VEGA TOR536Ex User Manual

Operating Instructions
VEGATOR 536 Ex
TEST
2
on
VEGATOR
536 Ex
Safety information ........................................................................ 2
Note Ex-area ................................................................................ 2
1 Product description .................................................................. 3
1.1 Configuration ........................................................................ 3
1.2 Technical data ....................................................................... 3
1.3 Dimensions ........................................................................... 5
2 Mounting ..................................................................................... 6
3 Electrical connection ................................................................ 8
3.1 Connection plan ................................................................... 9
4 Set-up ........................................................................................ 10
5 Diagnosis .................................................................................. 13
5.1 Recurring test acc. to WHG .............................................. 13
5.2 Failure removal ................................................................... 13
Contents

Safety information

The described module must only be installed and operated as described in these operating instructions. Please note that other action can cause damage for which VEGA does not take responsibility.
2 VEGATOR 536 Ex

Note Ex-area

Please note the attached safety instructions containing important information on installation and operation in Ex areas. These safety instructions are part of the oper­ating instructions manual and come with the Ex approved instruments.
Product description

1 Product description

1.1 Configuration

A measuring system with signal conditioning instrument consisting of:
- a VEGAVIB series 50 with oscillator VIB E50 Z (Ex)
- a VEGATOR 536 Ex signal conditioning instrument
- external instruments switched by VEGATOR
or
- a VEGASWING series 60 or 80A with oscil­lator SW E60ZEx, SW E82Z or SW E82ZEx
- a VEGATOR 536 Ex signal conditioning instrument
- external instruments switched by VEGATOR

1.2 Technical data

General
Series module unit for carrier BGT 596 Ex Dimensions W = 25,4 mm (5 TE), H = 128,4 mm, D = 162 mm Weight approx. 180 g Test key (per channel) for function test
Ambient conditions
Ambient temperature -20°C … +60°C Storage and transport temperature -40°C … +70°C
Power supply
Operating voltage 20 … 53 V AC, 20 … 72 V DC Power consumption max. 3 W Electrical connection multiple plug DIN 41 612,
Electrical protective measures
Protection class II Overvoltage category II Protection
- mounted into housing type 505 Ex IP 30 Protection (mounted into carrier BGT 596 Ex with Ex-module)
- front side (completely equipped) IP 30
- upper and lower side IP 20
- wiring side IP 00
VEGATOR 536 Ex 3
series F (d, b, z) 33-pole
Product description
Inputs
Number 1 sensor input Data transmission analogue Switching threshold 12 mA Current limitation 24 mA (permanently shortcircuit proof) Sensor supply voltage 15 … 18 V DC Connection line 2-wire Resistance per conductor max. 35 Integration time 0,2 … 20 s
(adjustment via DIL-switch)
Relay output
Number, function 1 switching relay (spdt), 1 fail safe relay Mode A/B-switch
A - max. detection or overfill protection
B - min. detection or dry run protection Contact 1 spdt each Contact material AgCdO and Au plated Turn-on voltage min. 10 mV
max. 250 V AC, 250 V DC Switching current min. 10 µA
max. 3 A AC, 1 A DC Breaking capacity max. 500 VA AC, 54 W DC
Transistor output
Number, function 2, synchronously switching with the relays Galvanic isolation floating Max. values UB max. 36 V DC
IB max. 60 mA Transistor voltage loss UCE min. - 1,5 V at IB 60 mA Blocking current < 10 µA
Indicating elements
LED in the front plate
- green on operating voltage on
- yellow switch point control
- red fault signal
Explosion protection
Certificate conformity certificate
TÜV 01 ATEX 1781 Classification ATEX II GD EEx ia IIC/IIB
Please note the attached safety instructions containing important information on installation and operation in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex approved instruments.
4 VEGATOR 536 Ex
Product description
Electrical connection
Mounted into
- carrier BGT 596 Ex 33-pole multipoint connector, series F (d, b, z)
- in housing type 505 Ex screw terminal, max. for 1,5 mm
with coding holes
2
CE-conformity
VEGATOR 536 Ex signal conditioning instrument meets the protective regulations of EMVG (89/336/EWG) and NSR (73/23/EWG). The conformity has been judged acc. to the following standards: EMVG Emission EN 50 081 - 1: 1993
Susceptibility EN 50 082 - 2: 1995
NSR EN 61 010 - 1: 1993

