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

Technical data

Weight (depending on the housing materials used)

VEGASON 54

- Version A 5.6 … 10.7 kg

- Version B 6.9 … 9.7 kg

- Version C 7.5 … 10.5 kg

- Version D 4.7 … 6.9 kg

VEGASON 55

- Version A 8.0 … 13.3 kg

- Version B 8.7 … 10.3 kg

- Version C 9.2 … 11.1 kg

- Version D 6.5 … 7.5 kg

VEGASON 56

- Version A 7.3 … 11.3 kg

- Version B 8.7 … 10.3 kg

- Version C 9.3 … 11.1 kg

- Version D 6.5 … 7.5 kg

CE conformity

VEGASON series 50 ultrasonic sensors meet the protective regulations of EMC
(89/336/EWG) and NSR (73/23/EWG). Conformity has been judged acc. to the following
standards:
EMC Emission EN 50 081 - 1: 1993

Susceptibility EN 50 082 - 2: 1995

NSR EN 61 010 - 1: 1993

EN 61 326 - 1: 1997/A1:1998

16 VEGASON 54K … 56K

Technical data

3.2 Dimensions

VEGASON 54 … 56 in version A

201

165

Plastic housing
(PBT)

10˚

101

Aluminium
housing (Al)

25

116

215

185

VEGASON 54

VEGASON 55

397

Min. distance
to the product

Min. distance
to the product

257

1,0 m

0,8 m

90

12xø22

1)

ø190 (ø196)

ø340

ø244
ø405

75

1)

20

110 (126)

12xø26

20

128

12xø22 (12xø26)

445,8

282

Reference plane

Reference plane

20

Reference plane

VEGASON 56

423

Min. distance
to the product

1,8 m

VEGASON 54K … 56K 17

ø198

2)

ø340 (ø405)

VEGASON 54 … 56 in version B

Technical data

6

8

4

4xø19

2

7

1

386

245

ø165

ø122,8

201

165

0

1

Plug connection

ø

2

> ø200

˚

7

11,5

11,5

Plastic housing
(PBT)

101

90

ø122,8

4xø19

3

0

5

ø165

>ø250

435

270

215

185

65

Plug connection

8

9

7

Aluminium
housing (Al)

25

116

ø165

ø122,8

4xø19

>ø210

,5

9

8

ø

1

9

0

(ø

VEGASON 54

1

9

6

)

m

,0

1

Reference plane

1

ø

2

4

4

m

,8

0

VEGASON 55

,5

4

8

4

ø

1

9

8

1,4 m

VEGASON 56

Note:

The swivelling holder is shown in DN 50.

18 VEGASON 54K … 56K

Technical data

VEGASON 54 … 56 in version C

Aluminium housing (Al)

Plug

215

25

116

185

m

,0

1

Plug connection

ø 45

78

68

7

130
150

ø 7

85

65

170

445,8

282

10120

m

,8

0

VEGASON 54

VEGASON 55

m

,4

1

Reference plane

VEGASON 56

VEGASON 54K … 56K 19

VEGASON 54 … 56 in version D

Technical data

Plug connection

3240

214

149

Plastic housing (PBT)

Plug

68

ø 45

78

233

7

3240

167,5

186

101

130
150

201

165

10˚

397,2

90

ø 7

85

65

120 10

170

257,2

3240

527

462,5

Reference plane

1,0 m

0,8 m

1,4 m

VEGASON 54 VEGASON 55 VEGASON 56

20 VEGASON 54K … 56K

Technical data

External indicating instrument VEGADIS 50

38

ø5

48

10

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

Pg 13,5

135

118

108

Adjustment module MINICOM

Tank 1
m (d)

12.345

67,5

ESC

+

-

74

32,5

OK

82

85

Note:

The diameter of the connection cable must be
5 … 9 mm.
Otherwise the seal effect of the cable entry will
not be ensured.

Adjustment module for insertion into
VEGASON series 50 sensor or into the exter­nal indicating instrument VEGADIS 50

VEGASON 54K … 56K 21

4 Mounting and installation

4.1 Mounting

Mounting and installation

Version A

Sensors in version A (flange version) are
supplied completely mounted and ready for
operation. Immediately after mounting on the
vessel and electrical connection, they are
ready for operation.

Version B

The sensors in version B are supplied in two
parts (transducer and sensor electronics).
First of all, mount the transducer on the ves­sel or above the medium. There is a four-pole
jack at the end of the transducer tube. The
respective counterpart to the jack protrudes
out of the lower side of the sensor electronics
housing. Insert the plug of the sensor elec­tronics (only possible in one position), into the
jack of the transducer tube. Continue push­ing the electronics housing onto the trans­ducer tube, on which there is a wide and a
narrow groove.

