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VEGA PULS67 User Manual

Operating Instructions
Radar sensor for continuous level measurement of bulk solids
VEGAPULS 67
HART - integrated accumulator
Document ID: 40795

Quick start

Mounting
Connect electrically
Quick start
The quick start enables a quick setup with many applications. You can nd further information in the respective chapters of the operating instructions manual.
1. Distance from the vessel wall > 200 mm
200 mm
(7.87
")
Fig. 1: Distance of the antenna to the vessel wall/socket conguration
2. Keep the socket short, round o the socket end For further information see chapter "Mounting".
1. Insert the battery charger into the socket of the power supply compartment and load the integrated accumulator before setting up the instrument.
2. Switch on the instrument by means of the button outside on the housing.
1
Set parameters
2
Fig. 2: Switch on/o button outside on the housing
1 On/O button
For further information see chapter "Connecting to power supply".
1. Go via the indicating and adjustment module to the menu "Setup".
2. Select in the menu item "Medium" the medium of your applica­tion, for example "Gravel/Pebble".
3. Select in the menu item "Application" the vessel, the application and the vessel form, for example, silo.
40795-EN-121011
Quick start
4. Carry out the adjustment in the menu items "Min. adjustment" and "Max. adjustment".
Parameterization example
Further steps
The radar sensor measures the distance from the sensor to the product surface. For indication of the real level, an allocation of the measured distance to the percentage height must be carried out.
")
0,5 m
(19.68
100%
2
")
10 m
(393.7
0%
1
Fig. 3: Parameterization example
1 Min. level ≙ max. meas. distance 2 Max. level ≙ min. meas. distance
For this adjustment, the distance is entered with full and virtually empty vessel. If these values are not known, an adjustment with distances, for example, of 10 % and 90 % is also possible. Starting point for these distance specications is always the seal surface of the thread or ange.
1. In the menu "Additional settings", menu item "Damping" you have to adjust the requested damping of the output signal.
2. Select the output characteristics in the menu item "Current out- put".
The quick start is then nished. For further information see chapter "Parameter adjustment".
40795-EN-121011
3
Contents
Contents
1 About this document
1.1 Function ............................................................................. 6
1.2 Target group ....................................................................... 6
1.3 Symbolism used ................................................................. 6
2 For your safety
2.1 Authorised personnel ......................................................... 7
2.2 Appropriate use .................................................................. 7
2.3 Warning about incorrect use ............................................... 7
2.4 General safety instructions ................................................. 7
2.5 CE conformity ..................................................................... 8
2.6 NAMUR recommendations ................................................ 8
2.7 Radio license for Europe .................................................... 8
2.8 Radio license for USA/Canada ........................................... 8
2.9 Environmental instructions ................................................. 8
3 Product description
3.1 Conguration .................................................................... 10
3.2 Principle of operation ........................................................ 11
3.3 Packaging, transport and storage ..................................... 11
3.4 Accessories and replacement parts ................................. 12
4 Mounting
4.1 General instructions ......................................................... 13
4.2 Collar or adapter ange .................................................... 13
4.3 Mounting strap ................................................................. 14
4.4 Instructions for installation ................................................ 15
5 Connecting to power supply
5.1 Connection of the battery charger .................................... 24
5.2 Wiring plan ....................................................................... 24
5.3 Switch-on phase ............................................................... 25
6 Set up with the indicating and adjustment module
6.1 Insert indicating and adjustment module .......................... 27
6.2 Adjustment system ........................................................... 28
6.3 Parameter adjustment ...................................................... 29
6.4 Saving the parameter adjustment data ............................. 42
7 Setup with PACTware
7.1 Connect the PC ................................................................ 44
7.2 Parameter adjustment with PACTware .............................. 45
7.3 Saving the parameter adjustment data ............................. 46
8 Set up with other systems
8.1 DD adjustment programs ................................................. 47
8.2 Communicator 375, 475 ................................................... 47
9 Diagnosis, Asset Management and service
9.1 Maintenance .................................................................... 48
9.2 Measured value and event memory ................................. 48
9.3 Asset Management function ............................................. 49
9.4 Rectify faults ..................................................................... 52
40795-EN-121011
4
9.5 Exchanging the electronics module .................................. 55
9.6 Software update ............................................................... 56
9.7 How to proceed in case of repair ...................................... 56
10 Dismounting
10.1 Dismounting steps ............................................................ 57
10.2 Disposal ........................................................................... 57
11 Supplement
11.1 Technical data .................................................................. 58
11.2 Dimensions ...................................................................... 63
Contents
Safety instructions for Ex areas
Please note the Ex-specic 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.
40795-EN-121011
Editing status: 2012-09-27
5

