Quick setup guide

Radar sensor for continuous level

measurement of bulk solids

VEGAPULS 68
4 … 20 mA/HART - four-wire

Document ID: 47167

Contents

Contents
1 For your safety
1.1 Authorised personnel........................................................................................................ 3
1.2 Appropriate use................................................................................................................. 3
1.3 Warning about incorrect use.............................................................................................. 3
1.4 General safety instructions................................................................................................ 3
1.5 CE conformity.................................................................................................................... 4
1.6 NAMUR recommendations............................................................................................... 4
1.7 Radio license for Europe................................................................................................... 4
1.8 Radio license for USA/Canada.......................................................................................... 5
1.9 Environmental instructions................................................................................................ 5
2 Product description
2.1 Configuration..................................................................................................................... 6
3 Mounting
3.1 Mounting preparations - Parabolic antenna....................................................................... 7
3.2 Mounting preparations...................................................................................................... 8
3.3 Mounting instructions........................................................................................................ 9
4 Connecting to power supply
4.1 Connection...................................................................................................................... 11
4.2 Wiring plan, double chamber housing............................................................................. 12
5 Set up with the display and adjustment module
5.1 Insert display and adjustment module............................................................................. 14
5.2 Parameter adjustment..................................................................................................... 14
6 Supplement
6.1 Technical data................................................................................................................. 20

Information:
This quick setup guide enables quick setup and commissioning of
your instrument.
You can find supplementary information in the corresponding, more
detailed Operating Instructions Manual as well as the Safety Manual
that comes with instruments with SIL qualification. These manuals are
available on the supplied DVD or in the download area of "www.vega.
47167-EN-160215

com".

Operating instructions VEGAPULS 68 - 4 … 20 mA/HART - four-

wire: Document-ID 36536
Editing status of the quick setup guide: 2016-02-04

2 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 1 For your safety

1 For your safety

1.1 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.

1.2 Appropriate use

VEGAPULS 68 is a sensor for continuous level measurement.
You can find detailed information about the area of application 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.

1.3 Warning about incorrect use

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. Also the pro-
tective characteristics of the instrument can be influenced.

1.4 General safety instructions

This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines. The instrument must only be operated in a
technically flawless and reliable condition. The operator is responsible
for the 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 regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
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. Arbi-
trary conversions or modifications are explicitly forbidden.
The safety approval markings and safety tips on the device must also
be observed.
Depending on the instrument version, the emitting frequencies are in
the C, K or W band range. The low emitting frequencies are far below
47167-EN-160215

the internationally approved limit values. When used correctly, the

device poses no danger to health.

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 3

1 For your safety

1.5 CE conformity
The device fulfills the legal requirements of the applicable EC guide-
lines. By affixing the CE marking, we confirm successful testing of the
product.
You can find the CE Certificate of Conformity in the download section
of our homepage.

Electromagnetic compatibility
Instruments in four-wire or Ex-d-ia version are designed for use in an
industrial environment. Nevertheless, electromagnetic interference
from electrical conductors and radiated emissions must be taken into
account, as is usual with class A instruments according to EN 61326-
1. If the instrument is used in a different environment, the electromag-
netic compatibility to other instruments must be ensured by suitable
measures.

1.6 NAMUR recommendations

NAMUR is the automation technology user association in the process
industry in Germany. The published NAMUR recommendations are
accepted as the standard in field instrumentation.
The device fulfills the requirements of the following NAMUR recom-
mendations:
• NE 21 – Electromagnetic compatibility of equipment
• NE 43 – Signal level for malfunction information from measuring
transducers
• NE 53 – Compatibility of field devices and display/adjustment
components
• NE 107 – Self-monitoring and diagnosis of field devices
For further information see www.namur.de.

