location of the radar sensor should be a place where no
Th
other equipment or fixtures cross the path of the microwave signals.
Vessel installations such as for example, ladders, limit switches,
heating spirals, struts etc. can cause false echoes that interfere with
the useful echo. Make sure when planning your measuring site that the
radar signals have a "clear view" to the measured product.
In case of existing vessel installations, a false echo storage should be
carried out during setup.
16VEGAPULS 63 • Foun
28451-EN-120530
dation Fieldbus
4 Mounting
Agitators
If large vessel installations such as struts or supports cause false
echoes, t
hese can be attenuated through supplementary measures.
Small, inclined sheet metal baffles above the installations scatter the
radar signals and prevent direct interfering reflections.
Fig. 10: Cover smooth profiles
with deflectors
If there are agitators in the vessel, a false signal memory should be
carried out with the agitators in motion. This ensures that the interfering
reflections from the agitators are saved with the blades in different
positions.
Foam generation
28451-EN-120530
VEGAPULS 63 • Foundation Fie
Fig. 11: Agitators
Through the
action of filling, stirring and other processes in the vessel,
dense foams which considerably damp the emitted signals may form
on the product surface.
If foams lead to measurement errors, you should use the biggest
possible radar antennas and low frequency radar sensors (C-band).
As an alternative, sensors with guided microwave can be used. These
are unaffected by foam generation and are best suited for such
applications.
ldbus17
max.
min.
2
1
4 Mounting
rement in the
Measu
standpipe (surge
pass tube)
or by-
By using a standpipe, the influ
ence of vessel installations and
turbulence can be excluded. Under these prerequisites, the measurement of products with low dielectric figure (from 1.6) is possible.
Surge or bypass tubes must extend all the way down to the requested
min. level, as measurement is only possible within the tube.
Surge pipe
Make sure you provide the necessary upper vent hole in the surge
pipe. The hole must be aligned so that it and the polarisation marking
on the sensor are in the same plane (see illustration: "Pipe antenna
system in a tank").
Fig. 12: Pipe
in one plane with the polarisation marking on the sensor.
1Marking of the polarisation direction
2Vent hole max. ø 5 mm (0.2 in)
antenna
in a tank. The vent hole in the surge pipe must be
system
If possible, the antenna diameter of the sen sor should correspond to
the inner diameter of the tube. With VEGAPULS 63 this is approx.
40 mm (1.575 in). The sensor can be used with tube diameters
between 40 … 80 mm (1.575 … 3.15 in).
Bypass tube
As an alternative to the surge pipe in the vessel, a tube system outside
of the vessel is possible as a bypass tube. Select during setup the
function "Bypass tube".
Align the sensor in such a way that the polarisation marking on the
process fitting is in the same plane as the tube holes or the tube
connection openings (see illustration: "VEGAPULS in a bypass tube").
28451-EN-120530
18VEGAPULS 63 • Foun
dation Fieldbus
100%
0%
1
> 300 mm
1
2
3
4
4 Mounting
Fig. 13: VEGAPULS 63 in a bypass
process fitting must be in one plane with the tube holes or the tube connection
openings.
1Marking of the polarisation direction
tube. The polarisation marking on the
When the sensor is mounted on a bypass tube, the distance from
VEGAPULS 63 to the upper tube connection should be approx.
300 mm (11.81 in) or more. In case of extremely rough tube inner
walls, you should use an inserted tube (tube in tube) or a radar sensor
with tube antenna.
tion:
Informa
With VEG
APULS 63 in flang
e version, the polarisation plane is always
in the center between two flange holes.
Fig. 14: Polarisation level with flange
bypass tube. The sensor housing is not shown.
1Position of the polarisation level
2Flange hole
3Upper tube connection
4Polarisation marking
version, view from top on the sensor and
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus19
5 Connecting to power supply
5 Connecting to power supply
ety instructions
Saf
Voltage supply
Connection cable
Cable gland ½ NP
5.1 Preparin
Always keep in mind the following safety instructions:
l Connect only in the complete absence of line voltage
l If overvoltage surges are expected, overvoltage arresters should
be installed according to Foundation Fieldbus specification
Tip:
We recomm
In hazardous areas you must take note of the respective regulations,
conformit
supply units.
The instrument requires a operating voltage of 9 … 32 V DC.
Operating voltage and the digital bus signal are carried on the sametwo-wire connection cable. Power is supplied via the H1 power supply.
Connection is carried out with screened cable according to Fieldbus
specification.
Use cable withround cross-section. A cable outer diameter of 5 … 9 mm
(0.2 … 0.35 in) ensures the seal effect of the cable gland. If you are
using cable with a different diameter or cross-section, exchange the
seal or use a suitable cable gland.
Make sure that the entire installation is carried out according to the
Fieldbus specification. In particular, make sure that the bus is
terminated with suitable terminating resistors.
T
On the instrument with cable entry ½ NPT and plastic housing there is
a metallic ½" threaded insert moulded into the plastic housing.
y and type approval certificates of the sensors and power
g the connection
end VEGA overvoltage arrester B63-32.
Caution:
No greas
steel tube into the threaded insert. Standard grease can contain
additives that corrode the connection between threaded insert and
housing. This would influence the stability of the connection and the
tightness of the housing.
Cable screening
grounding
20VEGAPULS 63 • Foun
and
With systems with potential equalisation, connect the cable screen
directly to ground potential at the power supply unit, in the connection
box and at the sensor. The screen in the sensor must be connected
directly to the internal ground terminal. The ground terminal outside on
the housing must be connected to the potential equalisation (low
impedance).
e should be used when screwing the NPT cable gland or
28451-EN-120530
dation Fieldbus
5 Connecting to power supply
In systems without potential equalisation, connect
directly to ground potential at the power supply unit and at the sensor.
In the connection box or T-distributor, the screen of the short stub to
the sensor must not be connected to ground potential or to another
cable screen. The cable screens to the power supply unit and to the
next distributor must be connected to each other and also connected
to ground potential via a ceramic capacitor (e.g. 1 nF, 1500 V). The low
frequency potential equalisation currents are thus suppressed, but the
protective effect against high frequency interference signals remains.
The total capacitance of the cable and of all capacitors must not exceed
10 nF in Ex
Take note of the corresponding installation regulations for Ex
appl
currents flow over the cable screen. In case of grounding on both sides
this can be achieved by the use of a capacitor or a separate potential
equalisation.
applications.
ications. In particular, make sure that no potential equalisation
the cable screen
5.2 Connection procedure
Proceed as follows:
1 Unscrew the housing cover
2 If an indicating and adjustment module is installed, remove it by
turning it to the left.
3 Loosen compression nut of the cable entry
4 Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
5 Insert the cable into the sensor through the cable entry
6 Lift the opening levers of the terminals with a screwdriver (see
following illustration)
28451-EN-120530
VEGAPULS 63 • Foundation Fie
ldbus21
5 Connecting to power supply
7 Insert the wire ends into the open terminals according to the wiring
plan
Fig. 15: Connection steps 6 and 7
8 Press
9 Check the hold of the wires in the terminals by lightly pulling on
10 Connect the screen to the internal ground terminal, connect the
11 Tighten the compression nut of the cable entry. The seal ring must
12 Screw the housing cover back on
The electrical connection is finished.
down the opening levers of the terminals, you will hear the
terminal spring closing
them
outer ground terminal to potential equalisation
completely encircle the cable
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as
version.
22VEGAPULS 63 • Foun
well as to the Ex-ia
28451-EN-120530
dation Fieldbus
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