Groove for locking the
headless screw

Mounting groove (must
no longer be visible after
mounting)

The wide groove is used for locking the
headless screws. The narrow groove is a
marking for mounting. Move the electronics
housing farther down over the transducer
tube until the mounting groove is no longer
visible. Fasten the housing with the headless
screws to the transducer tube. Use a 5 mm
hexagon screwdriver (or Allen wrench).

22 VEGASON 54K … 56K

Mounting and installation

Version C and D

The sensors in version C and D are supplied
in three parts (transducer, sensor electronics
and transducer cable). First mount the trans­ducer (see version B). There is a four-pole
jack at the transducer tube end. A respective
counterpart to the jack is provided in the
connection cylinder of the transducer cable.
Insert the connection cylinder plug into the
jack of the transducer tube.

Connection
cylinder

Mounting
bracket

Connection
cylinder

Transducer
cable

On the end of the transducer tube you find a
wide and a narrow groove. The wide groove
is used for locking the cylinder with the head­less screws. The narrow groove is the
mounting mark.

Then push the connection cylinder onto the
transducer tube (with a slight swivelling mo­tion) until the mounting mark is no longer
visible.

When the mounting mark is covered by the
cylinder, fasten the cylinder with the two
headless screws. Use a 5 mm hexagon
screwdriver (or Allen wrench).

Now mount the sensor electronics in the
requested location. The sensor electronics is
fastened to a mounting bracket, so that it can
be mounted to a plane surface or to the wall.
Make sure that the sensor housing is
mounted in such a way that there is enough
space above the housing to open the cover.

Now insert the plug at the other end of the
transducer cable into the jack on the elec­tronics housing.

Note:

Avoid bending the transducer cable too
sharply when laying it out. This is special
cable which could otherwise be damaged.

In addition, make sure that the cable is not
damaged during operation. A signal with a
voltage of approx. 1 kV is transmitted via the
screened wires of the cable . If the cable is
damaged, it could create a danger in Ex
areas.

Groove for locking the
headless screws

Mounting groove (must
no longer be visible after
mounting)

VEGASON 54K … 56K 23

4.2 General installation instructions

Mounting and installation

Measuring range

ducer end, or with instruments in flange ver­sion, the instrument flange (version A).

Beside other criteria, you select your instru­ment according to the required measuring
range.
The reference planes for the min. and max.

Please note the information on the reference
planes in chapter "3.2 Dimensions“. The
max. filling depends on the required min.
distance and the mounting location.

distance to the liquid or solid is the trans-

Reference plane

min. meas.
distance 1.0 m

100 %

0 %

Span

Min. distance, max. measuring range, span and reference plane

0 %

max. meas. range

max. meas. distance 25 m (type 54), 45 m (type 55), 70 m (type 56)

min. meas. distance 0.8 m

100 %

Span

Reference plane

min. meas. distance 1.4 m

100 %

0 %

Span

Beam angle and false echoes

At greater distances, the energy of the ultra­sonic impulses distributes over a large area,

The ultrasonic impulses are focused by the
transducer. The impulses leave the trans­ducer in conical form similar to the beam
pattern of a spotlight. The beam angle is 4°

thus causing weaker echoes from obstruct­ing surfaces. The interfering signals are
therefore less critical than those at close
range.

(VEGASON 54), 5° (VEGASON 55) and 6°
(VEGASON 56) at -3 dB emitted power.
Any object inside this emission cone will
cause a false echo. Especially within the first
few meters of the emission cone, pipes,

If possible, orient the sensor axis perpen­dicularly to the product surface and avoid
vessel installations (e.g. pipes and struts)
within the 100 % area of the emission cone.

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.

The following illustration of the ultrasonic
beams is simplified and represents only the
main beam. In reality, there are quite a
number of ancillary beams.

24 VEGASON 54K … 56K

Mounting and installation

100 %

50 %

70 m

0 m

7,5

3,7

7,5

3,7

0

m

6˚

12˚

0 m

Meas.
distance

4˚

Emitted power

50 %

100 %

VEGASON 56VEGASON 54

Emitted power

25 m

Meas.
distance

45 m

0 m

4

0,9

2,0

5˚

10˚

242

0

8˚

0,9

2,0

0

VEGASON 55

50 %

100 %

m

Emitted power

Emitted power

m

Meas.
distance

Emitted power

Emitted power

Therefore in practical application, the trans­ducer has to be oriented so that lowest pos­sible false echo signal strength is achieved.
Only giving attention to the large useful echo
is therefore not always sufficient. In most
cases, a low false echo level enables the
sensor to reliably pick up the useful echo.
With the adjustment software VVO on the PC
you can have a look at the echo image, see
chapter "6.2 Adjustment with the PC“ under
the subheading "Sensor optimisation/Echo
curve“.

VEGASON 54K … 56K 25

Mounting and installation

4.3 Measurement of liquids

Flat vessel top

On flat vessels, mounting is usually done on
a very short DIN socket piece. Reference
plane is the lower edge of the flange. The
transducer should protrude out of the flange
tube.