1.7 Radio license for Europe

The instrument is approved according to EN 302372-1/2 V1.2.1
(2011-02) for use in closed vessels.
For operation inside of closed vessels, the following conditions must
be fulfilled:
• The instrument must be permanently mounted on a closed vessel
made of metal, reinforced concrete, or comparable attenuating
materials.
• Flanges, process fittings and mounting accessories must ensure
the microwave impermeability of the vessel and not let the radar
signal escape to the outside
• If necessary, existing viewing windows in the vessel must be
coated with a microwave impermeable material (e.g. electrically
conductive coating)
•
47167-EN-160215

Manholes and flanges on the vessel must be closed and sealed to

avoid penetration of the radar signal
• The instrument should be preferably mounted on top of the vessel
with antenna orientation downward

4 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 1 For your safety

• The instrument must only be installed and maintained by appropri-

ately qualified staff

1.8 Radio license for USA/Canada

The instrument is in conformity with part 15 of the FCC regulations.
Take note of the following two regulations:
• This device may not cause interference, and
• The device must be resistant to interference signals, including
such that may cause undesired operating states of the device
Modifications not expressly approved by the manufacturer will lead to
expiry of the operating licence according to FCC/IC.
The instrument is in conformity with RSS-210 of the IC regulations.
The instrument may only be used in closed vessels made of metal,
concrete, or fibre-reinforced plastic.

1.9 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 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"
• Chapter "Disposal"
47167-EN-160215

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 5

2 Product description

2 Product description
2.1 Configuration
Type label The type label contains the most important data for identification and
use of the instrument:

1
2
3 15
4
14
5
6
13
7
8 12
9
10 11

Fig. 1: Layout of the type label (example)

1 Instrument type
2 Product code
3 Approvals
4 Power supply and signal output, electronics
5 Protection rating
6 Measuring range
7 Process and ambient temperature, process pressure
8 Material, wetted parts
9 Hardware and software version
10 Order number
11 Serial number of the instrument
12 Data-Matrix-Code for smartphone app
13 Symbol of the device protection class
14 ID number, instrument documentation
15 Reminder to observe the instrument documentation

Serial number - Instru- The type label contains the serial number of the instrument. With it
ment search you can find the following instrument data on our homepage:
• Product code (HTML)
• Delivery date (HTML)
• Order-specific instrument features (HTML)
• 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.
47167-EN-160215

Alternatively, you can access the data via your smartphone:

• Download the smartphone app "VEGA Tools" from the "Apple App
Store" or the "Google Play Store"
• Scan the Data Matrix code on the type label of the instrument or
• Enter the serial number manually in the app

6 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 3 Mounting

3 Mounting
3.1 Mounting preparations - Parabolic antenna
The instrument is also available in versions where the antenna has
a diameter larger than the process fitting (thread, flange). With such
versions the antenna must be disconnected from the process fitting
before mounting. Proceed as follows:
1. Clamp VEGAPULS 68 with the flange, e.g. in a bench vice
2. Hold the connection piece (1) with a wrench on the flat surfaces
(width across flats 22 mm)
3. Loosen counter nut (3) completely with a wrench (width across
flats 36 mm) in the direction of the antenna
4. Loosen compression nut (2) completely with a wrench (width
across flats 41 mm) in the direction of the antenna
5. Remove the parabolic antenna (4) axially
6. Mount sensor flange on the adapter flange and fasten it tightly
7. Check if the O-ring seal is present on the connection piece and
make sure it is not damaged.
Note:
A damaged O-ring seal must be replaced: FKM (SHS FPM 70C3
GLT), FFKM (Kalrez 6375)
8. Remount the parabolic antenna (4)
9. Fasten compression nut (2) with a wrench (width across flats 41),
max. torque see chapter "Technical data"
10. Fasten counter nut (3) with a wrench (width across flats 36), max.
torque see chapter "Technical data"
Note:
On the version with rinsing air connection, make sure that the holes
in the antenna and in the process fitting coincide. This ensures a suf-
ficient air flow (the air is led through the holes to the feed system. A
rinsing of the whole parabolic antenna is not intended).

2
3
4
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Fig. 2: Dismounting, parabolic antenna

1 Connection piece
2 Compression nut
3 Counter nut
4 Parabolic antenna

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 7

3 Mounting

3.2 Mounting preparations

The instrument is also available in versions with an antenna whose
diameter is larger than the process fitting (thread, flange). In such
cases the antenna must be disconnected from the process fitting
before mounting.

