VEGA SON54K User Manual
Operating Instructions
VEGASON 54K … 56K
Contents
Safety information ........................................................................ 2
Note Ex area ................................................................................ 2
1 Product description .................................................................. 4
1.1 Function ................................................................................. 4
1.2 Application features ............................................................. 5
1.3 Adjustment ............................................................................ 5
2 Types and v ersions ................................................................... 7
2.1 Type survey .......................................................................... 7
2.2 Type code ............................................................................. 8
2.3 Approvals ............................................................................. 8
2.4 Configuration of measuring systems ................................. 8
3 Technic al data .......................................................................... 12
3.1 Data ..................................................................................... 12
3.2 Dimensions ......................................................................... 17
Contents
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
work on the instruments, apart from that involved in normal installation and electrical connection, must be carried out only by qualified
VEGA personnel.
2 VEGASON 54K … 56K
Note Ex area
Please note the approval documents (yellow
binder), and especially the included safety
data sheet.
Contents
4 Mo unting and in stalla tion ..................................................... 22
4.1 Mounting ............................................................................. 22
4.2 General installation instructions ........................................ 24
4.3 Measurement of liquids ..................................................... 26
4.4 Measurement of solids ...................................................... 28
4.5 Socket extensions ............................................................. 29
4.6 False echoes ...................................................................... 30
4.7 Incorrect mounting ............................................................. 32
5 Electrical connection .............................................................. 35
5.1 Connection and connection cable .................................... 35
5.2 Connection of the sensor .................................................. 36
5.3 Connection of the external indicating instrument
VEGADIS 50 ....................................................................... 37
6 Set-up ........................................................................................ 38
6.1 Adjustment methods .......................................................... 38
6.2 Adjustment with the PC ...................................................... 38
6.3 Adjustment with adjustment module MINICOM ............... 40
7 Diagnosis .................................................................................. 46
7.1 Simulation ............................................................................ 46
7.2 Error codes ........................................................................ 46
VEGASON 54K … 56K 3
1 Product description
1.1 Function
Continuous level measurement with ultrasonic
sensors is based on the running time measurement of ultrasonic pulses.
VEGASON series 54 … 56 sensors are a
newly developed generation of extremely
compact ultrasonic sensors for level measurement. They were developed for liquids
and especially for solids and larger measuring ranges. Preferred areas of application
are silos, bunkers or material heaps.
Due to the small housing dimensions and
process fittings, the compact sensors are a
very reasonable solution for your level measurement applications. With the integrated
display and a special sensor intelligence, in
conjunction with large measuring ranges,
they can be used for applications in which
the advantages of a non-contact measurement could never before be realized.
The instruments produce an analogue
4 … 20 mA output signal.
Measuring principle
Piezoceramic high performance transducers
emit focused ultrasonic pulses which are
reflected by the product surface. The measurement electronics prepares a precise image of the environment from the reflected
ultrasonic pulses. The transducers work both
as transmitter and receiver. As receiver, the
transducers are high-sensitivity piezo microphones.
Product description
Meas. distance
emission - reflection - reception
The measurement electronics precisely calculates the distance between transducer and
medium from the speed of sound and the
measured running time of the emitted sound
pulses. The distance is then converted into a
level-proportional signal and made available
acc. to sensor settings as a precise, calibrated level value.
Since the speed of sound is subject to temperature influence, the transducer also continuously detects the ambient temperature,
so that the level is precisely measured even if
the ambient temperature varies.
Output signal
The level-proportional measurement signal is
made available as 4 … 20 mA output signal.
The analogue 4 … 20 mA signal is freely
programmable and reflects the measuring
range, i.e. the adjusted operating range, of
the sensor.
4 VEGASON 54K … 56K
Product description
Display of measured values
As an option, the series 50 ultrasonic sensors
can be equipped with an indicating instrument for direct, local level survey. The indicating instrument shows the precise level by
means of the analogue bar graph and the
digital number value. In addition to the indication in the sensor, you can have the level
displayed with the VEGADIS 50 external
indicating instrument at a distance of up to
25 m from the sensor. The external display of
measured values operates, like the integrated display, independently of the
4 … 20 mA output signal, can be modified
through individual parameter settings, and is
powered by the sensor.