< 100 mm

VEGASON 55 in flange version on short
DIN socket piece

< 400 mm

Reference plane

Min. distance
Type 54: 1 m
Type 55: 0.8 m

Reference plane

A mounting location directly on the vessel top
is ideal. A round opening in the vessel top is
sufficient to fasten the sensor with the flange,
or version B and C with swivelling holder.

Reference
plane

Min. meas. distance

1.8 m

Swivelling
holder

Min. meas. dis-

tance

1.4 m

Reference
plane

Flange version and swivelling holder on flat vessel
top

It is also possible to mount the sensors in
version C in a 1“ thread.

Min. distance

1.8 m

< 60 mm

VEGASON 56 in flange version on short
DIN socket piece

Reference
plane

Mounting of the transducer in 1“ thread

26 VEGASON 54K … 56K

Mounting and installation

Dished tank ceiling

On dished tank ceilings, please do not mount
the instrument in the centre, but approx. 1/
vessel radius from the centre. Dished tank
ceilings can act as paraboloidal reflectors. If
the transducer is placed at the focal point of
the parabolic ceiling, the transducer receives
amplified false echoes. The transducer
should be mounted outside the focal point.
Amplified echoes caused by parabolic sur­faces are thereby avoided.

2

Reference
plane

< 100 mm

1

/2 vessel radius

VEGASON 54 on dished vessel ceiling; the state­ments are also valid for VEGASON 55

< 400 mm

1

/2 vessel radius

VEGASON 56 on dished tank ceiling

Reference plane

Open vessels

On open vessels, using the instrument on an
extended mounting bracket is a practical
solution. Mount the low-weight sensor onto
such a bracket and ensure a sufficient dis­tance to the vessel wall.

Reference plane

Min. meas.

Min. meas.
distance

distance

Reference plane

Open vessels

VEGASON 54K … 56K 27

Mounting and installation

Pump shaft

Narrow shafts and shaft openings (vessel
openings) with very rough walls and shoul­ders make an ultrasonic measurement ex­tremely difficult due to strong false echoes.
This problem can be overcome by using an
extended socket piece or a complete meas­uring tube (see chapter "4.5 Socket exten­sion“).

see also „4.5 Socket
extension“

Socket piece

≥ 250 mm

min.
distance

4.4 Measurement of solids

Flange mounting

As with applications for liquids, the instrument
can be mounted on a short DIN socket con­nection on vessels for solids. However the
socket must be short enough to allow the
transducer end to protrude from it and to not
get in the way of the ultrasonic signals. The
swivelling holder enables not only the align­ment to the product surface but also the
minimisation of false echoes.

In the course of filling and emptying, the
product surface often takes on different
shapes. This can change the quality of the
useful echo. The alignment of the transducer
should thus ensure that false echoes are
always at a minimum, even when the con­tainer is empty. You can have a look at the
echoes on the PC with adjustment program
VVO (see chapter "6 Setup/Adjustment with
the PC/Sensor optimisation/Echo curve“).

Meas. range

Shaft pump

Example of a socket extension or measuring tube in a
shaft

Measuring tube

Shaft

Very good measuring results can be attained

Shaft pump

Reference plane

Min. distance

with a measuring tube in continuous narrow
shafts, see figure. The applied measuring
tube must have smooth walls inside (e.g. PE
sewage pipe) and a diameter ≥ 200 mm. This
arrangement works well as long as the inside
of the measuring tube collects no dirt or
buildup (cleaning necessary). You might
want to instead consider using hydrostatic
pressure transmitters or capacitive measur­ing probes. The measuring tube must either
be never immersed, or always immersed in
the medium (measurement carried out exclu­sively within the tube).

28 VEGASON 54K … 56K

VEGASON 54C with an adapter flange on a DN 200
vessel flange

Mounting and installation

Mounting boss

Reference plane

Min. distance

VEGASON 56 in 1“ mounting boss

The socket axis should point to the product
surface. The use of a swivelling holder would
be even better (type B, C), as described
previously.

Material heaps

4.5 Socket extensions

The ultrasonic sensors require a min. dis­tance to the product or solid. Take the min.
distance into account in your planning. In
some situations, it is possible to reach the
required min. distance, and hence the de­sired filling height, with a socket extension.
However, the socket extension increases the
noise level of the ultrasonic signal at the ex­tension outlet and can interfere with the
measurement. Only use a socket extension if
all other possibilities have to be excluded.
Carry out the extension as shown in the fol­lowing illustration.

Socket extensions in liquids

Chamfer and deburr the socket carefully and
make sure it has a smooth inner surface. The
socket should not protrude into the meas­ured product, in case buildup can form on
the socket through impurities or product
residues.