1 About this document

1 About this document

1.1 Function

This operating instructions manual provides all the information you need for mounting, connection and setup as well as important instruc­tions for maintenance and fault rectication. 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 qualied 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 warning is ignored, faults or malfunctions can 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.
Ex applications
This symbol indicates special instructions for Ex applications.
List
•
The dot set in front indicates a list with no implied sequence.
Action
→
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat­teries and accumulators.
40795-EN-121011
6

2 For your safety

2 For your safety

2.1 Authorised personnel

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.

2.2 Appropriate use

The VEGAPULS 67 is a sensor for continuous level measurement. Due to the integrated accumulator the instrument is particularly suitable as a portable measuring system or test sensor for special applications.
You can nd detailed information on the application range in chapter "Product description".
Operational reliability is ensured only if the instrument is properly used according to the specications in the operating instructions manual as well as possible supplementary instructions.

2.3 Warning about incorrect use

Inappropriate or incorrect use of the instrument can give rise to application-specic hazards, e.g. vessel overll or damage to system components through incorrect mounting or adjustment.

2.4 General safety instructions

This is a state-of-the-art instrument complying with all prevailing regulations and guidelines. The instrument must only be operated in a technically awless and reliable condition. The operator is responsible for the trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine the compliance of the necessary occupational safety measures with the current valid rules and regulations and also take note of new regula­tions.
The safety instructions in this operating instructions manual, the na­tional installation standards as well as the valid safety regulations and accident prevention rules must be observed by the user.
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 modications are explicitly forbidden.
The safety approval markings and safety tips on the device must also be observed.
Depending on the instrument version, the emitting frequencies are in the C or K band range. The low emitting frequencies are far below the internationally approved limit values. When used correctly, there is no danger to health.
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2 For your safety

2.5 CE conformity

The device fullls the legal requirements of the applicable EC guide­lines. By axing the CE marking, we conrm successful testing of the product.
You can nd the conformity certicate in the download section of our homepage.

2.6 NAMUR recommendations

NAMUR is the automation technology user association in the process industry in Germany. The published NAMUR recommendations are accepted as the standard in eld instrumentation.
The device fullls the requirements of the following NAMUR recom­mendations:
NE 21 – Electromagnetic compatibility of equipment
•
NE 43 – Signal level for malfunction information from measuring
•
transducers NE 53 – Compatibility of eld devices and indicating/adjustment
•
components NE 107 - Self-monitoring and diagnosis of eld devices
•
For further information see www.namur.de.

2.7 Radio license for Europe

The instrument is approved according to EN 302372-1/2 (2006-04) for use in closed vessels.

2.8 Radio license for USA/Canada

The instrument is in conformity with part 15 of the FCC regulations. Take note of the following two regulations:
The instrument must not cause any interfering emissions
•
The device must be insensitive to interfering immissions, including
•
those that may cause undesirable operating conditions
Modications not expressly approved by the manufacturer will lead to expiry of the operating licence according to FCC/IC.
The instrument is in conformity with RSS-210 of the IC regulations. The instrument may only be used in closed vessels made of metal,
concrete, or bre-reinforced plastic.