1.2 Application features
Voltage supply
• 24 V DC four-wire technology (supply and
signal separate)
Applications
• Level measurement of solids, liquids and
pastes.
• Gauge measurement, distance measurement, object monitoring and conveyor belt
monitoring
Display of measured value
• Display module integrated in sensor
• Optional display module separated from
sensor
• Adjustment module MINICOM in the sensor.
Process fittings
• G 1 A, DN 50, DN 80, DN 200, DN 250
Approvals
• CENELEC, ATEX, PTB
1.3 Adjustment
Each measuring situation is unique. For that
reason, every ultrasonic sensor needs some
basic information on the application and the
environment, e.g. a false echo storage is
important for a reliable measurement. Beside
this, many other settings and adjustments
are possible on VEGASON ultrasonic sensors.
The adjustment and parameter setting of
ultrasonic sensors are carried out with
- the PC
- the detachable adjustment module
MINICOM.
Signal output
• 4 … 20 mA
Rugged and precise
• Measurement unaffected by substance
properties such as density, conductivity,
dielectric constant…
• Suitable for corrosive substances
• Measuring range 0.8 m … 70 m
Means of adjustment
• With adjustment software VEGA Visual
Operating (VVO) on the PC
• With detachable adjustment module
MINICOM
• With the HART® handheld
VEGASON 54K … 56K 5
Adjustment with PC
The setup and adjustment of the ultrasonic
sensors is generally done on the PC with the
adjustment software PACT
dows®. The program leads quickly through
the adjustment and parameter setting by
means of pictures, graphics and process
visualisations.
The PC can be connected to the sensor or to
any individual position of the system or the
signal cable. It is connected by means of the
two-wire PC interface converter
VEGACONNECT 2 to the sensor or the signal
cable. The adjustment and parameter data
can be saved with the adjustment software
on the PC and can be protected by passwords. On request, the adjustments can be
quickly transferred to other sensors.
ware
TM
under Win-
-+
2
4 … 20 mA
2
Adjustment with the PC on the analogue
4 … 20 mA signal and supply cable or directly on the
sensor (four-wire sensor)
Adjustment with 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
ultrasonic sensor or into the optional, external
indicating instrument.
Tank 1
m (d)
12.345
ESC
+
-
OK
Product description
ESC
+
-
Tank 1
m (d)
12.345
OK
2
Tank 1
m (d)
12.345
+
-
4 ... 20 mA
ESC
OK
4
Adjustment with detachable adjustment module. The
adjustment module can be plugged into the ultrasonic
sensor or the external indicating instrument VEGADIS
50.
Adjustment with HART® handheld
Beside the PC and the adjustment module
MINICOM, it is also possible to adjust the
sensors with the HART® handheld. A special
DDD (Data Device Description) is not necessary, so that the sensors can be adjusted
with the HART® standard menus of the
handheld.
To adjust the sensor, just connect the 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.
®
20 ... 72 V DC
2
4 ... 20 mA
2
Detachable adjustment module MINICOM
HART® handheld
Unauthorised sensor adjustments can be
prevented by removing the adjustment module.
6 VEGASON 54K … 56K
HART® handheld on the 4 … 20 mA signal cable
Types and versions
2 Types and versions
2.1 Type survey
VEGASON series 54 … 56 sensors are a
newly developed generation of extremely
compact ultrasonic sensors for large measuring ranges. VEGASON 51 … 53 are used for
shorter measuring ranges.
Due to the small housing dimensions and
process fittings, the compact sensors do
your level monitoring inconspicuously, and
above all, at reasonable cost. Swivelling
holders allow a quick alignment of the transducer to the product and solid surface.
Mounting is simplified by the option of separating the sensor electronics from the transducer. The sensor electronics can be
mounted at a distance of 300 m from the
transducer. It is then possible to mount the
transducer in environments with an ambient
temperature up to 150°C (VEGASON 56).