With nonadhesive measured products, a
socket extension in the form of a measuring
tube can be permanently submerged in the
product. The ultrasonic measurement is then
carried out exclusively in the measuring tube
and works very well without interference from
other vessel installations (see "Pump shaft“).

Large material heaps are detected with sev­eral instruments, which can be mounted on
e.g. traverse cranes. For this type of applica­tion, it is best to orient the sensor toward the
solid surface.

Socket piece should not be immersed into adhesive
products (figure: VEGASON 54)

Transducer on traverse crane above material heaps

VEGASON 54K … 56K 29

Mounting and installation

The socket diameter should be as large and
the socket length as small as possible. Make
sure that the socket outlet is burr-free to
minimise false echoes.

Typ e 5 4

L

˚

5

4

ø

Socket extensions that do not protrude into the
measured product

Typ e 5 5

L

45˚

ø

Max. socket length in relation to socket diam­eter

ø in mm L in mm

Type 54 Type 55 Type 56

200 400 – – ––
250 500 500 500
300 –– –– 600

4.6 False echoes

The mounting location of the ultrasonic sensor
must be selected such that no installations or
inflowing material are in the path of the ultra­sonic impulses. The following examples and
instructions show the most frequent measur­ing problems and how to avoid them.

Vessel protrusions

Vessel forms with flat protrusions can, due to
their strong false echoes, adversely effect
the measurement. Shields above these flat
protrusions scatter the false echoes and
guarantee a reliable measurement.

Correct Wrong

Socket extensions for solids

For solids, use a conical socket extension
with a taper of at least 15° … 20°.

Vessel protrusions (slope)

Intake pipes, e.g. for the mixing of materials ­with a flat surface directed towards the sen­sor - should be covered with a sloping
shield. This shield will scatter false echoes.

Correct Wrong

15˚ 15˚

Socket extension in solids

Vessel protrusions (intake pipe)

30 VEGASON 54K … 56K

Mounting and installation

Vessel installations

Vessel installations such as, for example, a
ladder, often cause false echoes. Make sure
when planning your measurement loop that
the ultrasonic signals have free access to the
measured product.

Correct Wrong

Ladder

Vessel installations

Ladder

Struts

Struts, like other vessel installations, can
cause strong false echoes that are superim­posed on the useful echo signals. Small
shields effectively hinder a direct false echo
reflection. These false echoes are scattered
and diffused in the area and are then filtered
out as "echo noise“ by the measuring elec­tronics.

Inflowing material

Do not mount the instrument in or above the
filling stream. Ensure that you detect the
product surface and not the inflowing mate­rial.

Correct

Correct

Inflowing material

Wrong

Wrong

Buildup

Correct Wrong

If the sensor is mounted too close to the
vessel wall, and clumps of the product on the
vessel wall can cause false echoes. Position
the sensor at a sufficient distance from the
vessel wall. Please also note chapter "4.2

Shields

Struts

VEGASON 54K … 56K 31

General installation instructions“.

Mounting and installation

Correct

Buildup

Wrong

Strong product movements

Strong turbulences in the vessel, e.g. by
power ful stirrers or strong chemical reac­tions, seriously interfere with the measure­ment. A surge or bypass tube of sufficient
size (DN 200, DN 250) always allows, pro­vided the product causes no buildup in the
tube, a reliable measurement even with
strong turbulence in the vessel.

100 %

4.7 Incorrect mounting

Foam generation

Thick foam on the product can cause incor­rect measurements. Take measures to avoid
foam, carry out the measurement in a bypass
tube, or use a different measuring technol­ogy, e.g. capacitive measuring probes or
hydrostatic pressure transmitters.

Foam generation

Wrong orientation to the product

Weak measuring signals are the result 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.

60 %

0 %

Strong turbulences

Orient the sensor perpendicularly to the product
surface

32 VEGASON 54K … 56K

Mounting and installation

Strong heat fluctuations

Strong heat fluctuations, e.g. due to the sun,
cause measuring errors. Please provide a
sun shield.

Shield

Strong heat fluctuations

Min. distance to the medium

If the min. distance to the medium is not main­tained, the instruments show wrong meas­ured values. Mount the instrument at the
required min. distance.

Correct Wrong

Sensor too close to the vessel wall

If the sensor is mounted too close to the
vessel wall (dimension A in diagram), strong
false echoes can be caused. Buildup, rivets,
screws or weld joints on the vessel wall su­perimpose their echoes on the product or
useful echo. Please ensure the sufficient
distance of the sensor to the vessel wall,
depending on the maximum measuring dis­tance (dimension B in diagram). In case of
good reflection conditions (liquids, no vessel
installations), we recommend determining the
sensor distance according to Diagram curve

1. At a max. meas. distance of e.g. 10 m, the
distance of the transducer (according to
curve 1) should be approx. 1.5 m. In case of
solids with bad reflection properties, deter­mine the distance to the vessel wall accord­ing to Diagram curve 2. Under very bad
measuring conditions (rough vessel walls,
struts), it might be necessary to increase the
distance to the vessel wall, or to also filter out
the false echoes by storing them in memory,
thereby adapting the sensor more precisely
to the environment.

