Operating Instruction

Level and Pressure Operating Instruction VEGASEL 643 6 5 + + 3 5 + + max. min. on VEGASEL 643 5 6 7 8 9 10 11 12 13 14 in out

Contents Contents Safety information... 2 1 Product description 1.1 Function and configuration... 3 1.2 Approvals... 3 1.3 Types and versions... 4 1.4 Technical data and dimensions... 4 2 Mounting and installation instructions... 7 3 Electrical connection 3.1 Wiring instruction... 8 3.2 Wiring plan... 8 4 Set-up 4.1 Indicating and operating elements... 10 4.2 Set-up sequence... 11 4.3 Switch point adjustment... 11 5 Diagnosis 5.1 Maintenance... 13 5.2 Repair... 13 5.3 Failure removal... 13 Safety information The described module must only be inserted and operated as described in this operating instruction. Please note that other action can cause damage for which VEGA does not take responsibility. 2 VEGASEL 643

Product description 1 Product description 1.1 Function and configuration VEGASEL 643 auxiliary level switch is a build-in instrument with terminal socket, suitable for carrier rail mounting (DIN 46 277). Together with a sensor or a VEGAMET signal conditioning instrument it is used for level detection. Typical applications are two-point controls, e.g. pump controls (ON/OFF) and monitoring functions such as overfill protection and protection against dry running of pumps. The auxiliary level switch is provided with two passive inputs, a current and a voltage input as well as additionally with an active current input. Hence VEGASEL 643 can be connected for control either with a VEGAMET or a sensor (4 20 ma). Fig. 1.2 VEGASEL 643 with sensor 6 5 + + 3 5 + + on VEGASEL 643 max. min. 5 6 7 8 9 10 11 12 13 14 Sensor (4 20 ma) Function VEGASEL 643, controlled by a VEGAMET - The continuous current or voltage course of the VEGAMET signal processing instrument is processed into a switching command. In both cases a relay output is available for processing. Configuration With a VEGASEL 643 an available measuring system, consisting of sensor and VEGAMET signal conditioning instrument can be extended by a level detection. Or an own measuring system can be created with a 4 20 ma sensor. 100 % 0/4 20 ma 50 or 0 10 V 6 5 + + 3 5 + + max. min. 1.2 Approvals 0! on VEGAMET 602EX 5 6 7 8 9 10 11 12 13 14 on VEGASEL 643 5 6 7 8 9 10 11 12 13 14 If measuring systems are created according to the following approvals, the respective legal documents and their regulations have to be observed. These documents are supplied with the respective measuring system. Fig. 1.1 VEGASEL 643 on a VEGAMET p p WHG-approval, VbF-approval VEGASEL 643 auxiliary level switch together with a measuring system (sensor and VEGAMET) as part of an overfill protection acc. to WHG (test certificate applied) or acc. to the regulations for combustible liquids (test certificate applied). VEGASEL 643 with a 4 20 ma sensor - VEGASEL 643 auxiliary level switch powers via the active current input the sensors and processes its continuous 4 20 ma current signal into a switching command. CE-conformity see 1.4 Technical data. VEGASEL 643 3

Product description 1.3 Types and versions VEGASEL 643 Two-point auxiliary level switch with selectable mode; mode A (overfill protection) or mode B (protection against dry running of pumps) adjustable switching hysteresis Inputs: - passive current input 0/4 20 ma - active current input (connections of a sensor 4 20 ma) - passive voltage input 0/2 10 V Outputs: 1 relay (spdt) Approvals: as part of an overfill protection acc. to WHG and VbF Application: level detection, overfill protection, protection against dry running of pumps Max. Min. Level off on Time t Fig. 1.2 Two-point auxiliary level switch VEGASEL 643 1.4 Technical data and dimensions General data Power supply Operating voltage Power consumption Fuse 20 250 V AC, 50/60 Hz 20 72 V DC max. 1,7 W (4,5 VA) T 1 A, 250 V Measuring data inputs Input 1 1 current input Kind of input active two-wire input analog Range 4 20 ma Application connection of sensors (4 20 ma) Sensor supply voltage 16 24 V DC Switching threshold adjustable via coded key Min. hysteresis 1 % Current limitation appr. 25 ma, permanently shortcircuit proof Temperature error 0,05 %/10 K of range Switch point error 0,5 % of adjusted switch point Connection cable 2 wire (standard line) Resistor per conductor max. 35 Ω Interlock diode for connection of a measuring instrument max. load 15 Ω Input 2 1 additional current input Kind of input passive two-wire input analog Range 0/4 20 ma Inner resistor Ri = 50 Ω Application direct connection to active current output of e.g. VEGAMET 601, 602 Ex Switching threshold adjustable via coded key Min. hysteresis 1 % Temperature error 0,05 %/10 K of range Switch point error 0,5 % of adjusted switch point 4 VEGASEL 643