Common features
• Application to solids and liquids
• Measuring range 0.8 m … 70 m
• Ex approved in Zone 10 (IEC) and Zone 11
(ATEX) classification EEx ia [ia] IIC T6 or
Zone 20/21/22, VEGASON 56 also Zone 1.
• Display module integrated in the sensor or
in the external indicating instrument separated up to 25 m from the sensor
VEGASON 54
Version A Version B Version C Version D
VEGASON 55
Version A Version B Version C Version D
VEGASON 56
Version A Version B Version C Version D
VEGASON 54K … 56K 7
2.2 Type code
Types and versions
VEGASON 54 P EX.XX X X X X X X X
K - Plastic housing PBT, M20 x 1.5 cable entry
N - Plastic housing PBT, ½ NPT cable entry
A - Aluminium housing, M20 x 1.5 cable entry
FEP - Version A, flange DN 200 (PP)
FEA - Version A, flange DN 200 (Aluminium)
FLP - Version A, flange 8“ (PP)
FLA - Version A, flange 8“ (Aluminium)
SAS - Version B, flange swivelling holder DN 50
SBS - Version B, flange swivelling holder DN 80
GAS - Version C, flange swivelling holder DN 50
GBS - Version C, flange swivelling holder DN 80
RGS - Thread G 1 A
X - without display
A - with integrated display module
X - without adjustment module MINICOM
B - with adjustment module MINICOM (mounted)
A - Four-wire 20…72 V DC; 20…253 V AC; 4…20 mA
B - Four-wire 20…72 V DC; 20…253 V AC; 4…20 mA, HART
G - Profibus PA
.X - without approval
EXS.X ATEX II 1/2D IP68 TStEx Zone 10
K - Analogue 4 … 20 mA output signal (two-wire or
four-wire technology)
P - Profibus
Type 54 - Measuring range 1.0 … 25 m
Type 55 - Measuring range 0.8 … 45 m
Type 56 - Measuring range 1.6 … 70 m
Meas. principle (SON for ultrasonics)
®
2.3 Approvals
2.4 Configuration of measuring systems
When using ultrasonic sensors in Ex areas or
in marine applications, the instruments must
be suitable and approved for the explosion
zones and application areas.
The suitability is tested by approval authorities and is certified in approval documents.
VEGASON 50 ultrasonic sensors are approved for Ex zone 1, 10, 11, 21 and 22.
Please note the attached approval documents when using a sensor in Ex area.
8 VEGASON 54K … 56K
A measuring system consists of a sensor
with a 4 … 20 mA signal output and a module
that evaluates and further processes the
level-proportional current signal.
On the following pages you will find instrument configurations designated as measuring systems, several of which are shown with
signal conditioning units.
Types and versions
Measuring system consisting of VEGASON 54K … 56K with any 4 … 20 mA
processing unit
• Four-wire technology, 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 from the sensor)
• Adjustment with PC, HART® handheld or adjustment module MINICOM (pluggable in the
sensor or in the external VEGADIS 50 indicating instrument)
• Max. resistance on the signal output (load) 500 Ω
VEGADIS 50
3
4
1)
2
≥ 200 Ω
2
2
VEGACONNECT 2
-+
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 reach an adjustment load of 200 Ω to 350 Ω.
2)
4 … 20 mA active means, that the sensor delivers
a level-dependent current of 4 … 20 mA (source).
With respect to the processing system (e.g. display), the sensor acts electrically as a current
source.
The digital adjustment signal would otherwise be
extremely damped or short circuited because of insufficient resistance of the connected processing
system. Communication with the PC would no
longer be ensured.
VEGASON 54K … 56K 9
Types and versions
Measuring system consisting of VEGASON 54K … 56K with PLC
• Output signal 4 … 20 mA active
• Display module integrated into the sensor
• Optional external indicating instrument with analogue and digital indication (can be mounted
up to 25 m from the sensor in Ex area)
• Adjustment with PC, HART® handheld or adjustment module MINICOM (pluggable in the
sensor or in the external VEGADIS 50 indicating instrument)
VEGADIS 50
3
-+
1)
4
2
VEGACONNECT 2
4 … 20 mA
2)
active
2
2
2
PLC
3)
passive
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 reach an adjustment load of 200 Ω to 350 Ω.