1.3 Dimensions

Circuit board 100 x 160 x 1,5 European size
Multiple plug
100
5 TE
128,4 (3 HE)
on
5,5
9 15
VEGATOR 536 Ex 5
3
162
25,4

2 Mounting

VEGATOR can be either mounted with a module in a carrier BGT 596 or in a single housing type 505.
Mounting
Mounting single housing
Module (33)
for VEGATOR 536 Multipoint connector DIN 41 612, series F, 33­pole (d, b, z) with coded pin and mounting material for mounting in carrier BGT 596.
Module-Ex (33 Ex)
for VEGATOR 536 Ex Multipoint connector DIN 41 612, series F, 33­pole (d, b, z) with coded pin and mounting material for mounting in carrier BGT 596 Ex.
Single housing
Plastic housing type 505 for single mounting of signal conditioning instruments with an instrument width of 5 TE (25,4 mm).
Mounting carrier
Mount the appropriate module (standard or Ex-version) to your carrier BGT 596. Please wire the connections of the multiple plug according to the connection plans on the following pages.
The multipoint connection 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
2
You can either screw the socket directly to your mounting plate or plug on 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 plans on the following pages. For further information concerning mounting, see the operation in­structions of the housing.
Transparent cover
The front plate of VEGATOR can be provided with a lockable transparent cover to protect the instrument against unauthorised adjust­ment. The cover is attached to the instrument.
For further information concerning mounting, please see the operating instructions of the carrier.
6 VEGATOR 536 Ex
Mounting
Coding
The multiple plug of the instrument is pro­vided with one or several coding holes to avoid the interchanging of different instru­ments.
A fixed coded pin on the Ex-module ensures that only the Ex-instrument can be inserted.
Two additional coded pins are attached to the module to avoid the interchanging of differ­ent instruments. Insert the attached coded pins into the appropriate holes on the multipoint connector. The coded pins must be inserted in the following positions:
Instrument Ex-coding coding
VEGATOR 536 a17 / c7 ––
VEGATOR 536 Ex a17 / c7 c23
z b d
a c
o 1 o o 3 o o 5 o o 7 o o 9 o o11o o13o o15o
VEGATOR 536
o17o o19o o21o o23o o25o o27o o29o o31o
Fig. 2.8 Module 33 (Ex)
c7
c23
VEGATOR
Ex-coding
Ex-version
Ex-separating chamber
To ensure sufficient air and creeping dis­tances, an Ex-separating chamber must be mounted to the VEGATOR connections. Loop the lines through the Ex-separating chamber and connect the lines. Fasten the Ex-separat­ing chamber with the lower hold screw. Please note the operating instructions of the BGT 596 carrier.
Mounting in carriers
When mounting VEGATOR with Ex-approval in a carrier, you have to use a VEGA-Ex­module. Keep a distance of at least 10 mm (2 TE) to module cards of other manufacturers. If you want to mount VEGATOR in the far left position in the carrier, you have to mount a blind cover of at least 20 mm (4 TE) first, and then you can mount the instrument module.
2
on
VEGATOR
Blind cover
Protection in Ex-applications
In Ex-applications, a protection of IP 20 should be maintained. Cover the gaps or free modules at the front by appropriate blind covers.
Fig. 2.9
VEGATOR 536 Ex 7