Product description Input 3 1 voltage input Kind of input passive two-wire input analog Range 0/2 10 V DC Inner resistor Ri 100 kω Application direct connection to active voltage output of e.g. VEGAMET 601, 602 Ex Switching threshold adjustable via coded key Min. hysteresis 1 % Temperature error 0,05 %/10 K of range Switch point error 0,5 % of adjusted switch point Connection cable 2-wire (standard line) Resistor per conductor max. 100 Ω Electrical connection Screw terminal max. 1,5 mm 2 Electrical protective measures Protection - instrument IP 30 - terminal socket IP 20 Protection II Overvoltage category II Mechanical data Series module instrument with terminal socket incl. transparent cover, cover of the sensor terminals, coded pin, two connection bridges Mounting carrier rail mounting acc. to DIN 46 277, Bl. 3 Dimensions unassembled W = 36 mm, H = 118,5 mm, D = 134 mm Weight appr. 170 g Ambient conditions Permissible ambient temperature Storage and transport temperature -20 C +60 C -40 C +70 C Relay output Number 1 output Contact 1 spdt (open 12-13, closed 12-14) AgCdO and Au plated Turn-on voltage min. 10 mv DC max. 250 V AC, 60 V DC Switching current min. 10 µa DC max. 2 A AC, 1 A DC Breaking capacity max. 125 VA, 54 W Indicating elements LED in front plate Functions Mode Adjustments of the inputs green on: operating voltage on yellow on: relay energized overfill protection (A) protection against dry running of pumps (B) 0 20 ma or 4 20 ma 0 10 V or 2 10 V VEGASEL 643 5

Product description Operating elements Front plate Laterally on top 2 coded key 0 99 % 1 DIL-switch for adjustment - mode A/B (overfill protection/protection against dry running of pumps) - adjustment possibility of the inputs 0 20 ma or 4 20 ma 0 10 V or 2 10 V Electrical separating measures Reliable separation acc. to VDE 0106, part 1 - limit voltage 250 V - isolation resistance 3 kv between power supply, meas. data inputs and level relais CE-conformity VEGASEL signal conditioning instruments meet the protective regulations of EMVG (89/336/EWG) and NSR (73/23/EWG). The conformity has been judged acc. to the following standards: EMVG Emission EN 50 081-1 Immission EN 50 082-2 NSR EN 61 010 Carrier rail 35 x 7,5 or 35 x 15 acc. to EN 50 022 Transparent cover 54,5 118,5 VEGA 5 6 7 8 9 10 11 12 13 14 134 36 6 VEGASEL 643

Mounting and installation instructions 2 Mounting and installation instructions Mounting Each series 600 signal conditioning instrument consists of a terminal socket for carrier rail mounting DIN 46 277 and a module instrument. The supply voltage can be connected to terminals 9 and 10. For neighbouring series 600 signal conditioning instruments it is possible to provide and loop the connection L1 and N directly via the supplied bridges. The same is valid for the connection VEGAMETvoltage output 0 10 V to VEGASEL-voltage input 0 10 V /terminals 7 and 8). Coding The terminal socket must be provided with pins and the signal conditioning instrument with appropriate gaps (mechanical coding) to avoid interchanging of the individual signal conditioning instruments. An instrument coding ensures that interchanging among the signal conditioning instruments is avoided by differently positioned coded keys. Note, danger! Never use the bridges with single instrument or at the end of an instrument row. They may come in touch with the operating voltage or cause a shortcircuit. Instrument coding VEGASEL 643 (pin 4) Direct connection for voltage input 0 10 V Direct connection for supply voltage A o B o C o 1 o 2 o 3 o o o o 7 o 8 o 9 o o o o 0 10 V N L1 VEGA 5 6 7 8 9 10 11 12 13 14 VEGASEL 643 7

