VEGA TOR521, TOR522, TOR523, TOR527 User Manual
Operating Instructions
VEGATOR 521, 522, 523, 527
Level and Pressure
5
010
on
521
5
010
max
5
010
min
on
522
5
010
1
5
010
2
on
523
5
010
1
5
010
2
on
527
p
Contents
Safety information ........................................................................ 2
Note Ex area ................................................................................ 2
1 Product description
1.1 Function and configuration .................................................. 3
1.2 Types and versions ............................................................. 3
1.3 Approvals ............................................................................. 3
1.5 Dimensions ........................................................................... 6
2 Mounting
2.1 Mounting instructions ........................................................... 7
3 Electrical connection
3.1 Connection instructions ....................................................... 9
3.2 Connection schematic ......................................................... 9
4Setup
4.1 Indicating and adjustment elements ................................ 11
4.2 Principle of operation ......................................................... 13
4.3 Switching point adjustment ............................................... 14
Contents
5 Diagnostics
5.1 Maintenance ....................................................................... 21
5.2 Repair.................................................................................. 21
5.3 Failure rectification ............................................................. 22
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 VEGATOR
Note Ex area
Please note the approval documents (yellow
binder), and especially the included safety
data sheet.
Product description
1 Product description
1.1 Function and configuration
VEGATOR 521, 522, 523 and 527 level
switches are signal conditioning instruments
in European size (DIN 41 494) for level
detection. Typical applications are overfill
protection in vessels and dry run protection
or double point control of pumps. Depending
on the instrument type, up to 2 sensors with
analogue transmission of measured data can
be connected to the input. 2 relays (spdt)
and 2 floating transistors are available as
outputs. All instruments are equipped with a
fail-safe relay and transistor. The instruments
are provided with fault monitoring and
adjustable integration time.
All VEGATORs are available with Ex
approvals or as overfill protection systems
acc. to WHG and VbF.
Function
VEGATOR signal conditioning instruments
enable detection of min./max. levels. The
measured data of the sensor are converted
into a switching command, and connected
instruments can be switched on or switched
off. The integrated fault monitoring detects
short-circuit or break of the measuring cable
as well as selected failures from the
transmitter. The failure lamp lights and the
output relays and output transistors are
deenergised in case of failure.
1.2 T ypes and versions
VEGATOR 521 (Ex)
Signal conditioning instrument as level switch
for single point control. 1 sensor input for
capacitive electrodes or pressure
transmitters. 1 relay output (spdt) and 1
transistor output with fixed switching
hysteresis.
VEGATOR 522 (Ex)
Signal conditioning instrument as level switch
for one sensor for double point control. 1
sensor input for capacitive electrodes or
pressure transmitters. 1 relay output (spdt)
and 1 transistor output with adjustable
switching hysteresis.
VEGATOR 523 (Ex)
Signal conditioning instrument as level switch
for one sensor for dual single point control.
1 sensor input for capacitive electrodes or
pressure transmitters. 2 relay outputs (spdt)
and 2 transistor outputs with fixed switching
hysteresis.
VEGATOR 527 (Ex)
Signal conditioning instrument as level switch
for two sensors for single point control. 2
sensor inputs for capacitive electrodes or
pressure transmitters. 2 relay outputs (spdt)
and 2 transistor outputs with fixed switching
hysteresis.
In case of mains failure, the relays
deenergise.
Configuration
For configuration of a measuring system, a
VEGATOR and one or two sensors with
analogue measured data transmission, e.g. a
capacitive electrode or a pressure
transmitter are required.
VEGATOR 3
1.3 Approvals
VEGATOR is available with the following
approvals:
- explosion protection: respective instrument
with intrinsically safe circuit(s) [EEx ia] IIC
- overfill protection acc. to WHG applied for
For these applications, please note the relevant offical documents (test report, test
certificates, type approvals and conformity
certificates). These are supplied with the
respective instrument.
Product description
1.4 Technical data
General
Version European size DIN 41 612
Dimensions W = 25.4 mm (5 TE); H = 128.4 mm; D = 162 mm
Weight approx. 180 g
Ambient temperature -20°C … +60°C
Storage and transport temperature -40°C … +70°C
Power supply
Operating voltage 20 … 53 V AC, 50/60 Hz or 20 … 72 V DC
Power consumption max. 4 VA
Electrical protective measures
Protection class II
Overvoltage class II
Protection
- mounted in carrier
BGT 596 with module IP 00
- front side completely equipped IP 30
- upper and lower side IP 20 (only Ex carrier)
- wiring side (rear) IP 00
- single housing IP 20
Inputs
Transmission analogue
Switching threshold adjustable 4 … 20 mA
Hysteresis (fixed / min.) 80 µA
Current limitation 24 mA (permanently short-circuit proof)
Connection cable to the sensor 2-wire
Sensor supply voltage approx. 15 … 18 V DC
Resistance per wire max. 35 Ω
Temperature error 0.05 %/10 K (relating to range)
Integration time 0.2 … 20 s
Relay output
Number of
- VEGATOR 521, 522 1 level relay
- VEGATOR 523, 527 2 level relay
Modes A/B-switch
Contact floating spdt
Contact material AgNi and Au plated
Turn-on voltage min. 10 mV
Switching current min. 10 µA
Breaking capacitance max. 500 VA AC, 54 W DC
4 VEGATOR
1 fail-safe relay
1 fail-safe relay
A - max. detection or overfill protection
B - min. detection or dry run protection
max. 250 V AC/DC
max. 3 A AC, 1 A DC
Product description
Transistor ouput
Number of
- VEGATOR 521, 522 2 (synchronous switching with relays)
- VEGATOR 523, 527 3 (synchronous switching with relays)
Galvanic separation floating
Operating voltage max. 36 V DC
Operating current max. 60 mA
Transistor voltage loss U
- 1.5 V
CE
Approvals
VEGATOR 521 Ex, 522 Ex, 523 Ex, 527 Ex
with input in classification
Intrinsic safety EEx ia IIC, EEx ia IIB
EEx ib IIC, EEx ib IIB
Max. values U
= 20 V
O
IK = 126 mA
P = 626 mW
Characteristics linear
EEx ia IIC EEx ia IIB EEx ib IIC EEx ib IIB
Max. permissible external inductance (mH) 0.5 1 1.5 2 2 9
Max. permissible external capacitance (nF) 97 78 68 486 200 1000
The intrinsically safe circuits are reliably (galvanically) separated from the non-intrinsically
safe circuits up to a peak value of the nominal voltage of 375 V.