Distance of the
transducer to the
vessel wall

A

2 m 4 m 6 m 8 m

Curve 1 (liquids)

10 m

Sensor too close to the vessel wall

VEGASON 54K … 56K 33

B

20 m

30 m

max. meas.
distance

Curve 2 (solids)

Mounting and installation

Parabolic effects of rounded or arched
vessel tops

Round or parabolic tank tops act like a para­bolic mirror for the signals. If the sensor is
placed at the focal point of such a parabolic
tank top, the sensor receives amplified false
echoes. The optimum location is generally in
the area of half the vessel radius from the
centre.

Correct

< 100 mm

~ 1/

2

vessel
radius

Wrong

Socket piece too long

If the sensor is mounted in a socket exten­sion that is too long, strong false echoes are
caused, and measurement is hindered. Make
sure that the transducer protrudes at least
30 mm out of the socket piece.

Reference plane

< 100 mm

Wrong

Correct and wrong length of socket piece

Mounting on a vessel with parabolic tank top

34 VEGASON 54K … 56K

Electrical connection

5 Electrical connection

5.1 Connection and connection cable

Safety information

As a rule, do the work in the complete ab­sence of line voltage. Always switch off the
power supply before you carry out connect­ing work on the ultrasonic sensors. Protect
yourself and the instruments, especially when
using sensors which do not operate with low
voltage.

Qualified personnel

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

Connection

A standard two or four-wire cable (sensors
with separate supply) with max. 2.5 mm2 can
be used for connection. Very often the "elec­tromagnetic pollution“ from electronic actua­tors, energy cables and transmitting stations
is so considerable that the two-wire cable or
the four-wire cable should be shielded.

We recommend the use of a screened cable.
Screening is also a good preventative meas­ure against future sources of interference.
However, you must make sure that no
ground potential currents flow through the
sensor cable shields. Ground potential cur­rents can be avoided by potential equalisa­tion cables. When grounding at both ends, it
is possible to connect the cable shield on one
side (e.g. in the switching cabinet) via an Y­capacitor1) to the ground potential. Use a low­resistance ground connection (foundation,
plate or mains earth).

Note!

In Ex applications, grounding on both ends is
not allowed due to potential losses.

Ex protection

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

Please note the approval documents with the
safety data sheet attached to the Ex sensors.

Connection cable

Please make sure that the connection cables
are specified for the expected operating tem­peratures in your systems. The cable must have
an outer diameter of 5 … 9 mm or 3.6 … 8.6 mm,
to ensure the seal effect of the cable entry.

Protective conductor terminal

The electronics housing of the sensors has a
protective insulation. The protective conduc­tor terminal and the earth terminal in the elec­tronics housing are galvanically connected
with the metallic transducer diaphragm.
On sensors in version B, the protective con­ductor terminal is galvanically connected to
the transducer diaphragm via the transducer
tube when the sensor is completely mounted.
On version C and D, the connection is made
via the cable screen of the transducer cable
and the transducer tube.

1)

max. 10 nF, e.g. voltage resistance 1500 V, ce­ramic

VEGASON 54K … 56K 35

ESC

OK

Electrical connection

5.2 Connection of the sensor

After mounting the sensor at the measure­ment location according to the instructions in
chapter "4 Mounting and installation“, loosen
the closing screw on top of the sensor. The
sensor lid with the optional indication display
can then be opened. Unscrew the sleeve nut
and slip it over the connection cable (after
removing about 10 cm of insulation). The
sleeve nut of the cable entry has a self-lock­ing ratchet that prevents it from opening on
its own.

Version with aluminium housing

-

To the indicating
instrument in the
sensor cover or to
the external indicat­ing instrument
VEGADIS 50

1)

Voltage
supply

Voltage supply

4 … 20 mA active

+

-

+

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.

Version with plastic housing

Voltage supply

Cable entry
M20 x 1.5

4 … 20 mA active

-

+

+

-

To the indicating instru­ment in the cover or to
the external indicating
instrument VEGADIS 50

1)

M20 x 1.5

12 C 567843

Sockets for
connection of
VEGACONNECT
2 (communi­cation
sockets)

1)

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

12 C 5 6 7 843

(+) (-)
L1 N

Commu­nication+-4...20mA

-

+

Display

ESC

OK

Terminals
(max. 2.5 mm
wire cross-section)

Sockets for connec­tion of the HART
handheld or VEGA­CONNECT 2

pluggable
adjustment
module
MINICOM

2

12 C 567843

12 C 567843

Commu-

(+) (-)
L1 N

®

Tank 1
m (d)

12.345

nication

-

+ -

4...20 mA

+

Display

ESC

OK

Opening
tabs

36 VEGASON 54K … 56K

Electrical connection

5.3 Connection of the external indicating instrument VEGADIS 50

Loosen the four screws of the housing cover
on VEGADIS 50.
The connection procedure can be facilitated
by fixing the housing cover during connec­tion work with one or two screws on the right
of the housing (figure).