3 Electrical connection

Electrical connection
Danger
Please switch off the power supply before starting connection. Connect mains voltage according to the following diagram.
When connecting to the supply voltage or reconnecting the sensor, the instrument passes a function test. See also 5.1 Recur­ring test acc. to WHG.
In addition, two transistor outputs are avail­able switching synchronously with the relays.
Reset of alarm functions
Module with multipoint connector acc. to DIN 41 612 for carrier (rear view)
d b z
2 4 6
8 10 12 14 16 18 20 22 24
Ex-separat­ing chamber
26 28 30 32
You can use the fail safe relay of VEGATOR 536 Ex as second level relay for a signaller (horn etc.). To deactivate the connected signaller (horn, lamp etc.) in case of a level alarm (e.g. reaching of the max. permissible level), an additional key (opener) can be connected to VEGATOR 536 Ex. This key can deactivate a level alarm. In case of failure (e.g. line break), the alarm is not deleted.
When the key is connected, the fail safe relay has the same function as the level relay, how­ever the fail safe relay can be reset by pressing the key for reset of alarm functions.
When, on reaching the max. level, e.g. an acoustic warning system is activated, this can be switched off by pressing the key for reset of alarm functions. The second output (level relay) still signals the reaching of the max. level to the processing system.
Note
If very strong electromagnetic interferences are expected, we recommend the use of screened cable. The screening of the cable must only be earthed on one sensor end. The following connection plans show the currentless condition.
Sensor 1
2 3
1
Sensor channel 1
8 VEGATOR 536 Ex
Electrical connection
Double-pole double-throw switch (DPDT)
VEGATOR 536 Ex can also be operated with double-pole double-throw switch output (DPDT). The fail safe relay has the same function as the level relay. To achieve this function, the contacts z16 and z18 (reset of alarm functions) must be bridged.
If you neither need the reset of alarm func­tions nor the function of the double-pole dou­ble-throw switch, the connections Z16 and Z18 will be free.
Level relay
Level relay
Supply voltage
Fail safe transistor
Level transistor
L1 (+) N (–)
d b z
+–
2
6
10 12
+
16
18
+
20
22 24

3.1 Connection plan

All contacts in release condition
d b z
+–
2
6
10 12
+
16
18
+
20
22 24
28
+
30
32
+ –
L1 (+) N (–)
Supply voltage
Fail safe transistor
Level transistor
Fail safe relay
Level relay
Reset of alarm functions
28
+
+ –
30
32
VEGATOR 536 Ex 9

