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Vega VEGAPULS 63 Operating Instructions Manual

Radar sensor for continuous level measurement of liquids
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Operating Instructions

Radar sensor for continuous level
measurement of liquids
VEGAPULS 63
HART and accumulator pack
Document ID: 40794

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Summary of Contents for Vega VEGAPULS 63

  • Page 1: Operating Instructions

    Operating Instructions Radar sensor for continuous level measurement of liquids VEGAPULS 63 HART and accumulator pack Document ID: 40794...

  • Page 2: Table Of Contents

    Field Communicator 375, 475 ..................44 Diagnosis, asset management and service Maintenance ........................45 Measured value and event memory ................45 Asset Management function ................... 46 Rectify faults ........................49 Exchanging the electronics module ................52 VEGAPULS 63 • HART and accumulator pack...
  • Page 3 11.2 Dimensions ........................61 Safety instructions for Ex areas Please note the Ex-specific safety information for installation and op- eration in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex-approved instruments. Editing status: 2014-09-04 VEGAPULS 63 • HART and accumulator pack...

  • Page 4: About This Document

    This arrow indicates a single action. Sequence of actions Numbers set in front indicate successive steps in a procedure. Battery disposal This symbol indicates special information about the disposal of bat- teries and accumulators. VEGAPULS 63 • HART and accumulator pack...

  • Page 5: For Your Safety

    During work on and with the device the required personal protective equipment must always be worn. Appropriate use The VEGAPULS 63 is a sensor for continuous level measurement. Due to the integrated accumulator the instrument is particularly suitable as a portable measuring system or test sensor for special applications.

  • Page 6: Ce Conformity

    That is why we have introduced an environment management system with the goal of continuously improving company environmental pro- tection. The environment management system is certified according to DIN EN ISO 14001. Please help us fulfill this obligation by observing the environmental instructions in this manual: • Chapter "Packaging, transport and storage" VEGAPULS 63 • HART and accumulator pack...
  • Page 7 2 For your safety • Chapter "Disposal" VEGAPULS 63 • HART and accumulator pack...

  • Page 8: Product Description

    Operating instructions and quick setup guide at the time of ship- ment (PDF) • Order-specific sensor data for an electronics exchange (XML) • Test certificate (PDF) - optional Go to www.vega.com, "VEGA Tools" and "Instrument search". Enter the serial number. Alternatively, you can access the data via your smartphone: VEGAPULS 63 • HART and accumulator pack...

  • Page 9: Principle Of Operation

    Software from 4.5.1 Principle of operation Application area The VEGAPULS 63 is a radar sensor for continuous level measure- ment of aggressive liquids or with hygienic requirements. It is suitable for applications in storage tanks, process vessels, dosing vessels and reactors.

  • Page 10: Packaging, Transport And Storage

    The display and adjustment module PLICSCOM is used for measured value indication, adjustment and diagnosis. It can be inserted into the sensor or the external display and adjustment unit and removed at any time. You can find further information in the operating instructions "Display and adjustment module PLICSCOM" (Document-ID 27835). VEGAPULS 63 • HART and accumulator pack...
  • Page 11 You can find further information in the operating instructions "Elec- tronics module VEGAPULS series 60" (Document-ID 36801). Supplementary electron- The supplementary electronics "Power pack" is a replacement part for ics power pack sensors with integrated accumulator. You can find further information in the operating instructions "Sup- plementary electronics for 4 … 20 mA/HART and power pack" (Document-ID 41033). VEGAPULS 63 • HART and accumulator pack...

