8.1 Maintenance. Vega VEGACAL 63

8 Maintenance and fault rectification

8 Maintenance and fault rectification

8.1 Maintenance

If the device is used properly, no special maintenance is required in normal operation.

Reaction when malfunction occurs

Causes of malfunction

8.2 Rectify faults

The operator of the system is responsible for taking suitable measures to rectify faults.

VEGACAL 63 offers maximum reliability. Nevertheless, faults can occur during operation. These may be caused by the following, e.g.:

• Sensor

Process

• Voltage supply

Signal processing

Fault rectification

24 hour service hotline

The first measures to be taken are to check the output signals as well as to evaluate the error messages via the display and adjustment module. The procedure is described below. Further comprehensive diagnostics can be carried out on a PC with the software PACTware and the suitable DTM. In many cases, the causes can be determined and the faults rectified this way.

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 manned 7 days a week round-the-clock. Since we offer this service worldwide, the support is only available in the English language. The service is free, only standard call charges are incurred.

Check the 4 … 20 mA signal

Connect a multimeter in the suitable measuring range according to the wiring plan.

Error

4 … 20 mA signal not stable

Reason

Level fluctuations

4 … 20 mA signal missing Wrong connection

Current signal greater than

22 mA or less than 3.6 mA

Rectification

Set damping via the display and adjustment module

No power supply

Operating voltage too low or load resistance too high

Shortcircuit in the probe, e.g. because of moisture in the housing

Electronics module defective

Check connection according to chapter "Connection

steps" and if necessary, correct according to chapter

"Wiring plan"

Check cables for breaks; repair if necessary

Check, adapt if necessary

Remove the electronics module. Check the resistance between the marked plug connections. See the following instructions.

Exchange the instrument or send it in for repair

44 VEGACAL 63 • 4 … 20 mA/HART - two-wire

Check the resistance in the probe

8 Maintenance and fault rectification

Remove the electronics module. Check the resistance between the two plug connections.

There must no longer be a connection (high impedance). If there is still a connection, exchange the instrument or return it for repair

1 2 3

Fig. 26: Check the resistance in the probe

1 Shielding

2 Measuring probe

3 Ground potential

In Ex applications, the regulations for the wiring of intrinsically safe circuits must be observed.

Error messages via the display and adjustment module

Error

E013

E017

E036

Reason no measured value available

Shortcircuit in the probe, e.g. because of moisture in the housing

Rectification

•

Probe insulation damaged, short-circuit due to per-

• meating, conductive medium

Exchange the instrument or send it in for repair

• Remove the electronics module out of the probe and check the resistor between the two marked plug connections according to the figure in paragraph "Check

the resistance in the probe".

•

There should be no contact between any of the connections (high resistance)

•

If there is still a connection, exchange the instrument or return it for repair

Adjustment span too small Carry out a fresh adjustment and increase the distance between min. and max. adjustment no operable sensor software

Carry out a software update or send instrument for repair

Reaction after fault rectification

Depending on the reason for the fault and the measures taken, the steps described in chapter "Set up" may have to be carried out again.

8.3 Exchanging the electronics module

If the electronics module is defective, it can be replaced by the user.

VEGACAL 63 • 4 … 20 mA/HART - two-wire 45

8 Maintenance and fault rectification

Sensor serial number

In Ex applications, only instruments and electronics modules with appropriate Ex approval may be used.

If there is no electronics module available on site, one can be ordered from the VEGA agency serving you.

The new electronics module must be loaded with the order data of the sensor. These are the options:

• At the factory by VEGA

Or on site by the user

In both cases, the sensor serial number is needed. The serial numbers are stated on the type label of the instrument or on the delivery note.

Information:

When loading on site, the order data must first be downloaded from the Internet (see operating instructions manual "Electronics module").

Assignment The electronics modules are adapted to the respective sensor and differ in their signal output or in their power supply. You can find a suitable electronics module in the following overview.

The oscillators differ only in their signal output and are suitable for all series 60 sensors.

The following types are available:

• CL-E60H (4 … 20 mA/HART)

CL-E60P (Profibus PA)

CL-E60F (Foundation Fieldbus)

In Ex applications only an electronics module with respective Ex approval may be used.

8.4 How to proceed if a repair is necessary

You can find an instrument return form as well as detailed information about the procedure in the download area of our homepage: www.vega.com.