Electrical connection 3 Electrical connection 3.1 Wiring instruction The following wiring plan and the extension examples 1 and 2 are valid for standard as well as for Ex-versions of the signal conditioning instruments. Please note the following instructions: - the relay contact is shown in unpressurized condition - if strong electromagnetic interferences are expected, we recommend to use screened cable for the signal lines - the screening must only be earthed at one sensor side - in case of overvoltages we recommend the use of VEGA-overvoltage arresters - the connection must be made according to the appropriate national installation standards (e.g. in Germany according to VDE-regulations). 3.2 Wiring plan Sensor + + VEGASEL 643 active current input for connection of a sensor (4 20 ma) passive current input for connection of a signal conditioning instrument (VEGAMET ) 10 V + 7 8 passive voltage input for connection to the voltage output of a signal conditioning instrument (VEGAMET ) 9 10 L1 N + 11 12 13 14 Relay output Supply voltage 8 VEGASEL 643

Electrical connection Extension example 1 Instrument 1: VEGASEL 643 actively switched Instrument 2 up to max. instrument 5: VEGASEL 643 passively switched Note: The voltage inputs (7, 8) must not be used when the current inputs are switched. Sensor (4 20 ma) active passive + + Current + + Current + + inputs inputs passive Current inputs VEGASEL VEGASEL VEGASEL Instrument 1 Instrument 2... up to max.. instrument 5 Extension example 2 Instrument 1: VEGAMET 601 or 602 Ex Instrument 2 up to max. instrument 10: VEGASEL 643 each switched to passive voltage input (parallel switching) Note: Current inputs (3, 4) must not be used when the voltage inputs are switched. Sensor + + + + + + 1 2 3 4 10 V VEGAMET + Voltage input 10 V + 10 V + Voltage input 7 8 7 8 7 8 VEGASEL VEGASEL Voltage input Instrument 1 Instrument 2... up to max.. instrument 10 According to the extension examples it is possible to control several signal conditioning instruments with one sensor and hence to detect different levels. This kind of switching can be extended each up to 5 or 10 instruments. VEGASEL 643 9

Set-up 4 Set-up 4.1 Indicating and operating elements 1 2 3 4 6 5 + + 3 5 + + max. min. 7 8 1 Key for value falling 2 Coded key for max. switch point 3 Key for value raising 4 Coded key for min. switch point 5 Status indication of the output 6 LED-supply voltage 7 Separating wall 8 Terminals current input 9 Terminals voltage input 10 Terminals supply and relay output 5 6 on VEGASEL 643 5 6 7 8 9 9 10 11 12 13 14 10 Top view, laterally 11 12 11 Bar code, series number 12 DIL-switch block 13 Screws 14 Ventilation opening 15 Transparent cover 13 14 15 10 VEGASEL 643

Set-up Coded key Coded keys (2 and 4) are located in the front plate by which the switch point (with single point level switches) as well as the switching hysteresis (with double point level switches) can be adjusted. The figures are given in % and relate to the current or voltage input. By pushing the buttons + or you can adjust the requested values raising or falling in 1 % or 10 %-steps. Signal lamps Green (6) - Supply voltage on, ready for operation Yellow (5) - Status indication of the relay output (LED lights = relay energized, LED extinguished = relay de-energized) DIL-switch (13) Laterally on top. When the signal conditioning instrument is mounted, covered by the terminal socket. Description of the individual functions Mount the terminal socket. Wire the input terminals of the terminal socket acc. to the above mentioned conditions. Cover the input terminals with the separating chamber. Switch the output of the auxiliary level switch acc. to the technical requirements. Adjust on the DIL-switch (11) the range of the inputs. When connecting a sensor to the active current input (terminals 1 and 2) set the DIL-switch to 4 20 ma. Select on the DIL-switch (11) the desired mode. Adjust the switch points acc. to section 4.3. Mount the module unit to the terminal socket. Switch on the supply voltage, the green LED (6) lights. 4.3 Switch point adjustment Single point control With a single point control it is possible to generate at one point of the input signal (0 10 V or 0/4 20 ma) a switching signal. Coded key 0.. B 2..10V 4..20mA A % 100 79/80 max. 80 min. 79 Hysteresis 1 % Adjustment possibility - Current input 0 20 ma or 4 20 ma voltage output 0 10 V or 2 10 V - Mode A or B A = overfill protection, B = protection against dry running of pumps Mode A Mode B 0 t 12 13 14 12 13 14 4.2 Set-up sequence The following list states the essential set-up steps in short Pre-requirement: VEGASEL 643 auxiliary level switch is connected with a measuring system (sensor and VEGAMET ) or directly with a sensor (4 20 ma). Procedure Adjust the switch point on both coded keys. As example min. = 79 %, max. = 80 %, with this adjustment there is a hysteresis of 1 %. Possible adjustment range 1 % 99 %. The auxiliary level switch is hence ready for operation. Please cover with the transparent cover (15). VEGASEL 643 11