  • Page 12: Mounting

    The PTFE washer of the antenna encapsulation serves also as process seal. To compensate the normal prestress loss due to the seal materials, you have to use also disc springs in addition to the flange screws for fastening PTFE plated flanges. We recommend flexible retaining washers (e.g. Schnorr VS or S) or detent edged rings (e.g. Gross VS KD). VEGAPULS 63 • HART and accumulator pack...
  • Page 13 The emitted radar impulses of the radar sensor are electromagnetic Polarisation waves. The polarisation is the direction of the electrical wave compo- nent. By turning the instrument in the connection flange or mounting boss, the polarisation can be used to reduce the effects of false echoes. The position of the polarisation is marked on the process fitting of the instrument. Fig. 3: Position of the polarisation Marking hole VEGAPULS 63 • HART and accumulator pack...
  • Page 14 4 Mounting Installation position When mounting the VEGAPULS 63, keep a distance of at least 200 mm (7.874 in) to the vessel wall. If the sensor is installed in the center of dished or round vessel tops, multiple echoes can arise.
  • Page 15 Fig. 7: Deviating socket dimensions The below charts specify the max. socket length h depending on the diameter d. Socket diameter d Socket length h 50 mm ≤ 100 mm 80 mm ≤ 300 mm 100 mm ≤ 400 mm VEGAPULS 63 • HART and accumulator pack...
  • Page 16 Small, inclined sheet metal baffles above the installations scatter the radar signals and prevent direct interfering reflections. Fig. 9: Cover flat, large-area profiles with deflectors Agitators If there are agitators in the vessel, a false signal storage should be carried out with the agitators in motion. This ensures that the interfer- ing reflections from the agitators are saved with the blades in different positions. VEGAPULS 63 • HART and accumulator pack...

  • Page 17: Measurement Setup - Pipes

    Under these prerequisites, the measurement of products with low dielectric values (ε value ≤ 1.6) is possible. Note the following illustrations and instructions for measurement in a surge pipe. Information: Measurement in a surge pipe is not recommended for extremely adhesive products. VEGAPULS 63 • HART and accumulator pack...
  • Page 18 4 Mounting Configuration surge pipe 100% Fig. 11: Configuration surge pipe VEGAPULS 63 Radar sensor Polarisation marking 3 Thread or flange on the instrument Vent hole Holes 6 Welding connection through U-profile Ball valve with complete opening Surge pipe end 9 Reflector sheet 10 Fastening of the surge pipe VEGAPULS 63 • HART and accumulator pack...
  • Page 19 • A false signal suppression with the installed sensor is recom- mended but not mandatory • The measurement through a ball valve with unrestricted channel is possible VEGAPULS 63 • HART and accumulator pack...
  • Page 20 • An extension via welding neck flanges or pipe collars is not recom- mended. Measurement in the An alternative to measurement in a surge pipe is measurement in a bypass tube bypass tube outside of the vessel. VEGAPULS 63 • HART and accumulator pack...
  • Page 21 • A false signal suppression with the installed sensor is recom- mended but not mandatory • The measurement through a ball valve with unrestricted channel is possible VEGAPULS 63 • HART and accumulator pack...
  • Page 22 Flanges are welded to the tube according to the orientation of the polarisation • Gap size with junctions ≤ 0.1 mm, for example, when using a ball valve or intermediate flanges with single pipe sections • The antenna diameter of the sensor should correspond to the inner diameter of the tube • Diameter should be constant over the complete length VEGAPULS 63 • HART and accumulator pack...

  • Page 23: Connecting To Power Supply

    Fig. 14: Position of the power supply and electronics compartment Supply room (accumulator) 2 Electronics compartment Electronics compartment 4...20mA 6 7 8 Fig. 15: Electronics compartment, double chamber housing Internal connection to the terminal compartment Contact pins for the display and adjustment module VEGAPULS 63 • HART and accumulator pack...

  • Page 24: Switch-On Phase

    After pressing the key or changing the mode the yellow LED shows the accumulator status for approximately 10 s as follows: • LED lights = accumulator is full • LED flashes = accumulator should be charged • LED off = accumulator is empty Switch-on phase The instrument is switched on and off by means of a button outside on the housing. VEGAPULS 63 • HART and accumulator pack...
  • Page 25 PC As soon as a plausible measured value is found, it is displayed. The value corresponds to the actual level as well as the settings already carried out, e.g. factory settings. VEGAPULS 63 • HART and accumulator pack...

  • Page 26: Set Up With The Display And Adjustment Module

    The display and adjustment module is powered by the sensor, an ad- ditional connection is not necessary. Fig. 18: Insertion of the display and adjustment module Note: If you intend to retrofit the instrument with a display and adjustment module for continuous measured value indication, a higher cover with an inspection glass is required. VEGAPULS 63 • HART and accumulator pack...

