VEGA TOR632 User Manual
Operating Instructions
VEGATOR 632
Signal conditioning instrument
Document ID:
35243
conditioning instruments
and communication
Signal
Contents
Contents
1 About this document
1.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Symbolism used . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 For your safety
2.1 Authorised personnel . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Warning about misuse . . . . . . . . . . . . . . . . . . . . . . .
2.4 General safety instructions . . . . . . . . . . . . . . . . . . . .
2.5 CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Safety instructions for Ex areas . . . . . . . . . . . . . . . . .
2.7 Environmental instructions. . . . . . . . . . . . . . . . . . . . .
3 Product description
3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Packaging, transport and storage . . . . . . . . . . . . . . .
4 Mounting
4.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Instructions for installation . . . . . . . . . . . . . . . . . . . . .
5 Connecting to power supply
5.1 Preparing the connection . . . . . . . . . . . . . . . . . . . . .
5.2 Connection procedure. . . . . . . . . . . . . . . . . . . . . . . .
5.3 Wiring plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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10
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12
13
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6 Adjustment elements
6.1 Adjustment elements - Overview . . . . . . . . . . . . . . . .
7 Set up - Single channel control (level detection)
7.1 Adjust relay function . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Adjust switching delay . . . . . . . . . . . . . . . . . . . . . . .
7.4 Activate line break monitoring . . . . . . . . . . . . . . . . . .
7.5 Master/Slave function . . . . . . . . . . . . . . . . . . . . . . . .
8 Set up - Two-point control Δs (pump control)
8.1 Adjust relay function . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Adjust switching delay . . . . . . . . . . . . . . . . . . . . . . .
8.4 Activate line break monitoring . . . . . . . . . . . . . . . . . .
8.5 Master/Slave function . . . . . . . . . . . . . . . . . . . . . . . .
9 Set up - Two-channel control
9.1 Adjust relay function . . . . . . . . . . . . . . . . . . . . . . . . .
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35243-EN-120228
Contents
9.2 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Adjust switching delay . . . . . . . . . . . . . . . . . . . . . . .
9.4 Activate line break monitoring . . . . . . . . . . . . . . . . . .
9.5 Master/Slave function . . . . . . . . . . . . . . . . . . . . . . . .
10 Set up - Four-channel control
10.1 General information . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Adjust relay function . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Adjust switching delay . . . . . . . . . . . . . . . . . . . . . . .
10.5 Activate line break monitoring . . . . . . . . . . . . . . . . . .
10.6 Master/Slave function . . . . . . . . . . . . . . . . . . . . . . . .
11 Switching examples
11.1 Single channel operation. . . . . . . . . . . . . . . . . . . . . .
11.2 Two-channel operation . . . . . . . . . . . . . . . . . . . . . . .
11.3 Two-point control . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Four-channel operation . . . . . . . . . . . . . . . . . . . . . . .
11.5 Two-point control and two-channel operation . . . . . . .
12 Maintenance and fault rectification
12.1 Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Remove interferences . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Instrument repair . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Dismounting
13.1 Dismounting steps . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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14 Supplement
14.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery. You can find them listed in chapter "Product
description".
Editing status: 2012-02-20
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 3
54
1 About this document
1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important
instructions for maintenance and fault rectification. Please read this
information before putting t he instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained qualified
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbolism used
Information, tip, note
This symbol indicates helpful additional information.
Caution: If this warning is ignored, faults or malfunctions can
result.
Warning: If this warning is ignored, injury to persons and/or serious
damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
l List
The dot set in front indicates a list with no implied sequence.
à Action
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
4 VEGATOR 632 • Signal conditioning instrument
35243-EN-120228
2 For your safety
2 For your safety
2.1 Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2 Appropriate use
VEGATOR 632 is a universal signal conditioning instrument for
connection of a level switch.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbitrary
conversions or modifications are explicitly forbidden.
2.3 Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards, e.g. vessel overfill or damage to system
components through incorrect mounting or adjustment.
2.4 General safety instructions
This is a high-tech instrument requiring the strict observance of
standard regulations and guidelines. The user must take note of the
safety instructions in this operating instructions manual, the countryspecific installation standards as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition. The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 5
2 For your safety
2.5 CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines. By attaching the CE mark, VEGA provides a confirmation
of successful testing. You can find the CE conformity declaration in the
download area of
www.vega.com.
2.6 Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas. These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
2.7 Environmental instructions
Protection of the environment is one of our most important duties. That
is why we have introduced an environment management system with
the goal of continuously improving company environmental protection.
The environment management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
l Chapter "Packaging, transport and storage"
l Chapter "Disposal"
6 VEGATOR 632 • Signal conditioning instrument
35243-EN-120228
3 Product description
1
1
3.1 Structure
3 Product description
Scope of delivery
Constituent parts
Type label
The scope of delivery encompasses:
l VEGATOR 632 signal conditioning instrument
l Documentation
- this operating instructions manual
- Ex-specific "Safety instructions" (with Ex-versions)
- if necessary, further certificates
VEGATOR 632 consists of:
l VEGATOR 632 signal conditioning instrument
Fig. 1: VEGATOR 632
1 Pluggable terminal blocks
The type label contains the most important data for identification and
use of the instrument:
l Article number
l Serial number
l Technical data
l Article numbers, documentation
l Information about connection and adjustment of the instrument
The serial number allows you to access the delivery data of the
instrument via www.vega.com, "VEGA Tools" and "serial number
search".