Set-up Double point control With a double point control it is possible to generate switching signals at two different points of the input signal (0/2 10 V or 0/4 20 ma). Example 2 - Voltage input 2 10 V - Two-point control - Switch points min. = 20 %, max. = 60 % Procedure Mode A Mode B % 100 60 20 0 Coded key max. 60 ^ Hysteresis 40 % min. 20 t 12 13 14 12 13 14 2 10 V corresponds to 0 % 100 %, = 10 V 2 V = 8 V 20 % of 8 V = 1,6 V 60 % of 80 V = 4,8 V Switch point 20 % corresponds to 1,6 V + 2 V = 3,6 V Switch point 60 % corresponds to 4.8 V + 2 V = 6,8 V Example 3 - Current input 0 20 ma - Two-point control - Switch points min. = 20 %, max. = 60 % 0 20 ma corresponds to 0 % 100 %, = 20 ma Adjust the coded key with different values. Possible adjustment range 1 % 99 %. As example min. = 20 %, max. = 60 %, with this adjustment there is a hysteresis of 40 %. The auxiliary level switch is hence ready for operation. Please cover with the transparent cover (15). Note: Adjust the percentage values with the coded keys which relate to the input signal. Example 1 - Voltage input 0 10 V - Two-point control - Switch points min. = 20 %, max. = 60 % 0 10 V corresponds to 0 % 100 %, = 10 V 20 % of 10 V = 2 V 60 % of 10 V = 6 V Switch point 20 % corresponds to 2 V Switch point 60 % corresponds to 6 V 20 % of 20 ma = 4 ma 60 % of 20 ma = 12 ma Switch point 20 % corresponds to 4 ma Switch point 60 % corresponds to 12 ma Example 4 - Current input 4 20 ma - Two-point control - Switch points min. = 20 %, max. = 60 % 4 20 ma corresponds to 0 % 100 %, = 20 ma 4 ma = 16 ma 20 % of 16 ma = 3,2 ma 60 % of 16 ma = 9,6 ma Switch point 20 % corresponds to 3,2 ma + 4 ma = 7,2 ma Switch point 60 % corresponds to 9,6 ma + 4 ma = 13,6 ma The calculation and information examples are valid in the same way for the single point control. 12 VEGASEL 643

Diagnosis 5 Diagnosis 5.1 Maintenance The instrument is maintenancefree. 5.2 Repair For safety and guarantee reasons repairs on the instrument must only be carried out by VEGA-staff. In case of a defect please return the respective instrument along with a short description of the fault to our repair department. Occurring faults, possible reasons and their removals are stated under 5.3 Failure removal. 5.3 Failure removal Failure Instrument does not function, the green mains control lamp extinguishes Instrument does not switch correctly Instrument does not switch when using the active input Removal / Measure Check the supply voltage and the mains connection by means of the Connection instructions. When the instrument still does not function, contact our service department. Check the position of the coded keys. The switch points for min. and max. must not be set to the same values. Correct if necessary the values. Check the connected measuring data input - Check wiring, see 3.3 Wiring plan and extension examples - Check voltage or current values on their nominal range, see 1.4 Technical data. - The auxiliary level switch is internally provided with an interlock diode. A measuring instrument connected to terminal 2 and 3 is hence automatically switched into the circuit of the measuring line (switching in series). Hence it is possible to check the measuring line. The measuring instrument indicates the actual current. ma Load of the measuring instrument max. 15 Ω 12 34 VEGASEL 643 13

Notes 14 VEGASEL 643

Notes VEGASEL 643 15

VEGA Grieshaber KG Am Hohenstein 113 D-77761 Schiltach Phone (0 78 36) 50-0 Fax (0 78 36) 50-201 Fax (0 78 36) 50-203 ISO 9001 Technical data subject to alterations 2.19 955 / Sept. 1996