  • Page 27: Adjustment System

    Approx. 60 minutes after the last pressing of a key, an automatic reset to measured value indication is triggered. Any values not confirmed with [OK] will not be saved. Parameter adjustment The instrument is adapted to the application conditions via the pa- rameter adjustment. The parameter adjustment is carried out with an adjustment menu. VEGAPULS 63 • HART and accumulator pack...
  • Page 28 To adapt the sensor to these different measuring conditions, the selection "Liquid" or "Bulk solid" should be made in this menu item. Through this selection, the sensor is adapted perfectly to the product and measurement reliability, particularly in products with poor reflec- tive properties, is considerably increased. VEGAPULS 63 • HART and accumulator pack...
  • Page 29 Installations: small laterally mounted or large top mounted stirrer • Process/measurement conditions: – Relatively smooth product surface – High requirements to the measurement accuracy – Condensation – Slight foam generation – Overfilling possible • Properties, sensor: VEGAPULS 63 • HART and accumulator pack...
  • Page 30 • Process/measurement conditions: – Condensation, buildup on the antenna – Foam generation • Properties, sensor: – Measurement speed optimized by virtually no averaging – Sporadic false echoes are suppressed – False signal suppression recommended Standpipe: • Product speed: very fast filling and emptying • Vessel: VEGAPULS 63 • HART and accumulator pack...
  • Page 31 – False signals outside the vessel are not taken into consideration – False signal suppression recommended Transportable plastic tank: • Vessel: – Material and thickness different – Measurement through the vessel top • Process/measurement conditions: – Measured value jump with vessel change • Properties, sensor: VEGAPULS 63 • HART and accumulator pack...
  • Page 32 – Sensor accepts all measured value changes within the measur- ing range immediately – High sensitivity against interferences, because virtually no averaging Caution: If liquids with different dielectric constants separate in the vessel, for example through condensation, the radar sensor can detect under VEGAPULS 63 • HART and accumulator pack...
  • Page 33 – Large angles of repose • Properties, sensor: – Lower averaging – Very high measured value jumps are accepted Heap: • Sensor mounting on movable conveyor belts • Detection of the heap profile • Height detection during filling • Process/measurement conditions: VEGAPULS 63 • HART and accumulator pack...
  • Page 34 [OK] and jump to the next menu item with the [ESC] and the [->] key. Setup - Vessel form Also the vessel form can influence the measurement apart from the medium and the application. To adapt the sensor to these measure- VEGAPULS 63 • HART and accumulator pack...
  • Page 35 These settings can be made ahead of time without the instrument having to be installed. Setup - Min. adjustment Proceed as follows: VEGAPULS 63 • HART and accumulator pack...
  • Page 36 4. Enter the appropriate distance value in m (corresponding to the percentage value) for the full vessel. Keep in mind that the max. level must lie below the min. distance to the antenna edge. VEGAPULS 63 • HART and accumulator pack...
  • Page 37 Management functions it is absolutely necessary. If possible, the curve should be saved with a low level in the vessel. With the adjustment software PACTware and the PC, the high resolu- tion echo curve can be displayed and used to recognize signal VEGAPULS 63 • HART and accumulator pack...
  • Page 38 1. Select with [->] the menu item "False signal suppression" and confirm with [OK]. 2. Confirm again with [OK]. 3. Confirm again with [OK]. 4. Confirm again with [OK] and enter the actual distance from the sensor to the product surface. 5. All interfering signals in this section are detected by the sensor and stored after confirming with [OK]. VEGAPULS 63 • HART and accumulator pack...
  • Page 39 Additional adjustments When a reset is carried out, all settings (with only a few exceptions) - Reset are reset. The exceptions are: PIN, language, lighting, SIL and HART mode. VEGAPULS 63 • HART and accumulator pack...
  • Page 40 "Technical data" in the supplement Max. adjustment 0,000 m(d) Damping 0.0 s Current output 4 … 20 mA, < 3.6 mA mode Current output Min. current 3.8 mA, max. current Min./Max. 20.5 mA Lock adjustment Released VEGAPULS 63 • HART and accumulator pack...

  • Page 41: Saving The Parameter Adjustment Data

    If it is necessary to exchange a sensor, the display and adjustment module is inserted into the replacement instrument and the data are likewise written into the sensor via the menu item "Copy sensor data". VEGAPULS 63 • HART and accumulator pack...

  • Page 42: Setup With Pactware

    Further setup steps are described in the operating instructions manu- al "DTM Collection/PACTware" attached to each DTM Collection and which can also be downloaded from the Internet. Detailed descrip- tions are available in the online help of PACTware and the DTMs. VEGAPULS 63 • HART and accumulator pack...

  • Page 43: Saving The Parameter Adjustment Data

    The standard version is available as a download under www.vega.com/downloads and "Software". The full version is avail- able on CD from the agency serving you. Saving the parameter adjustment data We recommend documenting or saving the parameter adjustment data via PACTware.