The digital adjustment signal would otherwise be
extremely damped or short circuited because of insufficient resistance of the connected processing
system. Communication with the PC would no
2)
4 … 20 mA active means, that the sensor delivers
a level-dependent current of 4 … 20 mA (source).
With respect to the processing system (e.g. display), the sensor acts electrically as a current
source.
3)
4 … 20 mA passive means that the PLC consumes
a level-dependent current of 4 … 20 mA. The PLC
acts electrically as a resistor (consumer).
longer be ensured.
10 VEGASON 54K … 56K
Types and versions
Measuring system consisting of VEGASON 54K … 56K and
VEGADIS 371 Ex indicating instrument with current and relay output
• Output signal 4 … 20 mA active
• Display module integrated into the sensor
• Optional external indicating instrument with analogue and digital indication (can be mounted
up to 25 m from the sensor)
• Adjustment with PC, HART® handheld or adjustment module MINICOM (pluggable in the
sensor or in the external VEGADIS 50 indicating instrument)
StEx area
VEGADIS 50
4
Non Ex area
2
VEGACONNECT 2
3
2
4 … 20 mA
(active)
-+-+
3
2
VEGADIS
371 Ex
(see "3.2 Approvals“)
Relay 1
Relay 2
Relay 3
0/4 ... 20 mA
HART® handheld
VEGASON 54K … 56K 11
Technical data
3 Technical data
3.1 Data
Power supply
Power supply 230 V AC (20 … 253 V AC), 50/60 Hz
Current consumption max. 160 mA
Power consumption max. 2 W, 3.5 VA
Measuring range
(the transducer end is the reference plane for sensor version B … D. The lower edge of the
flange is the reference plane for sensor version A)
VEGASON 54 1.0 … 25 m (solid: 1.0 … 15 m)
VEGASON 55 0.8 … 45 m
VEGASON 56
- version A 1.8 … 70 m
- version B … D 1.4 … 70 m
Output signal
Signal output 4 … 20 mA current signal in four-wire technology
Load 500 Ω
Integration time 0 … 999 seconds (adjustable)
Fault signal current signal unchanged 20.5 mA, 22 mA
24 V DC (20 … 72 V DC)
fuse 0.315 A TR
(adjustable)
Four-wire technology:
Separate power supply. The analogue 4 … 20 mA output signal (measuring signal) is carried on a cable separate from the power supply.
Display module (optional)
Liquid crystal display
- in the sensor scalable measured value output as graph and
- powered externally by the sensor scalable measured value output as graph and
Adjustment
- PC with adjustment software VEGA Visual Operating
- Adjustment module MINICOM
- HART® handheld
12 VEGASON 54K … 56K
numerical value
numerical value. The display module can be
mounted up to 25 m away from the sensor.
Technical data
Accuracy
1)
(typical values under reference conditions, all statements relate to the nominal measuring
range)
Characteristics linear
Deviation in characteristics including
linearity, reproducibility and
hysteresis (determined by
limit point methods) < 0.1 %
Linearity better than 0.05 %
Average temperature coefficient of the
zero signal 0.06 %/10 K
Resolution in general max. 1 mm
Resolution of the output signal 0.01 % or 1 mm
Characteristics
1)
(typical values under reference conditions, all statements relate to the nominal measuring
range)
Min. measuring range
(between empty and full adjustment) > 20 mm (recommended > 50 mm)
Ultrasonic frequency (at 20°C)
- VEGASON 54 30 kHz
- VEGASON 55 18 kHz
- VEGASON 56 10 kHz
Measuring intervals
- VEGASON 54 1.0 s
- VEGASON 55 1.5 s
- VEGASON 56 2.0 s
Beam angle at -3 dB emitted power
- VEGASON 54 4°
- VEGASON 55 5°
- VEGASON 56 6°
Influence of the process temperature 1.8 %/10 K, however is compensated by an
integral, dynamic temperature detection
system in the transducer
Influence of the process pressure negligible within the approved sensor pressure
Adjustment time
2)
range
- VEGASON 54 > 2 s (depending on parameter adjustment)
- VEGASON 55, 56 > 4 s (depending on parameter adjustment)
1)
Similar to DIN 16 086, reference conditions acc. to IEC 770;
temperature 15°C … 35°C; moisture 45 % … 75 %; pressure 860 mbar … 1060 mbar.
