Guided Microwave

Commissioning Procedures
VEGAFLEX 61
4 … 20 mA/HART two-wire
 Contents

Contents
1 About this document
1.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Symbolism used. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 For your safety

2.1 Authorised personnel . . . . . . . . . . . . . . . . . . . . . . .. 4
2.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
2.3 Warning about misuse . . . . . . . . . . . . . . . . . . . . . .. 4
2.4 General safety instructions . . . . . . . . . . . . . . . . . . .. 4
2.5 Safety label on the instrument . . . . . . . . . . . . . . . . .. 5
2.6 CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
2.7 Fulfillment of NAMUR recommendations . . . . . . . . .. 5
2.8 Safety instructions for Ex areas . . . . . . . . . . . . . . . .. 5
2.9 Environmental instructions. . . . . . . . . . . . . . . . . . . .. 5

3 Installation Check
3.1 PruProductdescription
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
3.2 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Connecting to power supply

4.1 Preparing the connection . . . . . . . . . . . . . . . . . . . .. 9
4.2 Connection procedure. . . . . . . . . . . . . . . . . . . . . . .. 10
4.3 Wiring plan, single chamber housing . . . . . . . . . . . .. 11
4.4 Wiring plan, double chamber housing . . . . . . . . . . .. 12
4.5 Wiring plan with double chamber housing Ex d . . . .. 13

5 Set up with the indicating and adjustment module PLICSCOM

5.1 Short description . . . . . . . . . . . . . . . . . . . . . . . . . .. 15

5.2 Insert indicating and adjustment module. . . . . . . . . .. 15
5.3 Adjustment system . . . . . . . . . . . . . . . . . . . . . . . . .. 16
5.4 Setup steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
5.5 Menu schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21

2 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 1 About this document

1 About this document

1.1 Function
This commissioning instructions manual provides all the information you
need for mounting, connection and setup as well as important
instructions for maintenance and fault rectification.

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.

3 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 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

VEGAFLEX 61 is a sensor for continuous level measurement.
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 country-
specific 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 required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.

4 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 2 For your safety

2.5 Safety label on the instrument

The safety approval markings and safety tips on the device must be
observed.

2.6 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.

2.7 Fulfillment of NAMUR recommendations

With respect to compatibility, the NAMUR recommendation NE 53 is
fulfilled. This applies also to the corresponding indicating and
adjustment components. VEGA instruments are generally upward and
downward compatible.
l Sensor software to DTM VEGAFLEX 61
l DTM VEGAFLEX 61 for adjustment software PACTware
l Indicating and adjustment module for sensor software
The parameter adjustment of the basic sensor functions is independ-
ent of the software version. The range of available functions depends
on the respective software version of the individual components.

2.8 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.

2.9 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"

5 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 3 Installation Check

3 Installation Check
3.1 Product description

Constituent parts The VEGAFLEX 61 consists of the components:

l Process fitting with probe

l Housing with electronics
l Housing cover, optionally available with indicating and adjustment
module

1
2
3

Fig. 1: VEGAFLEX 61
1 Housing cover with integrated indicating and adjustment module (optional)
2 Housing with electronics
3 Process fitting

6 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 3 Installation Check

3.2 General instructions

Suitability for the pro- Make sure that all parts of the instrument exposed to the process, in
cess conditions particular the sensor element, process seal and process fitting, are
suitable for the existing process conditions. These include above all
the process pressure, process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data" or on the
type label.
Mounting position Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module. The housing can be rotated by 330° without the use of any
tools. You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).

Welding work Before beginning the welding work, remove the electronics module
from the sensor. By doing this, you avoid damage to the electronics
through inductive coupling.
Moisture You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry. Rain and condensation water can thus drain off. This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g. through cleaning processes) or
on cooled or heated vessels.

Fig. 2: Measures against moisture penetration

7 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 3 Installation Check

3.3 Mounting instructions

Mounting position Mount VEGAFLEX 61 in such a way that the distance to vessel
installations or to the vessel wall is at least 300 mm (12 in).
During operation, the probe must not touch any installations or the
vessel wall. If necessary, fasten the probe end.
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel, as measurement is then possible
down to the lowest point of the bottom. When using the cable version,
keep in mind that measurement down to the tip of the probe is not
possible. The exact value of the min. distance (lower dead band) is
stated in chapter "Technical data".

Fig. 3: Vessel with conical bottom

1 2

Fig. 4: Installation in plastic silo

1 Flange
2 Metal sheet

8 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply

4 Connecting to power supply

4.1 Preparing the connection
Safety instructions 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
In hazardous areas you should take note of the appropriate regulations,
conformity and type approval certificates of the sensors and power
supply units.