By doing this you help us carry out the repair quickly and without having to call back for needed information.

If a repair is necessary, please proceed as follows:

• Print and fill out one form per instrument

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.

46 VEGACAL 63 • 4 … 20 mA/HART - two-wire

9 Dismount

9 Dismount

9.1 Dismounting steps

Warning:

Before dismounting, be aware of dangerous process conditions such as e.g. pressure in the vessel or pipeline, high temperatures, corrosive or toxic products etc.

Take note of chapters "Mounting" and "Connecting to power supply" and carry out the listed steps in reverse order.

9.2 Disposal

The instrument consists of materials which can be recycled by specialised recycling companies. We use recyclable materials and have designed the electronics to be easily separable.

WEEE directive 2002/96/EG

This instrument is not subject to the WEEE directive 2002/96/EG and the respective national laws. Pass the instrument directly on to a specialised recycling company and do not use the municipal collecting points. These may be used only for privately used products according to the WEEE directive.

Correct disposal avoids negative effects on humans and the environment and ensures recycling of useful raw materials.

Materials: see chapter "Technical data"

If you have no way to dispose of the old instrument properly, please contact us concerning return and disposal.

VEGACAL 63 • 4 … 20 mA/HART - two-wire 47

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10.1 Technical data

General data

Material 316L corresponds to 1.4404 or 1.4435

Materials, wetted parts

Ʋ Process fitting - thread

Ʋ Process fitting - flange

Ʋ Process seal

Ʋ insulation (fully insulated)

316L, St C22.8 (1.0460), Alloy C22 (2.4602)

316L, Alloy C22 (2.4602), PTFE-plattiert

Klingersil C-4400

PTFE, PE

316L Ʋ Probe (rod fully insulated:

ø 12 mm/0.472 in)

Ʋ Probe (rod fully insulated:

ø 16 mm/0.63 in)

Materials, non-wetted parts

316L

Ʋ Plastic housing

Ʋ Aluminium die-cast housing plastic PBT (Polyester)

Aluminium die-casting AlSi10Mg, powder-coated - basis:

Polyester

316L Ʋ Stainless steel housing (precision casting)

Ʋ Stainless steel housing (electropolished)

316L

Ʋ Seal between housing and housing lid Silicone

Ʋ Ground terminal 316L

Ʋ Cable gland

Ʋ Sealing, cable gland

Ʋ Blind plug, cable gland

Process fittings

PA, stainless steel, brass

NBR

PA

Ʋ Pipe thread, cylindrical (DIN 3852-A) G½, G¾, G1, G1½

Ʋ Pipe thread, conical (ASME B1.20.1) ½ NPT, ¾ NPT, 1 NPT, 1½ NPT

Ʋ Flanges

Weight

DIN from DN 20, ASME from 1"

0.8 … 4 kg (0.18 … 8.82 lbs) Ʋ Instrument weight (depending on process fitting)

Ʋ Rod weight: ø 10 mm (0.394 in)

Ʋ Rod weight: ø 16 mm (0.63 in)

400 g/m (4 oz/ft)

1100 g/m (12 oz/ft)

Sensor length (L)

Ʋ Process fitting: thread and flanges 0.1 … 6 m (0.328 … 19.69 ft)

Ʋ Process fitting: Flanges - PTFE plated 0.15 … 6 m (0.492 … 19.69 ft)

Max. lateral lod - rod: ø 10 mm (0.394 in) 10 Nm (7.4 lbf ft)

Max. lateral load - rod: ø 16 mm (0.63 in) 10 Nm (7.4 lbf ft)

Torque of the flange screws (min.) 60 Nm (44.25 lbf ft)

48 VEGACAL 63 • 4 … 20 mA/HART - two-wire

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Max. torque (process fitting - thread) - rod: ø 10 mm (0.394 in)

Max. torque (process fitting - thread) - rod: ø 16 mm (0.63 in)

100 Nm (73 lbf ft)

100 Nm (73 lbf ft)

Torque for NPT cable glands and Conduit tubes

Ʋ Plastic housing

Ʋ Aluminium/Stainless steel housing max. 10 Nm (7.376 lbf ft) max. 50 Nm (36.88 lbf ft)

Output variable

Output signal

HART output values

Ʋ HART value (Primary Value)

Ʋ HART value (Secondary Value)