On instruments with 2 channels (VEGATOR 527 Ex) the intrinsically safe circuits are reliably
separated.
CE conformity
VEGATOR 521 Ex, 522 Ex, 523 Ex and 527 Ex signal conditioning instruments meet the
protective regulations of EMC (89/336/EW) 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
VEGATOR 5
1.5 Dimensions
Circuit board 100 x 160 x 1.5
European size
Multiple plug
Product description
5 TE
9
5,5
162
100
128,4
on
25,4
6 VEGATOR
Mounting
2 Mounting
2.1 Mounting instructions
VEGATOR can be mounted either in a card
slot in a carrier BGT 596 or in a single
housing type 505.
Card slot
Multipoint connector DIN 41 612, series F, 33pole (d, b, z) with coded pin and mounting
material for mounting in carrier BGT 596.
Card slot Ex
Multipoint connector DIN 41 612, series F, 33pole (d, b, z) with coded pins, Ex separating
chamber and mounting material for mounting
in carrier BGT 596 Ex.M.
Single housing
Plastic housing type 505 for individual
mounting of signal conditioning instruments
with instrument width 5 TE (25.4 mm).
Mounting carrier
Mount the respective module (standard or Ex
version) on your carrier BGT 596. Wire the
connections of the multipoint connector
according to the connection schematic on the
following page.
The multipoint connector is available as
follows:
- Wire-Wrap standard connection
1.0 x 1.0 mm
- Plug connection 2.8 x 0.8 mm
- Termi-Point standard connection
1.6 x 0.8 mm
- Soldering connection
- Screw terminals 2 x 0.5 mm
For further information on mounting, use the
operating instructions of the carrier.
2
Mounting single housing
The socket can be either screwed directly to
the mounting plate or plugged to a carrier rail
(TS 35 x 7.5 acc. to EN 50 022 or TS 32 acc.
to EN 50 035). Connect the terminals of the
basic plate according to the connection
schematic on the following page. For further
information on mounting, use the operating
instructions of the housing.
Coding
To prevent inadvertent swapping of the
various instruments, the multiple plug of the
instrument is provided with one or several
coding holes.
By means of a fixed coded pin on the Ex
module, it is ensured that only Ex instruments
can be inserted.
To prevent inadvertent swapping of the
various instruments, two additional coded
pins are included with the instrument. Insert
these coded pins into the predetermined
holes on the multipoint connector. The coded
pins must be inserted into the following
positions:
Instrument Ex coding
coding
VEGATOR 521 a9 / c7 ––
VEGATOR 521 Ex a9 / c7 c23
VEGATOR 522 a11 / c7 ––
VEGATOR 522 Ex a11 / c7 c23
VEGATOR 523 a13 / c7 ––
VEGATOR 523 Ex a13 / c7 c23
VEGATOR 527 a15 / c7 ––
VEGATOR 527 Ex a15 / c7 c23
VEGATOR 7
Mounting
z b d
a c
o 1 o
o 3 o
o 5 o
VEGATOR 521 a9
VEGATOR 522 a11
VEGATOR 523 a13
VEGATOR 527 a15
o 7 o
o 9 o
o11o
o13o
o15o
o17o
o19o
o21o
o23o
o25o
o27o
o29o
o31o
c7
VEGATOR
c23
Ex-Codierung
Transparent cover
To protect the instrument against unauthorized or inadvertent use, the front plate of
VEGATOR can be provided with a lockable
transparent cover.
Ex version
Ex separating chamber
To ensure sufficient "air and creeping
distance", an Ex separating chamber must
be mounted to the connections of VEGATOR.
Lead the cables through the Ex separating
chamber and connect the cables. Fasten the
Ex separating chamber with the lower
holding screw. Note the operating
instructions of the carrier BGT 596 Ex.M.
Mounting in carriers
When mounting VEGATOR with Ex approval
in a carrier, a VEGA-Ex card slot must be
used. Keep a distance of at least 10 mm
(2 TE) to modules of other manufacturers.
When mounting VEGATOR to the complete
left position in the carrier, a blind cover of at
least 20 mm (4 TE) must be mounted in front
of the card slot of the instrument.
2
on
VEGATOR
Blind cover
Protection for Ex applications
For Ex applications, a protection of IP 20
must be maintained. Cover the gaps or free
card slots with blind covers from the front.
8 VEGATOR
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