4 Set-up

Indicating and adjustment elements
off
1
1 2 3 4 5 6
on
10
1 Connection plan 2 Lockable screw 3 Test key 1) channel 1 4 LED-level relay 1 5 LED-fault signal channel 1
9
1
2
3
TEST
4 5
on
VEGATOR
6
7
8
6 LED-supply voltage 7 Screw 8 Multiple plug 9 DIL-switch block for channel 1 10 Transparent cover
Set-up
1
536
1)
Recurring test acc. to WHG In accordance with the type approval acc. to WHG (Z-65.11-154, Z-65.11-285) the recurring test acc. to WHG can be carried out by pressing the test key on the VEGATOR signal conditioning instrument. The sensor must neither be removed nor a response be triggered by filling the vessel. This applies to VEGASWING 61Ex, 63Ex, 81AEx and 83AEx with two-wire oscillator SW E60ZEx, SW E82ZEx.
10 VEGATOR 536 Ex
Set-up
Signal lamps
LEDs in the front plate show operation, switching condition and failures.
Green
- Operating control lamp (6)
- Mains voltage on, instrument in operation.
Red
- Failure lamp (5)
- Failure on the individual sensor current circuit by sensor failure or line defect.
- When the fail safe relay is denergised, the red signal lamp lights.
Yellow
- Relay control lamp (4)
- The yellow signal lamp reacts depending on the adjusted mode (A/B).
- The relay control lamps indicate the acti­vated (energised) condition of the relay.
- A dark relay control lamp means that the relay is in denergised condition.
DIL-switch block and potentiometer
The switch on and/or off delay can be ad­justed independently with the switches 2 and
3. The switch on or off delay refers to the switching conditioning of the relay and tran­sistor outputs.
On the illustrated example mode A (max. detection or overfill protection) is selected (switch 1). The switch on delay is activated (switch 3) and the integration time is adjusted to 8 seconds (switch 4, 5 and 6).
sec
0
00
zaze26
sec
12
1 A/B-mode 2 Switch off delay 3 Switch on delay 4 Integration time +2 s 5 Integration time +6 s 6 Integration time +12 s
B- -
123456
A
The integration time can be adjusted appro­priately with the switches 4,5 and 6. The times of the activated time switches. When the switch on (ze) and off delay (za) are switched on at the same time, the adjusted time applies to both delay modes.
Mode and integration time
A DIL-switch block with 6 switches (9) is located on the circuit board of VEGATOR. The individual switches are cordinated as follows: 1 A/B-switch
A - max. detection or overfill protection
B - min. detection or dry run protection 2 Switch off delay 3 Switch on delay 4 Integration time 2 s 5 Integration time 6 s 6 Integration time 12 s
Switch123456 Time za ze 2 s 6 s 12 s
0,2 s A/B off off off off off 0,5 s A/B off off off 2 s A/B on off off 6 s A/B off on off 8 s A/B on on o f f 12 s A/B off off on 14 s A/B on off on
Optionally switch 2 and/
or 3 to "on“. The times
are valid for the appro-
priately adjusted delay
18 s A/B off on on 20 s A/B on on on
mode.
The mode can be adjusted (A - overfill pro­tection or B - dry run protection) with switch 1.
VEGATOR 536 Ex 11
Set-up
Fault monitoring
The measuring system is monitored continu­ously. The following criteria are checked:
- two-wire line on line break and shortcircuit
- interruption of the connection line to the piezoelements
- corrosion or damage of the tuning fork (vibrating rod)
- break age of the tuning fork (vibrating rod)
- stop of vibration
- vibrating frequency too low
- corrosive medium penetrated into the sen­sor
Test key
A function test can be carried out with meas­uring systems in conjunction with two-wire oscillators (VIB E50Z(Ex), SW E60ZEx, SW E82ZEx). The VEGATOR 536 Ex signal conditioning instrument has an integral test key. The test key is lowered in the front plate of the signal conditioning instrument. Press the test key with a suitable object (screwdriver, pen etc.).
By pressing the test the key measuring sys­tem is checked according to the following criteria:
- switching function of the switching outputs
- potential separation of the outputs
- signal processing of the signal conditioning instrument.
After pressing the test key, the complete measuring system is checked for correct function. During the test, the following operat­ing conditions are simulated:
- fault signal
- empty signal (only with VEGASWING)
- full signal.
Check if all three switching conditions occur in the correct sequence and the stated dura­tion. If this is not the case, there is a failure in the measuring system (see 5.2 Failure re­moval).
Please note that the connection instruments are activated during the function test, which means that you can check the correct func­tion of the measuring system.
Due to this fault monitoring, the combination of the following instruments corresponds to classes 1 to 3 (AK 3) acc. to DIN 19 251. AK 3 means that the system is fail safe.
- VEGASWING 61Ex, 63Ex, 81AEx, 83AEx
- SW E60ZEx, SW E82ZEx oscillator
- VEGATOR 536 Ex, 537 Ex, 636 Ex signal conditioning instrument
VEGAVIB also passes the function test, how­ever it is not approved acc. to WHG and AK acc. to DIN 19 251.
Test course A-mode B-mode
1 Simulation of a fault signal (after release of the key approx. 3 s)
1)
Level relay deenergised
Fail safe relay deenergised
2 Simulation of an empty signal (approx. 1,5 s) only with VEGASWING
Level relay energised
Fail safe relay energised
3 Simulation of a full signal (approx. 1,5 s)
Level relay deenergised
Fail safe relay energised
4 Return to the actual operating condition (covered/uncovered)
1)
As long as the test key is pressed, the instrument remains at failure
12 VEGATOR 536 Ex
Diagnosis