4 … 20 mA/HART

Capacitance

Capacitance - scaled

Resolution 1.6 µA

Fault signal, current output (adjustable) mA value unchanged 20.5 mA, 22 mA, < 3.6 mA (adjustable)

Current limitation

Load

22 mA see load diagram under Power supply

Damping (63 % of the input variable)

Rise time

Met NAMUR recommendation

0 … 999 s, adjustable

500 ms (ti: 0 s, 0 … 100 %)

NE 43

Input variable

Measured variable

Measuring principle

Measuring range

Measuring frequency

Level of liquids phase-selective admittance processing (PSA)

0 … 3000 pF

270 kHz

Accuracy (according to DIN EN 60770-1)

Reference conditions according to DIN EN 61298-1

Ʋ Temperature

Ʋ Relative humidity

+18 … +30 °C (+64 … +86 °F)

45 … 75 %

860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) Ʋ Air pressure

Temperature error

Ʋ < 120 pF

Ʋ > 120 pF

Linearity error

< 1 pF

1 % of the current measured value

< 0.25 % of the complete measuring range

Ambient conditions

Ambient, storage and transport temperature

-40 … +80 °C (-40 … +176 °F)

VEGACAL 63 • 4 … 20 mA/HART - two-wire 49

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Process conditions

Process pressure

Ʋ Threaded versions

Ʋ Flange version

-1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig), depending on the process fitting

-1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig), depending on the process fitting

Ʋ Flange version ≥ 3"/DN 80, plated -0.4 … 64 bar/-40 … 6400 kPa (-5.8 … 928 psig), depending on the process fitting

Process temperature VEGACAL 63 of 316L

Ʋ Insulation PE

Ʋ Insulation PTFE

-40 … +80 °C (-40 … +176 °F)

-50 … +150 °C (-58 … +302 °F)

Process temperature (thread or flange temperature) with temperature adapter

(option with PTFE)

-50 … +200 °C (-58 … +392 °F)

Process temperature VEGACAL 63 of St C22.8

Ʋ Insulation PE

Ʋ Insulation PTFE

-20 … +80 °C (-4 … +176 °F)

-20 … +150 °C (-4 … +302 °F)

2

80°C

(176°F)

3

40°C

(104°F)

0°C

(32°F)

-50°C

(-58°F)

-40°C

(-40°F)

50°C

(122°F)

Fig. 27: Ambient temperature - Process temperature

1 Process temperature

2 Ambient temperature

3 Temperature range with temperature adapter

Dielectric constant ≥ 1.5

100°C

(212°F)

150°C

(302°F)

1

200°C

(392°F)

Electromechanical data - version IP 54

Cable entry

Ʋ Sensor housing (BNC plug)

Ʋ External housing

– 1 x BNC plug

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm)

Electromechanical data - version IP 67

Cable entry

Ʋ Sensor housing (hexagon housing)

Ʋ External housing

Screw terminals

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm)

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm) for wire cross-section up to 2.5 mm² (AWG 14)

50 VEGACAL 63 • 4 … 20 mA/HART - two-wire

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Electromechanical data - version IP 68

Cable entry

Ʋ Sensor housing (lateral cable outlet)

Ʋ External housing

Screw terminals

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm)

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm) for wire cross-section up to 2.5 mm² (AWG 14)

Electromechanical data - version IP 66/IP 67 and IP 66/IP 68; 0.2 bar

Cable entry/plug 7)

Ʋ Single chamber housing – 1 x cable gland M20 x 1.5 (cable: ø 5 … 9 mm), 1 x or: blind plug M20 x 1.5

– 1 x closing cap M20 x 1.5; 1 x blind plug M20 x 1.5

or:

Ʋ Double chamber housing

Spring-loaded terminals for wire crosssection

– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT or:

– 1␣x plug (depending on the version), 1␣x blind stopper

M20␣x␣1.5

– 1 x cable entry M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind plug M20 x 1.5; 1 x blind plug M16 x 1.5 or or: optionally available with 1 x plug M12 x 1 for external display and adjustment unit

– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT, 1 x blind plug M16 x 1.5 or optionally 1 x plug M12 x 1 for exteror: nal display and adjustment unit

– 1 x plug (depending on the version), 1 x blind plug

M20 x 1.5; 1 x blind plug M16 x 1.5 or optionally available with 1 x plug M12 x 1 for external display and adjustment unit