2.9 Environmental instructions

Protection of the environment is one of our most important duties. That is why we have introduced an environment management system with the goal of continuously improving company environmental pro­tection. The environment management system is certied according to DIN EN ISO 14001.
Please help us full this obligation by observing the environmental instructions in this manual:
Chapter "Packaging, transport and storage"
•
8
40795-EN-121011
Chapter "Disposal"
•
2 For your safety
40795-EN-121011
9

3 Product description

Type label
3 Product description
3.1 Conguration
The type label contains the most important data for identication and use of the instrument:
1
2
3
4 5
6
7 8 9
10
Fig. 4: Layout of the type label (example)
1 Instrument type 2 Product code 3 Approvals 4 Power supply and signal output, electronics 5 Protection rating 6 Measuring range 7 Process and ambient temperature, process pressure 8 Material, wetted parts 9 Hardware and software version 10 Order number 11 Serial number of the instrument 12 Symbol of the device protection class 13 ID numbers, instrument documentation 14 Note to observe the instrument documentation 15 Notied authority for CE marking 16 Approval directive
16
15
14
13
12
11
Serial number
Scope of this operating instructions manual
10
With the serial number of the instrument on the type label you have access to the following data on our homepage:
Article number of the instrument (HTML)
•
Delivery date (HTML)
•
Order-specic instrument features (HTML)
•
Operating instructions at the time of shipment (PDF)
•
Order-specic sensor data for an electronics exchange (XML)
•
Test certicate "Measuring Accuracy" (PDF)
•
For this purpose, move to www.vega.com and "VEGA Tools".
This operating instructions manual applies to the following instrument versions:
Hardware from 2.1.0
•
Software from 4.5.1
•
40795-EN-121011
3 Product description
Scope of delivery
Application area
Functional principle
Voltage supply
The scope of delivery encompasses:
Radar sensor with integrated accumulator
•
Battery charger
•
Documentation
•
– this operating instructions manual – Test certicate measuring accuracy (optional) – Operating instructions manual "Indicating and adjustment
module" (optional)
– Ex-specic "Safety instructions" (with Ex versions) – if necessary, further certicates

3.2 Principle of operation

The VEGAPULS 67 is a radar sensor for continuous level measure­ment of bulk solids under simple process conditions. It is suitable for smaller silos and vessels.
The instrument is also suitable for applications in liquids.
The antenna of the radar sensor emits short radar pulses with a duration of approx. 1 ns. These pulses are reected 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.
The instrument is powered via an integrated accumulator. This allows operation of the instrument independently of the mains or a control system. To achieve a longer battery lifetime, the instrument is preset to HART multidrop. This puts a load of only 4 mA current on the ac­cumulator.

3.3 Packaging, transport and storage

Packaging
Transport
Transport inspection
Storage
40795-EN-121011
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 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.
11
3 Product description
Storage and transport temperature
Indicating and adjust­ment module
Unless otherwise indicated, the packages must be stored only under the following conditions:
Not in the open
•
Dry and dust free
•
Not exposed to corrosive media
•
Protected against solar radiation
•
Avoiding mechanical shock and vibration
•
Storage and transport temperature see chapter "Supplement -
•
Technical data - Ambient conditions" Relative humidity 20 … 85 %
•