Horn antenna Proceed as follows:

1. Loosen the hexagon socket screws (3) on the antenna socket
with an Allen wrench (size 3)
2. Remove the antenna (4)
Note:
The plastic cone may not be pulled out of the antenna socket.
3. Insert the antenna from below into the vessel socket and secure it
against falling off
4. Retighten the antenna with hexagon screws to the antenna
socket; max. torque see chapter "Technical data"
Note:
The radar sensor with rinsing air connection or with antenna exten-
sion has a notch on the antenna socket for polarization. This notch
must be aligned with the marking on the process fitting.

2
3
4

Fig. 3: Dismounting of the horn antenna

1 Marking on the process fitting
2 Marking at the antenna socket
3 Screw locking device
4 Hexagon screws
5 Antenna

Caution:
A secure hold of the antenna is only ensured with the untwist guard.
47167-EN-160215

The untwist guards inserted on site must hence be used again.

Depending on temperature range and antenna material, these are
spring rings according to DIN 217 or wedge lock washers according
to DIN 25 201.

8 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 3 Mounting

Parabolic antenna Proceed as follows:

1. Clamp VEGAPULS 68 with the flange, e.g. in a bench vice
2. Hold the connection piece (1) with a wrench on the flat surfaces
(width across flats 22 mm)
3. Loosen counter nut (3) completely with a wrench (width across
flats 36 mm) in the direction of the antenna
4. Loosen compression nut (2) completely with a wrench (width
across flats 41 mm) in the direction of the antenna
5. Remove the parabolic antenna (4) axially
6. Mount sensor flange on the adapter flange and fasten it tightly
7. Check if the O-ring seal is present on the connection piece and
make sure it is not damaged.
Note:
A damaged O-ring seal must be replaced: FKM (SHS FPM 70C3
GLT), FFKM (Kalrez 6375)
8. Remount the parabolic antenna (4)
9. Fasten compression nut (2) with a wrench (width across flats 41),
max. torque see chapter "Technical data"
10. Fasten counter nut (3) with a wrench (width across flats 36), max.
torque see chapter "Technical data"
Note:
On the version with rinsing air connection, make sure that the holes
in the antenna and in the process fitting coincide. This ensures a suf-
ficient air flow (the air is led through the holes to the feed system. A
rinsing of the whole parabolic antenna is not intended).

2
3
4

Fig. 4: Dismounting, parabolic antenna

1 Connection piece
2 Compression nut
3 Counter nut
4 Parabolic antenna
47167-EN-160215

3.3 Mounting instructions

Mounting 1. Distance from the vessel wall > 200 mm, the antenna should
protrude > 10 mm into the vessel

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 9

3 Mounting

200 mm

ca. 10 mm
(7.87")

Fig. 5: Distance of the antenna to the vessel wall/vessel ceiling

2. Note min. socket diameter depending on the socket length

3. Note the instructions for sealing
For further information see chapter "Mounting".

47167-EN-160215

10 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 4 Connecting to power supply

4 Connecting to power supply

4.1 Connection
Connection technology The voltage supply and signal output are connected via the spring-
loaded terminals in the housing.
Connection to the display and adjustment module or to the interface
adapter is carried out via contact pins in the housing.
Information:
The terminal block is pluggable and can be removed from the
electronics. To do this, lift the terminal block with a small screwdriver
and pull it out. When reinserting the terminal block, you should hear it
snap in.

Connection procedure Proceed as follows:

1. Unscrew the housing lid
2. Loosen compression nut of the cable gland and remove blind
plug
3. Remove approx. 10 cm (4 in) of the cable mantle (signal output),
strip approx. 1 cm (0.4 in) insulation from the ends of the indi-
vidual wires
4. Insert the cable into the sensor through the cable entry

Fig. 6: Connection steps 5 and 6

5. Insert the wire ends into the terminals according to the wiring plan
Information:
Solid cores as well as flexible cores with wire end sleeves are insert-
47167-EN-160215

ed directly into the terminal openings. In case of flexible cores without

end sleeves, press the terminal from above with a small screwdriver,
the terminal opening is then free. When the screwdriver is released,
the terminal closes again.