< 2.5 mm² (AWG 14)

Electromechanical data - version IP 66/IP 68 (1 bar)

Cable entry

Ʋ Single chamber housing

Ʋ Double chamber housing

1 x IP 68 cable gland M20 x 1.5; 1 x blind plug M20 x 1.5

1␣x IP␣68 cable gland M20␣x␣1.5; 1␣x blind stopper

M20␣x␣1.5; 1␣x blind stopper M16␣x␣1.5

Connection cable

Ʋ Wire cross-section

Ʋ Wire resistance

Ʋ Tensile strength

Ʋ Standard length

Ʋ Max. length

0.5 mm² (AWG 20)

< 0.036 Ω/m (0.011 Ω/ft)

< 1200 N (270 lbf)

5 m (16.4 ft)

1000 m (3280 ft)

7) Depending on the version M12 x 1, according to DIN 43650, Harting, 7/8" FF.

VEGACAL 63 • 4 … 20 mA/HART - two-wire 51

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Ʋ Min. bending radius

Ʋ Diameter approx.

Ʋ Colour - standard PE

Ʋ Colour - standard PUR

Ʋ Colour - Ex-version

25 mm (0.984 in) with 25 °C (77 °F)

8 mm (0.315 in)

Black

Blue

Blue

Display and adjustment module

Voltage supply and data transmission

Indication

Adjustment elements through the sensor

LC display in dot matrix

4 keys

Protection rating

Ʋ unassembled IP 20

Ʋ mounted into the sensor without cover IP 40

Ambient temperature - Display and adjustment module

-20 … +70 °C (-4 … +158 °F)

Material

Ʋ Housing

Ʋ Inspection window

ABS

Polyester foil

Voltage supply

Operating voltage U

B

Ʋ Non-Ex instrument

Ʋ Ex ia instrument

Ʋ Ex-d-ia instrument

12 … 36 V DC

12 … 30 V DC

18 … 36 V DC

Operating voltage U

B

Ʋ Non-Ex instrument

- illuminated display and adjustment module

20 … 36 V DC

Ʋ Ex ia instrument

Ʋ Ex-d-ia instrument

Reverse voltage protection

20 … 36 V DC

Lighting not possible

Integrated

52 VEGACAL 63 • 4 … 20 mA/HART - two-wire

10 Supplement

Ω

1000

750

500

2

1

250

4

12 14 16 18 20

Fig. 28: Voltage diagram

1 HART load

2 Voltage limit Ex-ia instrument

3 Voltage limit non-Ex-/Ex-d-ia instrument

4 Operating voltage

Permissible residual ripple

Ʋ < 100 Hz

Ʋ 100 Hz … 10 kHz

Load

22 24 26 28 30 32 34 36 V

U ss

U ss

< 1 V

< 10 mV see diagram

Potential connections and electrical separating measures in the instrument

Electronics Not non-floating

Ground terminal Galvanically connected with the metal process fitting

Galvanic separation between electronics and metal housing parts

Ʋ Reference voltage 500 V AC

Electrical protective measures

Protection rating

Housing material

Plastic

Aluminium

Version

Single chamber

Double chamber

Single chamber

Double chamber

IP-protection class

IP 66/IP 67

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 68 (0.2 bar)

NEMA protection

Type 4X

Type 4X

Type 6P

Type 6P

Type 4X

Type 6P

Type 6P

Type 6P Stainless steel (electropolished)

Stainless steel (precision casting)

Single chamber

Single chamber

Double chamber

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

Type 6P

Type 6P

Type 4X

Type 6P

Type 6P

3

VEGACAL 63 • 4 … 20 mA/HART - two-wire 53

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Connection of the feeding power supply unit

Networks of overvoltage category III

Altitude above sea level

Ʋ by default bis 2000 m (6562 ft)

Ʋ with connected overvoltage protection up to 5000 m (16404 ft)

Pollution degree 8)

Protection class

4

II (IEC 61010-1)

Functional safety (SIL)

Functional safety is already activated on instruments with SIL qualification ex factory. On instruments without SIL qualification ex factory, the functional safety must be activated by the user via the display and adjustment module or via PACTware for applications according to SIL.