3.2 Principle of operation
Application area
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 7
VEGATOR 632 is a single signal conditioning instrument with two
channels (relay) for processing the signals of conductive probes.
3 Product description
Functional principle
The following switching functions are possible:
l Single channel control (simple level detection)
l Two-point control (pump control)
l Two-channel control (two separate switching points)
l Four-channel control or combination of two-point and two-channel
control (with two VEGATOR 632)
The VEGATOR 632 signal conditioning instrument powers connected
sensors and simultaneously processes their measuring signals.
It delivers a small alternating current to the measuring cell via the
signal cable. Electrolytic decomposition of the electrode rods and the
medium is avoided by using alternating current.
The cable is connected to the measurement loop or the metallic vessel
and the probe.
When the medium reaches the switching point of the sensor, the
voltage on the sensor drops. The output relays then switch according
to the set mode.
Voltage supply
Packaging
Transport
Transport inspection
Detailed information about the power supp ly can be found in chapter
"Technical data".
3.3 Operation
The damping and the mode can be adjusted on the signal conditioning
instrument via the slide switch. The instrument function can be
preadjusted with a DIL switch block.
The switching point can be adjusted with a potentiometer.
3.4 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environmentfriendly, recyclable cardboard. For special versions, PE foam or PE foil
is also us ed. Dispose of the packaging material via specialised
recycling companies.
Transport must be carried out under consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or
concealed defects must be appropriately dealt with.
35243-EN-120228
8 VEGATOR 632 • Signal conditioning instrument
3 Product description
Storage
Storage and transport
temperature
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
l Not in the open
l Dry and dust free
l Not exposed to corrosive media
l Protected against solar radiation
l Avoiding mechanical shock and vibration
l Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
l Relative humidity 20 … 85 %
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 9
a
a
a
? ? ? ? ?
E
X
E
X
E
X
4 Mounting
4 Mounting
4.1 General instructions
Installation location
Front plate
Protected mounting lo-
cation
Installation
Min. distances
VEGATOR 632 signal conditioning instrument for mounting on carrier
rail according to EN 60715 TH 35 x 7.5 or EN 60715 TH 35 x 15.
The adjustment elements of VEGATOR 632 are protected under a
hinged front plate against unauthorised or inadvertent adjustment.
VEGATOR 632 must be mounted outside the hazardous area in a
switching cabinet (at least protection rating IP 55).
For moisture-protected mounting outside the switching cabinet, we
offer an insulated protective housing with transparent cover (IP 65) for
surface mounting.
4.2 Instructions for installation
A VEGATOR 632 in Ex version is an auxiliary, intrinsically safe
instrument and may not be installed in explosion-endangered areas.
Please keep the following min. distances when mounting.
Fig. 2: Min. distances to other instruments
a Distance ≥ 50 mm (1.97 in)
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35243-EN-120228
1
1
2
b
b
a
a
4 Mounting
Carrier rail mounting
Dismounting
Snap in the instrument vertically on a suitable carrier rail (EN 60715
TH 35 x 7.5 or EN 60715 TH 35 x 15).
Fig. 3: Mounting of the signal conditioning instrument
1 Carrier rail EN 60715 TH 35
Dismount the instrument in the following sequence.
1 Switch off power supply
Fig. 4: Dismounting of the signal conditioning instrument
2 Remove the terminal blocks with a screwdriver ①
3 Open the slide with a screwdriver ②
4 Flip up the signal conditioning instrument and remove it from the
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 11
carrier rail
5 Connecting to power supply
5 Connecting to power supply
5.1 Preparing the connection
Note safety instructions
Take note of sa-
fety instructions
for Ex applications
Select power supply
Selecting connection
cable
Cable screening and
grounding
Always keep in mind the following safety instructions:
l Connect only in the complete absence of line voltage
l If overvoltage surges are expected, overvoltage arresters should
be installed
Tip:
We recommend VEGA overvoltage arresters B61-300 (power supply
VEGATOR 632) and B62-36G (sensor supply).
In hazardous areas you must take note of the respective regulations,
conformity and type approval certificates of the sensors and power
supply units.
The power supply can be 85 … 253 V AC, 50/60 Hz or 20 … 60 V DC.
The operating voltage of VEGATOR 632 is connected with standard
cable according to the national installation standards. The line
resistance must be max. 25 Ω per wire. If electromagnetic interference
is expected which is above the test values of EN 61326 for industrial
areas, screened cable should be used.
If screened cable is necessary, connect the cable screen on both ends
to ground potential. In the sensor, the screen must be connected
directly to the internal ground terminal. The ground terminal on the
outside of the housing must be connected to the potential equalisation
(low impedance).