OUTPUT
(to the sensor)

2

1

3

5

7

4

8

6

Adjustment
module

VEGADIS 50

+

-

Tank 1
m (d)

12.345

ESC

OK

Voltage
supply

+

12 C 567843

2

(+) (-)

L1 N

Tank 1
m (d)

12.345

-

4 … 20 mA
active

C567843

Commu-

+

nication

4...20 mA

-

DISPLAY

(in the cover of
the indicating
instrument)

­Display

ESC

+

OK

Screws

Four-wire sensor

(separate supply)

VEGASON 54K … 56K 37

6 Set-up

Set-up

6.1 Adjustment methods

Series 50 ultrasonic sensors can be adjusted
with

- PC (adjustment program VVO)

- with detachable adjustment module
MINICOM

- with HART® handheld.

The adjustment must only be carried out with
one adjustment device. If, for example you
try the parameter adjustment with the
MINICOM and the HART® handheld, the ad­justment will not work.

PC

With the adjustment program VVO
Visual Operating System) on the PC you can
adjust the ultrasonic sensors very easily. The
PC communicates with the sensor via the
interface adapter VEGACONNECT 2. 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 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.

HART® handheld

VEGASON 50K ultrasonic sensors, like other
HART® protocol-compatible instruments, can
be adjusted with the HART® handheld. A
manufacturer-specific DDD (Data-Device­Description) is not required. The ultrasonic
sensors are adjusted with the HART® stand­ard menus. All main functions are therefore
accessible.
Functions that are rarely used, such as for
example, the scaling of the A/D converter for
the signal output, or the adjustment with me­dium, are not possible or are blocked with
the HART® handheld. These functions must
be carried out with the PC or the MINICOM.

(VEGA

6.2 Adjustment with the PC

The adjustment with the PC and the adjust­ment program VVO is no longer outlined in
this operating instructions manual but in the
„VEGA Visual Operating (VVO)“ manual.
Apart from the adjustment of the sensor, will
find further instructions on the functionality of
the adjustment media with the PC in the
VEGA Visual Operating manual.

PC on the sensor

To connect the PC to the sensor, the interface
converter VEGACONNECT 3 is required.
Make sure that the pins of VEGACONNECT 3
are completely inserted into the sensor sock­ets, as new pins have a slightly increased
resistance to insertion. The pins should be
inserted up to a depth of approx. 13 mm to
15 mm.

PC on the signal cable

Connect the two-wire cable of
VEGACONNECT 3 to the signal cable of the
sensor. If the resistance of the systems (PLC,
current source etc.) connected to the signal
cable is less than 250 Ω, a supplementary
resistor must be connected to the supply
cable during adjustment, in order to get a
signal cable load of 250 Ω ... 350 Ω. Reason:
The digital signals superimposed on the
signal cable would be considerably damped
or even „short circuited“ due to insufficient
system resistance.

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

VEGADIS 371 no additional

resistor
necessary

VEGASEL 643 150 … 200 Ohm

VEGAMET 513 S1, 514 S2
515 S1, S2, VEGALOG EA card 100 … 150 Ohm

38 VEGASON 54K … 56K

Set-up

250 Ω

PLC

Ri > 250 Ω

PLC

Ri < 250 Ω

Rx

VEGAMET/VEGALOG

VEGA signal conditioning instr. Rx

VEGADIS 371 no additional

resistor
necessary

VEGASEL 643 150 … 200 Ohm

VEGAMET 513 S1, 514 S2
515 S1, S2, VEGALOG EA card 100 … 150 Ohm

VEGASON 54K … 56K 39

Set-up

6.3 Adjustment with adjustment

module MINICOM

You can also adjust the sensor with the small,
detachable adjustment module MINICOM.
The adjustment module is plugged into the
sensor or into the external indicating instru­ment (optional).

ESC

+

-

Tank 1
m (d)

12.345

OK

2

Tank 1
m (d)

12.345

4

When adjusting with the adjustment module,
all sensor versions (adjustment options), as
with the PC and the adjustment program
VVO, are available. The adjustment with
MINICOM, however, is different.

+

-

4 ... 20 mA

ESC

OK

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 programmed

(service)

- Fault signal also appears during

programming

E040 Hardware failure, electronics

defective

Adjustment steps

On pages 64 and 65 you can find the com­plete menu diagram of the adjustment mod­ule MINICOM.
Set up the sensor in the numbered se­quence:

1. Measurement in gases

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.

You carry out all adjustment steps with the 6

1. Measurement in gases

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 of a menu adjustment.