Voltage supply Power supply and current signal are carried on the same two-wire
cable. The voltage supply range can differ depending on the
instrument version.
The data for power supply are specified in chapter "Technical data".
Provide a reliable separation between the supply circuit and the mains
circuits according to DIN VDE 0106 part 101. The VEGA power supply
units VEGATRENN 149A Ex, VEGASTAB 690 as well as all
VEGAMETs and VEGASCANs meet this requirement.
Keep in mind the following additional influences on the operating
voltage:
l Output voltage of the power supply unit can be lower under
nominal load (with a sensor current of 20.5 mA or 22 mA in case of
fault message)
l Influence of additional instruments in the circuit (see load values in
chapter "Technical data")
Connection cable The instrument is connected with standard two-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas, screened cable should be
used.
Use cable with round cross-section. A cable outer diameter of 5 … 9 mm
(0.2 … 0.35 in) ensures the seal effect of the cable gland. If you are
using cable with a different diameter or cross-section, exchange the
seal or use a suitable cable gland.
We generally recommend the use of screened cable for HART
multidrop mode.

Cable gland ½ NPT On the instrument with cable entry ½ NPT and plastic housing there is
a metallic ½" threaded insert moulded into the plastic housing.

9 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply
Cable screening and If screened cable is necessary, connect the cable screen on both ends
grounding 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).

4.2 Connection procedure

Proceed as follows:
1 Unscrew the housing cover
2 If an indicating and adjustment module is installed, remove it by
turning it slightly to the left.
3 Loosen compression nut of the cable entry
4 Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
5 Insert the cable into the sensor through the cable entry
6 Lift the opening levers of the terminals with a screwdriver (see
following illustration)
7 Insert the wire ends into the open terminals according to the wiring
plan

Fig. 10: Connection steps 6 and 7

8 Press down the opening levers of the terminals, you will hear the
terminal spring closing

9 Check the hold of the wires in the terminals by lightly pulling on

them

10 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply

10 Connect the screen to the internal ground terminal, connect the

outer ground terminal to potential equalisation
11 Tighten the compression nut of the cable entry. The seal ring must
completely encircle the cable
12 Screw the housing cover on
The electrical connection is finished.

4.3 Wiring plan, single chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-ia

version.
Electronics and connec-
tion compartment

Display
I²C 1

1 2 5 6 7 8
4 2

Fig. 11: Electronics and connection compartment with single chamber housing
1 Plug connector for VEGACONNECT (I²C interface)
2 Spring-loaded terminals for connection of the external indication VEGADIS
61
3 Ground terminal for connection of the cable screen
4 Spring-loaded terminals for voltage supply

Wiring plan

Display
I2C

1 2 5 6 7 8

Fig. 12: Wiring plan, single chamber housing

1 Voltage supply/Signal output

11 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply

4.4 Wiring plan, double chamber housing

The following illustration apply to non-Ex as well as Ex ia versions. The

Exd version is described in the next subchapter.

Electronics compart-
ment

Display
1
I²C

1 2 5 6 7 8

3 2

Fig. 13: Electronics compartment, double chamber housing

1 Plug connector for VEGACONNECT (I²C interface)
2 Internal connection cable to the connection compartment
3 Terminals for VEGADIS 61

Connection compart-
ment
Display

1 2 I²C

Fig. 14: Connection compartment, double chamber housing

1 Plug connector for VEGACONNECT (I²C interface)
2 Ground terminal for connection of the cable screen
3 Spring-loaded terminals for voltage supply

12 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply

Wiring plan

I2C

1 2

Fig. 15: Wiring plan with double chamber housing

1 Voltage supply/Signal output

4.5 Wiring plan with double chamber housing Ex d

Electronics compart-
ment

Display
1
I²C

1 2 5 6 7 8

3 2

Fig. 16: Electronics compartment, double chamber housing

1 Plug connector for VEGACONNECT (I²C interface)
2 Internal connection cable to the connection compartment
3 Terminals for VEGADIS 61

13 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 4 Connecting to power supply

Connection compart-
ment

1 2

Fig. 17: Connection compartment with double chamber housing Ex d

1 Spring-loaded terminals for power supply and cable screen
2 Ground terminal for connection of the cable screen

Wiring plan

1 2

Fig. 18: Wiring plan with double chamber housing Ex d

1 Voltage supply/Signal output

14 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 5 Set up with the indicating and adjustment module PLICSCOM

5 Set up with the indicating and adjustment

module PLICSCOM
5.1 Short description
Function/Configuration The indicating and adjustment module is used for measured value
display, adjustment and diagnosis. It can be mounted in the following
housing versions and instruments:
l All sensors of the plics® instrument family, in the single as well as
in the double chamber housing (optionally in the electronics or
connection compartment)
l External indicating and adjustment unit VEGADIS 61

5.2 Insert indicating and adjustment module

Mount/Dismount indica- The indicating and adjustment module can be inserted into the sensor
ting and adjustment mo- and removed again at any time. It is not necessary to interrupt the
dule power supply.
Proceed as follows:
1 Unscrew the housing cover
2 Place the indicating and adjustment module in the desired position
on the electronics (you can choose any one of four different
positions - each displaced by 90°)
3 Press the indicating and adjustment module onto the electronics
and turn it to the right until it snaps in.
4 Screw housing cover with inspection window tightly back on
Removal is carried out in reverse order.
The indicating and adjustment module is powered by the sensor, an
additional connection is not necessary.