If potential equalisation currents are expected, the connection on the
processing side must be made via a ceramic capacitor (e. g. 1 nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed, but the protective effect against high frequency interference si gnals remains.
Select connection cable for Ex
applications
12 VEGATOR 632 • Signal conditioning instrument
Take note of the corresponding installation regulations for Ex
applications.
35243-EN-120228
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
1 2 3 4
5
6 7
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
5 Connecting to power supply
5.2 Connection procedure
Fig. 5: Terminal assignment
1 Ground
2 Sensor input - Channel 1 (CH 1)
3 Sensor input - Channel 2 (CH 2)
4 Master/Slave
5 Level relay 1
6 Voltage supply
7 Level relay 2 or operating relay
Move on to electrical connection and proceed as follows:
1 Snap VEGATOR 632 onto the carrier rail
2 Connect the sensor cable to terminals 7 to 10 (see the following
wiring plans)
3 Connect relay outputs (4 to 6 and 15 to 17)
4 Connect power supply (switched off) to terminal 1 and 2
The electrical connection is finished.
5.3 Wiring plan
Note:
In conductive vessels, the ground cable has contact to the grounded
vessel via the process fitting.
In non-conductive vessels, the probe requires a ground rod which is
connected to the ground terminal of VEGATOR 632.
Line monitoring
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VEGATOR 632 • Signal conditioning instrument 13
The line break monitoring or alarm function defines the function of the
signal conditioning instrument in case of failure.
The line monitoring is required for probes with approval according to
WHG (WRA) or Ex.
To realize a line monitoring, an additional electronics must be
integrated in the connection housing of the probe.
1
2
5 Connecting to power supply
Fig. 6: Additional electronics for line break monitoring in conjunction with a
conductive probe
1 Connect the eyelet according to the following illustration.
Make sure that the eyelets have no contact to other metal parts.
2 Open one of the other terminals and attach the additional
electronics.
3 Tighten the terminal.
Fig. 7: Mounting of the additional electronics for line break monitoring
1 Connection to terminal 1 (ground rod = longest rod)
2 Connection to terminal 2 (max. rod = shortest rod)
3 Additional electronics for line break monitoring
If you are using a probe without additional electronics for line break
monitoring, a fault signal will be triggered.
Keep in mind that in case of a fault signal also the switching output will
be activated.
Only failures of channel 1 are monitored.
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35243-EN-120228
1 2
2
1
6
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
3
5
4
Level detection in conductive vessels
5 Connecting to power supply
Take note of the operating instructions of the conductive probe.
Fig. 8: Level detection in metallic (conductive) vessels
1 Ground
2 max. - channel 1 (CH 1)
3 Level relay 1
4 Level relay 2 or fail safe relay
5 Voltage supply
6 Probe, e.g. EL1
You can find detailed information under "Set up - Single point control"
as well as under "Switching examples".
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VEGATOR 632 • Signal conditioning instrument 15
1
2
2
1
6
1
2
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
3
5
4
5 Connecting to power supply
Level detection in nonconductive vessels
Fig. 9: Level detection in non-conductive vessels
1 Ground
2 max. - channel 1 (CH 1)
3 Level relay 1
4 Level relay 2 or fail safe relay
5 Voltage supply
6 Probe, e.g. EL3
You can find detailed information under "Set up - Single point control"
as well as under "Switching examples".
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35243-EN-120228
1 3
2
2
3
1
7
1
2
3
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
4
6
5
Two-point control (min./
max. control)
5 Connecting to power supply
Fig. 10: Two-point control
1 Ground
2 max. - channel 1 (CH 1)
3 min. - channel 2 (CH 2)
4 Level relay 1
5 Level relay 2 or fail safe relay
6 Voltage supply
7 Probe, e.g. EL3
You can find detailed information under "Set up - Two-point control" as
well as under "Switching examples".
35243-EN-120228
VEGATOR 632 • Signal conditioning instrument 17
1
2 3
4
5
1
4
2
5
3
3
4
5
1
9
A B
2
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
6
8
7
1
2
15
16
4
5
6
17
7
8
9
10
4
5
6
17
TOR
149A
ON
L1L+N
L–
7 8 9 10
4 5 6 17
1 2
15 16
CH2
CH1
Master/
Slave
6
8
7
5 Connecting to power supply
Four-channel control
with two signal conditioning instruments
Fig. 11: Four-channel control with two signal conditioning instruments VEGATOR
632
1 Ground
2 max. - channel 1 (CH 1)
3 min. - channel 2 (CH 2)
4 min. - channel 2 (CH 2)
5 max. - channel 1 (CH 1)
6 Level relay 1
7 Level relay 2 or fail safe relay
8 Voltage supply
9 Probe, e.g. EL3
A Min./max. control (signal conditioning instrument 1 - Master)
B Min./max. control (signal conditioning instrument 2 - Slave)
You can find detailed information under "Set up - Four-channel control"
as well as under "Switching examples".
18 VEGATOR 632 • Signal conditioning instrument
35243-EN-120228
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