  • Page 44: Set Up With Other Systems

    This software is updated via the Internet and new EDDs are automatically taken over into the device catalogue of this software after they are released by the manufacturer. They can then be transferred to a Field Communicator. VEGAPULS 63 • HART and accumulator pack...

  • Page 45: Diagnosis, Asset Management And Service

    Changes in the measure- ment conditions during operation or buildup on the sensor can thus be recognized. The echo curve of the setup is stored via: • PC with PACTware/DTM • Control system with EDD • Display and adjustment module VEGAPULS 63 • HART and accumulator pack...

  • Page 46: Asset Management Function

    This status message is inactive by default. It can be activated by the user via PACTware/DTM or EDD. Maintenance: Due to external influences, the instrument function is limited. The measurement is affected, but the measured value is still valid. Plan in maintenance for the instrument because a failure is expected in the near future (e.g. due to buildup). VEGAPULS 63 • HART and accumulator pack...
  • Page 47 F260 – Error in the calibration car- – Exchanging the electronics ried out in the factory – Send instrument for repair Error in the – Error in the EEPROM calibration VEGAPULS 63 • HART and accumulator pack...
  • Page 48 – if necessary, increase Impermissi- operating voltage ble operating voltage Maintenance The following table shows the error codes and text messages in the status message "Maintenance" and provides information on causes as well as corrective measures. VEGAPULS 63 • HART and accumulator pack...

  • Page 49: Rectify Faults

    • Checking the output signal • Treatment of measurement errors Further comprehensive diagnostics options are available with a PC with PACTware and the suitable DTM. In many cases, the reasons can be determined in this way and faults rectified. VEGAPULS 63 • HART and accumulator pack...
  • Page 50 – Amplitude or position of a false – Determine the reason for the signal has changed (e.g. con- changed false signals, carry out densation, buildup); false signal false signal suppression, e.g. suppression no longer matches with condensation actual conditions VEGAPULS 63 • HART and accumulator pack...
  • Page 51 – Remove contamination on the sensor goes into overfill protec- time antenna tion mode. The max. level (0 m – Use a sensor with a more suit- distance) as well as the status able antenna message "Overfill protection" are outputted. VEGAPULS 63 • HART and accumulator pack...

  • Page 52: Exchanging The Electronics Module

    24 hour service hotline Should these measures not be successful, please call in urgent cases the VEGA service hotline under the phone no. +49 1805 858550. The hotline is also available outside normal working hours, seven days a week around the clock.

  • Page 53: Software Update

    Clean the instrument and pack it damage-proof • Attach the completed form and, if need be, also a safety data sheet outside on the packaging • Please contact the agency serving you to get the address for the return shipment. You can find the agency on our home page www.vega.com. VEGAPULS 63 • HART and accumulator pack...

  • Page 54: Dismount

    Unscrew the cover of the supply room • Loosen the plug connector • Loosen the fixing screws • Pull out the complete insert by means of the plastic strap Correct disposal avoids negative effects on humans and the environ- ment and ensures recycling of useful raw materials. VEGAPULS 63 • HART and accumulator pack...

  • Page 55: Supplement

    Max. torque for NPT cable glands and Conduit tubes Ʋ Plastic housing 10 Nm (7.376 lbf ft) Ʋ Aluminium/Stainless steel housing 50 Nm (36.88 lbf ft) Input variable Measured variable The measured quantity is the distance between process fitting of the sensor and product surface. The reference plane is the seal surface on the process fitting or the lower side of the flange. VEGAPULS 63 • HART and accumulator pack...
  • Page 56 45 … 75 % Ʋ Air pressure 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) Installation reference conditions Ʋ Min. distance to internal installations > 200 mm (7.874 in) Ʋ Reflector Flat plate reflector VEGAPULS 63 • HART and accumulator pack...
  • Page 57 180 °C/356 °F 0.17 % 2.1 % 264 °C/507 °F 0.12 % 1.44 % 9.2 % 366 °C/691 °F 0.07 % 1.01 % 5.7 % 13.2 % 76 % Characteristics and performance data Measuring frequency K-band (26 GHz technology) VEGAPULS 63 • HART and accumulator pack...
  • Page 58 Time span after a sudden measuring distance change by max. 0.5 m in liquid applications, max 2 m with bulk solids applications, until the output signal has taken for the first time 90 % of the final value (IEC 61298-2). Outside the specified beam angle, the energy of the radar signal is reduced by 50 % (-3 dB) EIRP: Equivalent Isotropic Radiated Power VEGAPULS 63 • HART and accumulator pack...
  • Page 59 Ʋ Yellow LED in the supply room Indication of the charging condition Adjustment elements Ʋ Rotary switch in the supply room Selection of the mode Ʋ Button outside on the housing Switching on and off Integrated clock Date format Day.Month.Year VEGAPULS 63 • HART and accumulator pack...
  • Page 60 IP 66/IP 68 (0.2 bar), NEMA 6P housing - investment casting, stain- less steel housing - electro-polished Overvoltage category The prerequisites for maintaining the protection rating are a suitable cable as well as correct mounting. IEC 61010-1 VEGAPULS 63 • HART and accumulator pack...