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 11

4 Connecting to power supply

6. Check the hold of the wires in the terminals by lightly pulling on

them
7. Connect the screen to the internal ground terminal, connect the
outer ground terminal to potential equalisation in case of power
supply via low voltage
8. Connect the lead cable for power supply in the same way accord-
ing to the wiring plan, in addition connect the ground conductor to
the inner ground terminal when powered with mains voltage.
9. Tighten the compression nut of the cable glands. The seal ring
must completely encircle the cables
10. Screw the housing lid back on
The electrical connection is finished.
Information:
The terminal blocks are pluggable and can be removed from the
housing insert. To do this, lift the terminal block with a small screwdriv-
er and pull it out. When inserting the terminal block again, you should
hear it snap in.

4.2 Wiring plan, double chamber housing

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

Connection compartment
with mains voltage
4...20mA
common

IS GND
passive
active

power supply

(+)1 2(-) 5 6 7 8
/L
/N
PE

Fig. 7: Connection compartment with double chamber housing with mains

voltage

Terminal Function Polarity

1 Voltage supply +/L
2 Voltage supply -/N
5 4 … 20 mA output (active) +
6 4 … 20 mA output (passive) +
7 Mass - output -
47167-EN-160215

8 Function ground when in-

stalling according to CSA
(Canadian Standards Asso-
ciation)

12 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 4 Connecting to power supply

Connection compartment
with low voltage
4...20mA

common

IS GND
passive
active
power supply

(+)1 2(-) 5 6 7 8
/L
/N

Fig. 8: Connection compartment with double chamber housing with low voltage

Terminal Function Polarity

1 Voltage supply +/L
2 Voltage supply -/N
5 4 … 20 mA output (active) +
6 4 … 20 mA output (passive) +
7 Mass - output -
8 Function ground when in-
stalling according to CSA
(Canadian Standards Asso-
ciation)
47167-EN-160215

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 13

5 Set up with the display and adjustment module

5 Set up with the display and adjustment

module
5.1 Insert display and adjustment module
The display and adjustment module can be inserted into the sensor
and removed again at any time. You can choose any one of four differ-
ent positions - each displaced by 90°. It is not necessary to interrupt
the power supply.
Proceed as follows:
1. Unscrew the housing lid
2. Place the display and adjustment module on the electronics in the
desired position and turn it to the right until it snaps in.
3. Screw housing lid with inspection window tightly back on
Disassembly is carried out in reverse order.
The display and adjustment module is powered by the sensor, an ad-
ditional connection is not necessary.

Fig. 9: Installing the display and adjustment module in the double chamber
housing

Note:
If you intend to retrofit the instrument with a display and adjustment
module for continuous measured value indication, a higher lid with an
inspection glass is required.

5.2 Parameter adjustment

Set parameters 1. Go to the menu "Setup" via the display and adjustment module.
47167-EN-160215

2. Select in the menu item "Medium" the medium of your applica-

tion, for example "Powder/Dust".

14 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 5 Set up with the display and adjustment module

3. Select in the menu item "Application" the vessel, the application

and the vessel form, for example, silo.

4. Carry out the adjustment in the menu items "Min. adjustment" and
"Max. adjustment".

Parameterization example The radar sensor as a distance measuring instrument measures the
distance from the sensor to the product surface. For indication of the
real level, an allocation of the measured distance to the percentage
height must be carried out.

3
(39.37")
1m

100% 2
(1378")
35 m

0% 1

Fig. 10: Parameterization example

1 Min. level ≙ max. meas. distance
2 Max. level ≙ min. meas. distance

For this adjustment, the distance is entered for min. and max. level.
If these values are not known, an adjustment with distances, for
47167-EN-160215

example, of 10 % and 90 % is also possible. Starting point for these
distance specifications is always the seal surface of the thread or
flange.

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 15

5 Set up with the display and adjustment module

Diagnostics - Echo curve The function "Echo curve memory" makes it possible to save the echo
memory curve at the time of setup. This is generally recommended, and it is
absolutely necessary to do this if you want to use the Asset Manage-
ment functions. 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
changes during operation. In addition, the echo curve of setup can be
displayed in the echo curve window and compared with the current
echo curve.

Additional adjustments - The following circumstances cause interfering reflections and can
False signal suppression influence the measurement:
• High sockets
• Vessel internals such as struts
• Agitators
• Buildup or welded joints on vessel walls

Note:
A false signal suppression detects, marks and saves these false
signals so that they are no longer taken into account in the level
measurement.
This should be done with a low level so that all potential interfering
reflections can be detected.
Proceed as follows:
1. Select with [->] the menu item "False signal suppression" and
confirm with [OK].