3.4 Accessories and replacement parts

The indicating and adjustment module PLICSCOM is used for meas­ured value indication, adjustment and diagnosis. It can be inserted into the sensor and removed at any time.
You can nd further information in the operating instructions "Indicat- ing and adjustment module PLICSCOM" (Document-ID 27835).
Interface adapter
Protective cover
Electronics module
Accumulator insert
The interface adapter VEGACONNECT enables the connection of communication-capable instruments to the USB interface of a PC. For parameter adjustment of these instruments, an adjustment software such as PACTware with VEGA-DTM is required.
You can nd further information in the operating instructions "Interface adapter VEGACONNECT" (Document-ID 32628).
The protective cover protects the sensor housing against soiling and intense heat from solar radiation.
You will nd additional information in the supplementary instructions manual "Protective cover" (Document-ID 34296).
The electronics module VEGAPULS series 60 is a replacement part for radar sensors of VEGAPULS series 60. There is a dierent version available for each type of signal output.
You can nd further information in the operating instructions "Elec- tronics module VEGAPULS series 60" (Document-ID 36801).
The accumulator insert VEGAPULS Serie 60 is an replacement part for radar sensors of VEGAPULS series 60 with integrated accumula­tor.
You can nd further information in the operating instructions "Accumu- lator insert VEGAPULS series 60" (Document-ID 41033).
40795-EN-121011
12
Screwing in

4 Mounting

4 Mounting

4.1 General instructions

With instruments with threaded process tting, suitable tools must be applied for tightening the hexagon.
Warning:
The housing must not be used to screw the instrument in! Applying tightening force can damage internal parts of the housing.
Moisture
Suitability for the process conditions
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 o. 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.
Make sure that all parts of the instrument exposed to the process, in particular the active measuring component, process seal and process tting, 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 nd the specications in chapter "Technical data" and on the type label.
4.2 Collaroradapterange
For mounting the instrument on a socket, a combi compression ange for DN 80 (ASME 3" or JIS 80) is also available for retro tting. Option­ally, the instrument can be also equipped with an adapter ange from DN 100 (ASME 4" or JIS 100).
With the housing versions plastic, aluminium single chamber and stainless steel, the collar ange can be placed directly over the hous­ing. With the aluminium double chamber housing, retroactive mount­ing in this way is not possible - the mounting type must be specied with the order.
You can nd drawings of these mounting options in chapter "Dimen- sions".
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4 Mounting
Mounting strap
Fig. 5: Flange mounting of the radar sensor

4.3 Mounting strap

The mounting strap enables simple mounting on the vessel wall or silo top. It is suitable for wall, ceiling or boom mounting. Especially in open vessels this is a very easy and eective way to align the sensor to the bulk solid surface.
14
Fig. 6: Radar sensor with mounting strap
The strap is supplied unassembled and must be screwed to the sensor before setup with three hexagon screws M5 x 10 and spring washers. Max. torque, see chapter "Technical data". Required tools: Allen wrench size 4.
There are two ways to screw the strap onto the sensor. Depending on the selected version, the sensors can be swivelled in the strap as follows:
Single chamber housing
•
– Angle of inclination 180°, innitely variable
40795-EN-121011
Tight installation of the plastic horn antenna
4 Mounting
– Angle of inclination in three steps 0°, 90° and 180°
Double chamber housing
•
– Angle of inclination 90°, innitely variable – Angle of inclination in two steps 0° and 90°
Fig. 7: Adjustment of the angle of inclination
Fig. 8: Turning by fastening in the centre