Fig. 20: Insert indicating and adjustment module

15 VE GAFLEX 61 • 4 … 20 mA/HART two- wire
 5 Set up with the indicating and adjustment module PLICSCOM

5.3 Adjustment system

2
1
1.1

Fig. 21: Indicating and adjustment elements

1 LC display
2 Indication of the menu item number
3 Adjustment keys

Key functions l [OK] key:

- Move to the menu overview
- Confirm selected menu
- Edit parameter
- Save value
l [->] key to select:
- Menu change
- Select list entry
- Select editing position
l [+] key:
- Change value of the parameter
l [ESC] key:
- interrupt input
- jump to the next higher menu

Adjustment system The sensor is adjusted via the four keys of the indicating and
adjustment module. The LC display indicates the individual menu
items. The functions of the individual keys are shown in the above
illustration. Approx. 10 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.

16 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 5 Set up with the indicating and adjustment module PLICSCOM

5.4 Setup steps

Switch on phase After connecting VEGAFLEX 61 to power supply or after a voltage
recurrence, the instrument carries out a self-check for approx. 30
seconds:
l Internal check of the electronics
l Indication of the instrument type, the firmware as well as the
sensor TAGs (sensor designation)
l Output signal jumps briefly (approx. 10 seconds) to the set fault
current
Then the corresponding current is outputted to the cable (the value
corresponds to the actual level as well as the settings already carried
out, e.g. factory setting).

Carry out min. adjust- Proceed as follows:

ment
1 Move from the measured value display to the main menu by
pushing [OK].
▶ Basic adjustment
Display
Diagnostics
Service
Info

2 Select the menu item "Basic adjustment" with [->] and confirm with
[OK]. Now the menu item "Min. adjustment" is displayed.
Min. adjustment
0.00 %
=
10.000 m(d)
8.000 m(d)

3 Prepare the % value for editing with [OK] and set the cursor to the
requested position with [->]. Set the requested percentage value
with [+] and save with [OK]. The cursor jumps now to the distance
value.
4 Enter the suitable distance value in m for the empty vessel (e.g.
distance from the sensor to the vessel bottom) corresponding to
the percentage value.
5 Save the settings with [OK] and move to "Max. adjustment" with [-
>].
Carry out max. adjust- Proceed as follows:
ment
Max. adjustment
100.00 %
=
1.000 m(d)
2.000 m(d)

1 Prepare the % value for editing with [OK] and set the cursor to the
requested position with [->]. Set the requested percentage value
with [+] and save with [OK]. The cursor jumps now to the distance
value.
17 VEGAFLEX 61 • 4 … 20 mA/HART two-wire
 5 Set up with the indicating and adjustment module PLICSCOM

2 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 dead band.
3 Save the settings with [OK].

Application Each product has different reflective properties. In addition, there are
various interfering factors which have to be taken into account:
agitated product surfaces and foam generation (with liquids); dust
generation, material cones and echoes from the vessel wall (with
solids). To adapt the sensor to these different conditions, you should
first select in this menu item under "Medium" either "Liquid" or "Solid".

Application
Liquid

Standard
(DK ≥ 2)

Depending on the dielectric figure (dielectri value or εr), measured

products can have a different reflective property. Therefore an
additional selection possibility is available.
Under "Sensitivity" you can select "Standard (DK ≥ 2)" or "Increased
sensitivity (DK < 2)".
Through this the sensor is optimally adapted to the product and
measurement reliability, particularly in products with bad reflective
properties, is considerably increased.
Enter the requested parameters via the appropriate keys, save your
settings and jump to the next menu item with the [->] key.

Damping To suppress fluctuations in the measured value display, e. g. caused

by an agitated product surface, a damping can be set. This time can
be between 0 and 999 seconds. Keep in mind that the reaction time of
the entire measurement will then be longer and the sensor will react to
measured value changes with a delay. In general, a period of a few
seconds is sufficient to smooth the measured value display.

Damping

0s

Enter the requested parameters via the appropriate keys, save your
settings and jump to the next menu item with the [->] key.