5 Diagnosis

5.1 Recurring test acc. to WHG

The implementation of the recurring test acc. to WHG is regulated in the general type ap­proval no. Z-65.11-154, (see item 8 of the certificate).
Note the additional approvals when VEGAS­WING 81A and 83A are used as part of an overfill protection acc. to WHG.
VEGASWING 61Ex, 63Ex, 81AEx and 83AEx with signal conditioning instruments VEGATOR 536 Ex, 537 Ex, 636 Ex meet the fail safe requirements acc. to AK 3 in mode A (overfill protection).
Recurring test acc. to WHG
In accordance with the type approval acc. to WHG (no. Z-65.11-154, Z-65.11-285) the recurring test acc. to WHG can be carried out by pressing the test key on the VEGATOR 536 Ex, 537 Ex, 636 Ex signal conditioning instrument. The sensor must neither be removed, nor should a response be triggered by filling the vessel. This ap­plies to VEGASWING 61, 63, 81AEx and 83AEx with SW E60ZEx and SW E82ZEx the two-wire oscillator.
The implementation and the switching se­quence of the function test is stated under "Test key“ and the following table in the oper­ating instructions of the appropriate VEGATOR signal conditioning instrument.

5.2 Failure removal

Failure Measure, failure removal
The red failure- Check the sensor inputs on the following failures: LED of the signal - shortcircuit on the input conditioning instru­ment lights - sensor not correctly connected
- sensor line interrupted
- supply voltage too low
Check if the sensor is connected correctly.
- Failures on the sensor effecting a current change below 2 mA or above 23 mA, cause a fault signal in the signal conditioning instru­ments.
Measure the current on the connection line to the sensor.
In normal condition, the terminal voltage of the sensor is at least 12 V.
4 … 20 mA 12 … 20 V
mA
+ –
Sensor
V
28
+
+
30
32
VEGATOR series 500
Please note that in Ex-applications, the Ex-protection is not influ­enced by the measuring instruments.
VEGATOR 536 Ex 13
Diagnosis
a. Current value < 2 mA
- Check the supply voltage on the connection line to the sensor. The voltage should be approx. 17 … 20 V. Should you measure a value below 17 V, then this shows a defect in the signal conditioning instrument. In this case please send the in­strument to VEGA for repair.
- Should the red failure lamp continue to light, separate the connection line from the signal conditioning instrument and connect a resistor of 1 k to the sensor inputs of the signal conditioning instrument. If the failure lamp continues to light, the signal conditioning instrument is defective. In this case please return the instrument to VEGA for repair.
- Should the failure lamp extinguish, connect the signal conditioning instrument again. Separate the sensor from the connection line and connect a resistor of 1 kOhm instead .
- Should the failure lamp continue to light, the connection line probably is interrupted. Check the connection line to the sensor.
- When the failure lamp extinguishes, the sensor is defective. Check the connected sensor.
b.Current value > 22 mA
- Check all connections and the connection line to the sensor.
- Should the red failure lamp continue to light, separate the sensor from the connection line and connect a resistor of 1 kΩ instead. If the failure lamp extinguishes, the sensor is defective. Check the connected sensor.
- Should the failure lamp continue to light, connect the sensor again. Separate the signal conditioning instrument from the connection line and connect a resistor of 1 k to the sensor input instead.
- Should the failure lamp continue to light, the signal conditioning instru­ment is defective. In this case please send the instrument to VEGA for repair.
- When the failure lamp extinguishes, there is probably a shortcircuit in the connection line. Check the connection line to the sensor.
Malfunction during After pressing the test key, the switching conditions are not in the function test correct sequence or of the correct duration, e.g. a full signal is not
triggered.
- Measure the line resistance When the line is high-resistance, you have to reduce it to a standard resistor by appropriate measures. Check for example terminals and cable connections for corrosion.
14 VEGATOR 536 Ex
VEGATOR 536 Ex 15
VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone 07836 50-0 Fax 07836 50-201 E-mail info@de.vega.com
www.vega.com
ISO 9001
The statements on types, application, use and operating conditions of the sensors and processing systems correspond to the actual knowledge at the date of printing.
Technical data subject to alteration.
23460-EN-030718
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