Adjustment is only necessary when the
measurement is done in gases (Co2, He, etc.)
deviating from air. In case of measurement in
gases, sound the distance of the sensor to

The volume of information of the small display,
however, cannot be compared with that of the
adjustment program VVO, but you will soon
get used to it and be able to carry out your
adjustments quickly and directly with the

the product surface and enter it in the menu
item "Measurement in gases“. The sensor
can then take the modified sound velocity in
gases into account (as opposed to air) and
output correct levels.

small MINICOM.

40 VEGASON 54K … 56K

Set-up

2. Operating range

Without special adjustment, the operating
range corresponds to the measuring range.
The measuring range has already been ad­justed with the min./max. adjustment. Gener­ally it is useful to set the operatign range
slightly larger (approx. 5 %) than the measur­ing range.

Example:
Min./max. adjustment: 0.300 … 5.850 m;
adjust operating range to approx.

0.250 … 6.000 m.

Max.

Min.

100 % (1.270 m) correspond
to 1200 liters

Span (4.58 m)

0 % (5.850 m) corresponds
to 45 liters

Adjustment without medium

(adjustment independent of the actual level)

Key adjustment Display indication

Sensor

m(d)

4.700

Para-

OK

OK

OK

OK

+

meter

Adjust­ment

w.o
medium

Ad­just­ment
in

m(d)

(min. adjustment)

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

3. Adjustment

OK

Confirm the adjustment with

"OK“.
Under the menu item "
the sensor which measuring range it should
operate with.

Adjustment

“ you inform

Ad­just­ment
in

m(d)

0.0%

at

m (d)

XX.XXX

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 cycle.

+ –

or

With"+“ and "–“ you adjust the

percentage value for the min.

value or the lower level (exam-

ple 0.0 %).

OK

The adjusted percentage

value is written in the sensor

and the distance corres-

ponding to the percentage

value flashes.

VEGASON 54K … 56K 41

Set-up - Adjustment with the adjustment module MINICOM

+ –

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.

100.0%

at

m (d)

XX.XXX

(max. adjustment)

The max. adjustment (upper product dis­tance) is made in the same way (example:
100 % and 1.270 m).

Note:

The difference between the adjustment 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 inaccurate. A char­acteristics 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. When the adjust­ment points are too close together, small
errors multiply to considerably larger errors
at the output of the 0 % or the 100 % value.

Adjustment with medium

with
medium

Max.

Min.

adjust

adjust

at %

at %

XXX.X

XXX.X

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 100 % in the menu "

adjust

“ with the "+“ and "–“ keys.

Max.

4. Conditioning

Signal
condit
ioning

Scal
ing

0 %

100 %

corres

corres

ponds

ponds

XXXX

XXXX

Under the menu item "
choose the 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 figure 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.

prop.

Deci-

to

mal
point

888.8

Conditioning

0 % corresponds

Mass

Unit

Kg

“ you

“

• Confirm with "OK“.

42 VEGASON 54K … 56K

Set-up - Adjustment with the adjustment module MINICOM

With the "—>“ key you change to the 100 %
menu. Enter here the value of your parameter
corresponding to a 100 % filling. In the exam­ple 1200 for 1200 liters.

• Confirm with "OK“.

If necessary, choose a decimal point. How­ever, note that only max. 4 digits can be
displayed. In the menu "

prop. to

“ you choose
the parameter (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

Integr
ation
time

0 s

A linear correlation between the percentage
value of the product distance and percent­age value of the filling volume is preadjusted.
With the menu "Lin. curve“ you can choose
between linear, spherical tank and cylindrical
tank. The creation of a customised
linearisation curve is only possible with the
PC and the adjustment program VVO.

5. Meas. conditions

(see menu diagram page 64)

7. Useful level and noise level

In the menu

you get important information on the signal
quality of the product echo. The higher the
"S-N“ value, the more reliable the measure­ment (menu diagram MINICOM).

Ampl.: means amplitude of the level echo in

S-N: means Signal-Noise, i.e. the useful

The bigger the "S-N“ value (difference be­tween the amplitude useful 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 noise level

53 dB signal level difference indicates very
high measurement reliability.

Ampl.:

XX dB

S-N:

XX

dB

dB (useful level)

level minus the level of the back­ground noise

8. Outputs

6. False echo storage

Under the menu "Outputs“ you determine, if

for example, the current output should be
A false echo storage is always useful when
unavoidable false echo sources (e.g. struts)

inverted, or which parameter should be

shown on the sensor display.
must be minimised. By creating a false echo
memory, you authorise the sensor electronics
to note 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.

VEGASON 54K … 56K 43

Set-up - Adjustment with the adjustment module MINICOM

Menu schematic for the adjustment module MINICOM

Sensor

m(d)

4.700

PPara­meter

Sensor
opti­mise

Meas.
enviro
nment

Opera­ting
range

Begin

m (d)

0.50

2.