Linearisation curve A linearization is necessary for all vessels in which the vessel volume
does not increase linearly with the level - e.g. in a horizontal cylindrical
or spherical tank - and the indication or output of the volume is
required. Corresponding linearization curves are preprogrammed for

18 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 5 Set up with the indicating and adjustment module PLICSCOM

these vessels. They represent the correlation between the level

percentage and vessel volume. By activating the appropriate curve,
the volume percentage of the vessel is displayed correctly. If the
volume should not be displayed in percent but e.g. in l or kg, a scaling
can be also set in the menu item "Display".

Linearisation curve

linear

Enter the requested parameters via the appropriate keys, save your
settings and jump to the next menu item with the [->] key.
Sensor-TAG In this menu item you can enter an unambiguous designation for the
sensor, e.g. the measurement loop name or the tank or product
designation. In digital systems and in the documentation of larger
plants, a singular designation should be entered for exact identification
of individual measuring points.

Sensor-TAG

Sensor

With this menu item, the Basic adjustment is finished and you can now
jump to the main menu with the [ESC] key.

Gating out of false sig- High sockets or vessel installations, such as e. g. struts or agitators as
nals well as buildup and weld joints on the vessel walls, cause interfering
reflections that can impair the measurement. A false echo storage
detects and marks these false echoes, so that they are no longer taken
into account for the level measurement. A false echo memory should
be created with low level so that all potential interfering reflections can
be detected.

Gating out of false signals

Change now?

Proceed as follows:
1 Move from the measured value display to the main menu by
pushing [OK].
2 Select the menu item "Service" with [->] and confirm with [OK].
Now the menu item "False signal suppression" is displayed.
3 Confirm "False signal suppression - Change now" with [OK] and
select in the below menu "Create new". Enter the actual distance
from the sensor to the product surface. All false signals in this area
are detected by the sensor and saved after confirming with [OK].

19 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 5 Set up with the indicating and adjustment module PLICSCOM

Copy sensor data This function enables reading out parameter adjustment data as well
as writing parameter adjustment data into the sensor via the indicating
and adjustment module. A description of the function is available in the
operating instructions manual "Indicating and adjustment module".
The following data are read out or written with this function:
l Measured value presentation
l Adjustment
l Medium
l Vessel form
l Damping
l Linearisation curve
l Sensor-TAG
l Displayed value
l Display unit
l Scaling
l Current output
l Unit of measurement
l Language
l Sensitivity
The following safety-relevant data are not read out or written:
l HART mode
l PIN
l SIL
l Sensor length/Sensor type
l Gating out of false signals
Copy sensor data

Copy sensor data?

20 VEGAFLEX 61 • 4 … 20 mA/HART two-wire

 5 Set up with the indicating and adjustment module PLICSCOM

5.5 Menu schematic

Basic adjustment
▶ Basic adjustment 1
Display
Diagnostics
Service
Info

Min. adjustment 1.1 Max. adjustment 1.2 Damping 1.3 Linearisation curve 1.4
0.00 % 100.00 %
= = 0s linear
10.000 m(d) 1.000 m(d)
8.000 m(d) 2.000 m(d)

Sensor-TAG 1.5

Sensor

Display
Basic adjustment 2
▶ Display
Diagnostics
Service
Info

Displayed value 2.1 Unit 2.2 Scaling 2.3 Lighting 2.4

Volume
Scaled hl 0 % = 000.5 hl Switched on
100 % = 005.0 hl

Diagnostics
Basic adjustment 3
Display
▶ Diagnostics
Service
Info

Pointer 3.1 Sensor status 3.2 Curve selection 3.3 Echo curve 3.4

Distance min.: 0.234 m(d) OK Echo curve Presentation of the echo

Distance max.: 5.385 m(d) curve

VEGAFLEX 61 • 4 … 20 mA/HART two-wire 21

 5 Set up with the indicating and adjustment module PLICSCOM

Service
Basic adjustment 4
Display
Diagnostics
▶ Service
Info

Sensor 4.1 Application 4.2 Gating out of false signals 4.3 Current output 4.4
Liquid ▼ Output mode: 4-20 mA ▼
5.00 m(d) ▼ Change now? Failure mode: 20.5 mA ▼
Rod ▼ Standard min. current: 4 mA ▼
(DK ≥ 2) ▼ max. current: 20.5 mA ▼

Simulation 4.5 Reset 4.6 Unit of measurement 4.7 Language 4.8

Start simulation? Select reset? m(d) Deutsch ▼

select?

SIL 4.9 HART mode 4.10 Copy sensor data 4.11 PIN 4.12
Standard
Activated! ▼ Address 0 Copy sensor data? Enable?

Info
Basic adjustment 5
Display
Diagnostics
Service
▶ Info

Instrument type 5.1 Date of manufacture 5.2 Last change using PC 5.3 Sensor characteristics 5.4
12. Dec. 2005
Serial number Software version 04. March 2004 Display now?
12345678 3.22

22 VEGAFLEX 61 • 4 … 20 mA/HART two-wire