4.4 Instructions for installation

For tight installation of the version with plastic horn antenna with com­pression or adapter ange, the following conditions must be fullled:
1. Use suitable at seal, e.g. of EPDM with Shore hardness 25 or 50
2. Make sure the number of ange screws corresponds to the num­ber of ange holes
3. Tighten all screws with the torque stated in the technical data
Polarisation plane
40795-EN-121011
The emitted radar impulses of the radar sensor are electromagnetic waves. The polarisation plane is the direction of the electrical wave component. By turning the instrument in the connection ange or mounting boss, the polarisation can be used to reduce the eects of false echoes.
The position of the polarisation level is marked by markings on the instrument.
Fig. 9: Position of the polarisation level
1 Marking bar
1
15
4 Mounting
Installation position
Inowingmedium
Mount the instrument at least 200 mm (7.874 in) away from the vessel wall.
200 mm
")
(7.87
Fig. 10: Mounting of the radar sensor on the vessel top
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.
Filling from the top: Mounting should not be too close to the inow­ing material as the microwave signal will be interferred. The optimum mounting position is on the opposite of the lling. To avoid strong pollution, the distance to the lter or dust extraction must be as big as possible.
16
Fig. 11: Mounting of the radar sensor with inowing medium with lling from the
top
Laterallling: With bulk solids silos with lateral pneumatic lling, mounting should not be in the lling stream as the microwave signal will be interferred. The optimum mounting position is next to the lling. To avoid strong pollution, the distance to the lter or dust extraction must be as big as possible.
40795-EN-121011
4 Mounting
Fig. 12: Mounting of the radar sensor with inowing medium with lateral lling
Socket with plastic horn antenna
A corresponding collar ange for DN 80 (ASME 3" or JIS 80) as well as a suitable adapter ange are available for mounting VEGAPULS
67.
With the housing versions plastic, aluminium single chamber and stainless steel, the collar ange can be placed directly over the hous­ing. With the aluminium double chamber housing, retroactive mount­ing in this way is not possible - the mounting type must be specied with the order.
Information:
The socket should be as short as possible and the socket end rounded. Thus, false reections by the vessel socket are reduced.
Fig. 13: Recommended socket mounting
40795-EN-121011
17
4 Mounting
If the medium has good reective properties, VEGAPULS 67 can also be mounted on a longer socket piece. Recommended values for socket heights are specied in the following illustration. You must carry out a false echo storage afterwards.
h
d
The below charts specify the max. socket piece length h depending on the diameter d.
Socket diameter d Socket length h
80 mm 300 mm
100 mm 400 mm
150 mm 500 mm
Socket diameter d Socket length h
3" 11.8 in
4" 15.8 in
6" 19.7 in
Tip:
In new facilities it is useful to incline the vessel socket in the direction of the outlet. False reections from the vessel wall are thus reduced and measurement all the way down to the bottom of the conical outlet is possible.
18
40795-EN-121011
Fig. 15: Alignment in silos
4 Mounting
Orientation
To detect nearly the complete vessel volume the sensor should be directed in such a way that the measuring beam reaches the lowest level in the vessel, i.e. the outlet.
Fig. 16: Mounting in open vessel
40795-EN-121011
19
4 Mounting
Fig. 17: Mounting on the vessel ceiling
Caution:
When mounting on the vessel ceiling mark sure that the sensor does not overll. Depending on the measured product, this can cause a mechanical damage.
In a cylindrical silo with conical outlet, the mounting iis carried out on a socket. It should be positioned on one third up to the half of the vessel radius.
r
1
1
rr...
2
3
/
/
Material heaps
20
Fig. 18: Mounting position and orientation
Large material heaps are best measured with several instruments, which can be mounted on e.g. traverse cranes. For this type of ap­plication it is advantageous to orient the sensor perpendicular to the bulk solid surface.
The sensors do not inuence each other.
40795-EN-121011
4 Mounting
Information:
Keep in mind that for these applications, the sensors are designed for relatively slow level changes. If the sensor is used on a movable boom, the max. measuring rate must be observed (see chapter "Technical data").
Fig. 19: Radar sensors on traverse crane
Vessel installations
Agitators
The mounting location of the radar sensor should be a place where no other equipment or xtures cross the path of the microwave signals.
Vessel installations, such as e.g. ladders, limit switches, heating spi­rals, struts, etc., can cause false echoes and impair the useful echo. Make sure when planning your measuring site that the radar sensor has a "clear view" to the measured product.
In case of existing vessel installations, a false echo storage should be carried out during setup.
If large vessel installations such as struts or supports cause false echoes, these can be attenuated through supplementary measures. Small, inclined sheet metal baes above the installations scatter the radar signals and prevent direct interfering reections.
Fig. 20: Cover smooth proles with deectors
If there are agitators in the vessel, a false signal suppression should be carried out with the agitators in motion. This ensures that the interfering reections from the agitators are saved with the blades in dierent positions.
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