Functional safety according to IEC 61508-4

Ʋ Single channel architecture (1oo1D) up to SIL2

Ʋ double channel diversitary redundant architecture (1oo2D) up to SIL3

You can find detailed information in the supplied Safety Manual of the instrument series or under

"www.vega.com", "Downloads", "Approvals".

Approvals

Instruments with approvals can have different technical specifications depending on the version.

For that reason the associated approval documents of these instruments have to be carefully noted. They are part of the delivery or can be downloaded under www.vega.com "Instrument

search (serial number)" as well as in the general download area.

8) When used with fulfilled housing protection

54 VEGACAL 63 • 4 … 20 mA/HART - two-wire

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10.2 Dimensions

Housing in protection IP 66/IP 68 (0.2 bar)

~ 69 mm

(2.72")

ø 77 mm

(3.03")

~ 116 mm (4.57")

ø 84 mm (3.31")

~ 87 mm (3.43")

ø 84 mm

(3.31")

M16x1,5

M20x1,5/

½ NPT

1

~ 59 mm

(2.32")

ø 80 mm

(3.15")

M20x1,5/

½ NPT

M20x1,5

2

~ 69 mm

(2.72")

ø 77 mm

(3.03")

M20x1,5/

½ NPT

3

~ 87 mm (3.43")

ø 84 mm

(3.31")

M16x1,5

M20x1,5/

½ NPT

M20x1,5/

½ NPT

4 5 M20x1,5/

½ NPT

6

Fig. 29: Housing versions with protection rating IP 66/IP 68 (0.2 bar) - with integrated display and adjustment module the housing is 9 mm/0.35 in higher

1 Plastic single chamber (IP 66/IP 67)

2 Aluminium - single chamber

3 Aluminium - double chamber

4 Stainless steel single chamber (electropolished)

5 Stainless steel single chamber (precision casting)

6 Stainless steel double chamber housing (precision casting)

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Housing in protection IP 66/IP 68 (1 bar)

~ 150 mm (5.91")

ø 84 mm (3.31")

~ 103 mm

(4.06")

ø 77 mm

(3.03")

~ 105 mm (4.13")

ø 84 mm

(3.31")

M16x1,5

M20x1,5 M20x1,5 M20x1,5

1 2 M20x1,5/

½ NPT

3

Fig. 30: Housing version with protection rating IP 66/IP 68 (1 bar) - with integrated display and adjustment module the housing is 9 mm/0.35 in higher

1 Aluminium - single chamber

2 Stainless steel single chamber (precision casting)

2 Stainless steel double chamber housing (precision casting)

56 mm (2.21")

22 mm (0.86")

G¾, G 1, G 1½

Fig. 31: VEGACAL 63, threaded version G1 (ISO 228 T1)

L Sensor length, see chapter "Technical data"

ø 16mm

(0.63")

56 VEGACAL 63 • 4 … 20 mA/HART - two-wire

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Fig. 32: Temperature adapter

ø 40 mm (1.58")

ø 27 mm

(1.06")

Fig. 33: VEGACAL 63, concentric tube, for example with small dielectric constant or for linearization

L Concentric tube length, see chapter "Technical data"

VEGACAL 63 • 4 … 20 mA/HART - two-wire 57

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10.3 Industrial property rights

VEGA product lines are global protected by industrial property rights. Further information see www.vega.com.

VEGA Produktfamilien sind weltweit geschützt durch gewerbliche Schutzrechte.

Nähere Informationen unter www.vega.com.

Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellectuelle. 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 industrial. Para mayor información revise la pagina web www.vega.com.

Линии продукции фирмы ВЕГА защищаются по всему миру правами на интеллектуальную собственность. Дальнейшую информацию смотрите на сайте www.vega.com.

VEGA系列产品在全球享有知识产权保护。

进一步信息请参见网站<www.vega.com。

10.4 Trademark

All the brands as well as trade and company names used are property of their lawful proprietor/ originator.

58 VEGACAL 63 • 4 … 20 mA/HART - two-wire

Notes

VEGACAL 63 • 4 … 20 mA/HART - two-wire 59

Printing date:

All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing.

Subject to change without prior notice

© VEGA Grieshaber KG, Schiltach/Germany 2017

VEGA Grieshaber KG

Am Hohenstein 113

77761 Schiltach

Germany

Phone +49 7836 50-0

Fax +49 7836 50-201

E-mail: [email protected]

www.vega.com