End

SON
51K

2.00

m (d)

6.00

When switching on, the sensor
type and the software version are
displayed for a few seconds.

Confi­gura­tion

Sensor
Tag

Sensor

5.

Meas.
condit
ions

Condit
ions

Liquid

Condit
ion

Solid

Fast
change

No

Fast
change

No

Agitat
ed sur
face
No

High
dust
level
No

Sensor
addr.

Foam­ing
prod.
No

Large
angle
repose
No

Multidrop operation (HART® sensor ad­dress):

• Sensor address zero: The sensor outputs
beside the 4…20 mA signal also a digital
(HART®) level signal.

• Sensor address 1…15: the sensor delivers
only a digital (HART®) level signal. The
sensor current is frozen to 4 mA (power
supply).

Meas.
unit

0

m (d)

Measur
ing in
gas

Meas.
dist.

Measur
ing in
gas
No

Measur
ing in
gas
No

Mul­tiple
echoes
No

Mul­tiple
echoes
No

mm (d)

2,381

Correc­tion
Now!

OK?

1.

Sound
speed

m/s

333

Correc­tion
Now!

OK?

3. 4. 8.

Adjust
ment

w.out
medium

Adjust
ment
in

m(d)

with
medium

Min.
adjust
at %

XXX.X

0.0 %

at

m (d)

XX.XXX

Max.
adjust
at %

100.0%

at

m (d)

XX.XXX

XXX.X

Signal
condit
ioning

Sca­ing

0 %
corres
ponds

XXXX

Lin.
curve

Linear

100 %
corres
ponds

XXXX

Integr
ation
time

Dezi­mal
point

888.8

Out­puts

Curr.
out-

0 s

Prop.

Unit

to

Mass

Kg

put

Curr.
out­put

4-20mA

Prop.
to

Dis­tance

Error
mode

22mA

Sensor
dis­play

44 VEGASON 54K … 56K

Set-up - Adjustment with the adjustment module MINICOM

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

ESC

6. 7.

False
echo
memory

Create
new

Meas.
dist.

m (d)

X.XX

Meas.
dist.

learn­ing

Simu­lation

Simu­lation
Now!

Simu­lation

XXX.X

OK?

OK?

%

Dis­tance

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.

Error codes:
E013 No v alid meas ured valu e

- Sensor in the warm-up phase

- Loss of the useful echo
E017 Adj us tmen t span too small
E036 Sensor program not operating

- Sensor must be programmed

(service)

- Fault signal also appears during

programming

E040 Hardware failure, electronics

defective

Delete

Delete
Now!

delet­ing

Ampl.:
S-N:

OK?

XX dB

XX

dB

max.
range

m (d)

7.000

Add´l
func­tions

Info

Sensor
Tag

Sensor

Dis­tance

m (d)

4.700

Sensor
type

PULS54
K

Ampl.:
S-N:

act.
dist.
m

X,XX

High
dust
level
No

Fast
change

Yes

Basic
reset

Reset
Now!

OK?

Reset­ing

XX dB

XX

Serial
number

1094
0213

dB

Lan­guage

Eng­lish

Softw.

Softw.

vers.

date

2.00

15.09.
1999

Cur-

Tempe-

rent

rature

mA

8.565

Actual

Min.

temp.

temp.

18°C

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 .

OK

4°C

Sensor
addr.

0

Max.
temp.

59°C

VEGASON 54K … 56K 45

7 Diagnosis

Diagnosis

7.1 Simulation

To simulate a certain filling, you can call up
the function "Simulation“ on the adjustment
module MINICOM, in the software program
VVO or on the signal conditioning instrument.

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.

Simulation with VVO or PC

If you start the simulation mode with the ad­justment program VVO on the PC, the simu­lated level is outputted until you quit the
simulation mode.

Simulation with HART® handheld

If you call up the simulation mode with the
HART® handheld, the sensor only returns to
operating mode after quitting the simulation
mode.

Simulation with MINICOM

If you start the simulation mode on the adjust­ment module MINICOM, the sensor returns to
standard operating mode after one hour.

7.2 Error codes

Error codes Rectifying measure

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, an echo treatment and
false echo reduction must be carried out in the
menu "Sensor optimisation“.

E017 Adjustment span too small Carry out a readjustment.

E036 Sensor software does not run Sensor must have a new software (service).

E040 Hardware failure/Electronics defec- Check all connection cables.

tive Transducer defective.

46 VEGASON 54K … 56K

Make sure that the difference between
min. and max. adjustment is at least 10 mm.

Message appears during a software update.

Contact our service department.

Notes

VEGASON 54K … 56K 47

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, use and
operating conditions of the sensors and processing systems corre­spond to the information available at the time of printing.

Technical data subject to alterations

24106-EN-030723