2. Confirm again with [OK].

3. Confirm again with [OK].

47167-EN-160215

4. Confirm again with [OK] and enter the actual distance from the
sensor to the product surface.

16 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 5 Set up with the display and adjustment module

5. All interfering signals in this section are detected by the sensor

and stored after confirming with [OK].
Note:
Check the distance to the product surface, because if an incorrect
(too large) value is entered, the existing level will be saved as a false
signal. The level would then no longer be detectable in this area.
If a false signal suppression has already been saved in the sensor,
the following menu window appears when selecting "False signal
suppression":

Delete: An already created false signal suppression will be com-

pletely deleted. This is useful if the saved false signal suppression no
longer matches the metrological conditions in the vessel.
Extend: is used to extend an already created false signal suppres-
sion. This is useful if a false signal suppression was carried out with
too high a level and not all false signals could be detected. When
selecting "Extend", the distance to the product surface of the created
false signal suppression is displayed. This value can now be changed
and the false signal suppression can be extended to this range.

Menu and parameter Menu - Setup

overview
Menu item Parameter Default setting
Measurement Sensor
loop name
Medium Liquid
Water based
Application Storage tank
Vessel form Vessel top Dished form
Vessel bottom Dished form
Vessel height/ 35 m
Measuring range
Max. adjustment 0,000 m(d)
100.00 %
Min. adjustment 35 m
47167-EN-160215

0.00 %
Damping Integration time 0.0 s

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 17

5 Set up with the display and adjustment module

Menu item Parameter Default setting

Current output Output character- 4 … 20 mA
mode istics
Failure mode ≤ 3.6 mA
Current output - Min. current 3.8 mA
Min./Max.
Max. current 20.5 mA
Lock adjustment Released

Menu - Display
Menu item Default setting
Language Order-specific
Displayed value Filling height in %
Backlight Switched on

Menu - Diagnosis
Menu item Parameter Default setting
Sensor status -
Peak value Distance -
Electronics tem- Temperature -
perature
Meas. certainty -
Simulation Percent
Curve indication Echo curve -
False signal sup- -
pression
Echo curve -
memory

Menu - Additional adjustments

Menu item Default setting
Instrument units Distance in m
Temperature in °C
False signal suppres- -
sion
Linearization Linear
PIN -
Date/Time Actual date/Actual time
Reset -
47167-EN-160215

HART mode Address 0

Copy instrument set- -
tings

18 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 5 Set up with the display and adjustment module

Menu - Info
Menu item Parameter
Device name VEGAPULS 6.
Instrument version Hardware and software version
Date of manufacture Date
Instrument features Order-specific characteristics
47167-EN-160215

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 19

6 Supplement

6 Supplement
6.1 Technical data
Electromechanical data - version IP 66/IP 67
Cable gland M20 x 1.5 or ½ NPT
Wire cross-section (spring-loaded terminals)
ƲƲ Massive wire, stranded wire 0.2 … 2.5 mm² (AWG 24 … 14)
ƲƲ Stranded wire with end sleeve 0.2 … 1.5 mm² (AWG 24 … 16)

Voltage supply
Operating voltage
ƲƲ Version for low voltage 9.6 … 48 V DC, 20 … 42 V AC, 50/60 Hz
ƲƲ Version for mains voltage 90 … 253 V AC, 50/60 Hz
Reverse voltage protection Integrated
Max. power consumption 4 VA; 2.1 W

47167-EN-160215

20 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 Notes
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VEGAPULS 68 • 4 … 20 mA/HART - four-wire 21

Notes

47167-EN-160215

22 VEGAPULS 68 • 4 … 20 mA/HART - four-wire

 Notes
47167-EN-160215

VEGAPULS 68 • 4 … 20 mA/HART - four-wire 23

 Printing date:

47167-EN-160215

All statements concerning scope of delivery, application, practical use and operat-
ing 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 2016

VEGA Grieshaber KG Phone +49 7836 50-0

Am Hohenstein 113 Fax +49 7836 50-201
77761 Schiltach E-mail: info.de@vega.com
Germany www.vega.com