2)
The adjustment time is the time, required by the sensor, to output the correct level after a quick level
change (with max. 10 % deviation).
VEGASON 54K … 56K 13
Ambient conditions
Ambient temperature (housing) -20°C … +60°C
Process temperature (transducer)
- VEGASON 54, 55 -40°C … +80°C (StEx: -20°C … +75°C)
- VEGASON 56 -40°C … +150°C
- storage and transport temperature -40°C … +80°C
Vessel pressure max. (gauge pressure)
- VEGASON 54
Version A 0.5 bar (flange version)
Version B … C 0.5 bar
Version D 0.5 bar
- VEGASON 55
Version A 0.5 bar (flange version)
Version B … C 0.5 bar
Version D 0.5 bar
- VEGASON 56
Version A 0.5 bar (flange version)
Version B … C 0.5 bar
Version D 2 bar
Protection
- sensor IP 67
- transducer, process IP 68
Protection class
- two-wire sensor II
- four-wire sensor I
Overvoltage category III
Self-heating
at 40°C ambient temperature
- sensor 45°C
- transducer, process 55°C
Technical data
Ex technical data
Classification m (encapsulation of the transducer)
Temperature class (permissible ambient
temperature around the transducer when
used in Ex areas)
- T6 42°C
- T5 58°C
- T4 60°C
- T3 60°C
Ex approved in category or zone
- VEGASON 56
ATEX Zone 1 (II 2G)
IEC, CENELEC, PTB Zone 1
- VEGASON 54 … 56
ATEX Zone 21/22 (II 2D/3D)
IEC, CENELEC, DMT Zone 10/11
14 VEGASON 54K … 56K
Technical data
Process fittings
VEGASON 54 G 1 A, 1-11.5 NPT, DN 50, DN 80, DN 200
VEGASON 55 G 1 A, 1-11.5 NPT, DN 50, DN 80, DN 250
VEGASON 56 G 1 A, 1-11.5 NPT, DN 50, DN 80, DN 200
Note:
Generally an adapter flange is necessary for G 1 A, 1-11.5 NPT, DN 50 and DN 80.
Connection cables
Four-wire sensors supply and signal in two separate cables
Electrical connection spring-loaded terminals, wire cross-section
generally 2.5 mm
- option screw connection
Ground connection max. 4 mm
2
2
Transducer cable
- VEGASON 54, 55 5 … 300 m (cable diameter 7.2 … 7.6 mm)
- VEGASON 56 5 … 300 m (cable diameter 9.5 … 9.9 mm)
Cable entry for signal and supply cable
with spring-loaded terminals
- plastic housing (PBT) 2 x M20 x 1.5 (cable diameter 5 … 9 mm)
or 2 x 1/2“ NPT (cable diameter
3.1 … 8.7 mm or 0.12 … 0.34 inch)
- Aluminium housing and
Ex d terminal compartment 2 x 1/2“ NPT (cable diameter 3.1 … 8.7 mm
or 0.12 … 0.34 inch)
Materials
Housing PBT (Valox) or aluminium
Process fitting
- flange version Alu or PP
- swivelling holder and thread galvanised steel
Transducer
- VEGASON 54 PA (1.4301 at StEx)
- VEGASON 55, 56 UP
Transducer diaphragm
- VEGASON 54 1.4571
- VEGASON 55 Alu/PE foam
- VEGASON 56 Alu/PTFE nonadhesive coating
Transducer cable (cable cover)
- VEGASON 54, 55 PUR (1.1082)
- VEGASON 56 silicone (1.1083)
VEGASON 54K … 56K 15
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