  • Page 61: Dimensions

    11 Supplement Protection class 11.2 Dimensions The following dimensional drawings represent only an extract of all possible versions. Detailed dimensional drawings can be downloaded at www.vega.com/downloads under "Drawings". Housing ~ 87 mm ~ 84 mm (3.43") ø 84 mm (3.31") ø...
  • Page 62 11 Supplement VEGAPULS 63, flange version ø 44 mm (1.73") ø 75 mm (2.95") Fig. 41: VEGAPULS 63, flange version DN 50 and 2" DN 80 … DN 150 and 3" … 6" Diameter and number of holes in the flange VEGAPULS 63 • HART and accumulator pack...
  • Page 63 11 Supplement VEGAPULS 63, flange version, low temperature ø 44 mm ø 75 mm (1.73") (2.95") Fig. 42: VEGAPULS 63, flange version, low temperature DN 50 and 2" DN 80 … DN 150 and 3" … 6" Diameter and number of holes in the flange VEGAPULS 63 • HART and accumulator pack...
  • Page 64 11 Supplement VEGAPULS 63, hygienic fitting 1 ø 50 mm (1.97") ø 90 mm ø 66 mm (3.54") (2.60") ø 90 mm ø 78 mm (3.07") (3.54") Fig. 43: VEGAPULS 63, hygienic fitting 1 NeumoBiocontrol Tuchenhagen Varivent DN 25 Hygienic fitting LA Hygienic fitting LB VEGAPULS 63 • HART and accumulator pack...
  • Page 65 Clamp 2" (ø 64 mm), 2½" (ø 77.5 mm), 3" (ø 91 mm) according to DIN 32676, ISO 2852/316L 3½" (ø 106 mm), 4½" (ø 119 mm) according to DIN 32676, ISO 2852/316L VEGAPULS 63 • HART and accumulator pack...
  • Page 66 ø 133 mm (5.24") Fig. 45: VEGAPULS 63, hygienic fitting 3 Slotted nut DIN 11851, DN 50, 2" and 3" Slotted nut DIN 11851, DN 80, 4" Slotted nut DIN 11864-2, DN 50 Slotted nut DIN 11864-2, DN 80 VEGAPULS 63 • HART and accumulator pack...
  • Page 67 11 Supplement VEGAPULS 63, hygienic fitting 4 ø 84 mm ø 65 mm (3.31") (2.56") ø 105 mm (4.13") ø 114 mm (4.49") Fig. 46: VEGAPULS 63, hygienic fitting 4 SMS DN 51 SMS DN 76 VEGAPULS 63 • HART and accumulator pack...
  • Page 68 Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellec- tuelle. Pour plus d'informations, on pourra se référer au site www.vega.com. VEGA lineas de productos están protegidas por los derechos en el campo de la propiedad indus- trial. Para mayor información revise la pagina web www.vega.com.
  • Page 69 Linearisation curve 39 Main menu 28 Meas. reliability 37 Measured value memory 45 Measurement in a surge pipe 17 Measurement in the bypass tube 20 NAMUR NE 107 47, 48 Operation – System 27 Overfill protection according to WHG 39 VEGAPULS 63 • HART and accumulator pack...
  • Page 70 Notes VEGAPULS 63 • HART and accumulator pack...
  • Page 71 Notes VEGAPULS 63 • HART and accumulator pack...
  • Page 72 Subject to change without prior notice © VEGA Grieshaber KG, Schiltach/Germany 2014 VEGA Grieshaber KG Phone +49 7836 50-0 Am Hohenstein 113...

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